MP -I Unit - 1 1

MANUFACTURING PROCESS – I

UNIT NO. 1
Q.1 What are master patterns? How does their size differ
from other pattern`s ? Explain
Ans : Master patterns are used for preparing the moulds
for metal castings which are later used as patterns for
further moulding work, called metal patterns. The master
patterns are accurately finished wooden patterns, which
carry double shrinkage allowance and the required machining
allowance. For example, an alluminium pattern is to be
made which is to be used further for making moulds for
brass castings. The alluminium pattern should, obviously,
be larger than the desired brass casting by an amount equal
to shrinkage that will take place during solidification of
this casting. For making this alluminium pattern a wooden
pattern is to be used which should be larger than the
alluminium pattern by an amount equal to the alluminium
shrinkage, added with proper machining allowance for
finishing the alluminium casting. Mathematically, it can
be represented thus :
Let Sb represent the size of the desired casting in
brass.
And Let Sa represent the size of alluminium pattern.
And Let Cb represent the contraction allowance for brass.
Then Sa=Sb+Cb
Again, let S represent the size of the master pattern.
And let Ca represent the contraction allowance for
alluminium.
Also let Am represent the machining allowance required
to finish the alluminium casting to the required size of
pattern and to give smooth surface finish.
MP -I Unit - 1 2
Then S = Sa+Ca+Am
= Sb+Cb+Ca+Am or
Size of master pattern = Size of the final casting to be
Made + shrinkage allowance for
the material of final
casting + shrinkage allowance
of the metal of which the
pattern is to be made
+ Finishing allowance for the
metal pattern.

Q.2. What considerations are necessary while designing a

pattern?
Ans. The following points should be considered, while
designing a pattern :
1. Proper allowances should be provided, wherever
necessary.
2. The parting line should be carefully selected so as to
allow as small portion of the pattern in the cope as
possible.
3. A proper material should always be selected for the
pattern after carefully considering the factors mentioned
in Art.9.4.
4. An endeavor should always be made to employ full cores
instead of jointed half cores as far as possible. This
will reduce cost and ensure greater dimensional accuracy.
5. The wall thickness and sections should be kept as
uniform as possible. Abrupt changes should invariably be
avoided.
6. The use of offset parting, instead of cores, should be
encouraged to as great an extent as it is possible.
7. For large-scale production of small castings, the use
of gated or match-plate patterns should be encouraged
wherever the existing facilities permit.
MP -I Unit - 1 3
8. All sharp corners and edges should be invariably
provided with suitable fillets or otherwise rounded to
enable an easy withdrawal of pattern, smooth flow of
molten metal and ensure a sound casting.
9. All those surfaces of the casting which are
specifically required to be perfectly sound and clean
should be so designed that they will be molded in the
drag.
10. The pattern should be given a high-class surface
finish as it directly effects the corresponding finish of
the casting.
11. If gates, runners and risers are attached to the
pattern, they should be properly located and their sudden
contraction or enlargement should be avoided.
12. Shape and size of the casting and that of the core
should be carefully considered to decide the size and
location of the core prints.

Q.3. Shortly explain the following :

(1) Segmental patterns
(2) Core prints
Ans: Segmental patterns:-These patterns are used for
preparing moulds of large circular castings, avoiding the

use of a solid pattern of the exact size. In principle

they work like a sweep, but the difference is that a sweep
is given a continuous revolving motion to generate the
desired shape, whereas a segmental pattern is a portion of
the solid pattern itself and the mould is prepared in parts
by it. It is mounted on a central pivot and after
MP -I Unit - 1 4
preparing the part mould in one position, the segment is
moved to the next position. The operation is repeated till
the complete mould is ready. A typical example is shown in
Fig.
(2) Core prints :
When a casting is required to have a hole, through or
blind, a core is used in the mould to produce the same.
This core has to be properly seated in the mould on formed
impressions in the sand. To form these impressions, extra
projections are added on the pattern surface at proper
places. These projections are known as core prints.

Q.4.(a) What do you understand by acid and basic cupolas?

Where each type is preferred and why?
Ans : Cupolas are termed as basic or acid according to the
type of refractory lining used inside them. The refractory
lining is provided by setting bricks, made of refractory
material all along the inside surface of the cupola shell.
Basic cupolas find their specific use in the production of
ductile cast iron. They help in the reduction of sulphur
content in iron to the tune of 0.005 percent. They also
enable a higher carbon pick-up than acid cupola, with the
use of same raw material. This enables use of a higher
proportion of steel scrap in the metal charge. However, if
higher percentage, say upto 0.1 percent of sulphur is
admissible in the cast metal the acid cupola proves to be
relatively cheaper.

(b) Write a short notes on following casting defects.

(1) Metal penetration
(2) Warpage
Ans.: (1) Metal penetration :
This defect occurs as a rough and uneven external
surface on the casting. It takes place when the molten
MP -I Unit - 1 5
metal enters into the spaces between the sand grains and
holds some of the sand tightly with it even after fettling.
The principal causes for the promotion of this defect are
the use of coarse sand, having high permeability and low
strength, and soft ramming. Use of fine sand with low
permeability and hard ramming will minimise this defect.

(2) Warpage :
It is an undesirable deformation in the casting, which
may occur during or after solidification. The deformation
takes place due to the internal stresses developed in the
casting due to differential solidification in different
sections. Such stresses are also developed and
differential solidification occurs in case of castings
having very large and wide flat surfaces. Both the causes
can be attributed to faulty design of the casting, which
needs modification to ensure proper directional
solidification.

(c) Explain, how the grain size and shape effect the
performances of a foundry sand.
Ans. Sand Grain :
The shape and size of the sand grains has a remarkable
effect on the physical properties of the foundry sand. The
sand grains may have smooth, conchoidal or rough surfaces.
Out of these the first type i.e., smooth, is preferred for
moulding for the reason that such a surface renders higher
permeability, sinter point and plasticity to the sand
mass, but the percentage of binder required is also equally
high.
Similarly the sand grains may have different shapes.
The commonly formed shapes are rounded, sub-angular,
angular and compound. The rounded grains do not bind
together two well when rammed and, hence, render the sand
MP -I Unit - 1 6
mould highly permeable but the strength of the mould is
also reduced.
Sub-angular grains give a relatively stronger bond
than above but the permeability is reduced. Angular or
sharp grains produce a much stronger bond and a low
permeability when rammed. Thus they enable a mould of
greater strength. Sand grains which are cemented together
such that they do not separate when screened are called
compound. They may consist of one, two or a combination of
all the above three shapes. They are not
much preferred.

Like the shape the size of sand grains also effects

the mould structure and its characteristics. Large, regular
and uniform grains increase permeability. Smaller grains
increase smoothness on mould surfaces.

Q.5. What are the common materials used for pattern making?
Discuss their relative merits and demerits.
Ans.: Pattern materials
The common materials of which the patterns are made
are the following:
1. Wood. It is the most common material used for pattern
making because of the following advantages :
(i) It is cheap and available in abundance.
(ii) It can be easily shaped into different forms and
intricate designs.
(iii) Its manipulation is easy because of lightness in
weight.
MP -I Unit - 1 7
(iv) Good surface finish can be easily obtained by only
planning and sanding.
(v) It can be preserved for a fairly long time by applying
proper preservatives like shellac varnish.
On the other hand, it has certain disadvantages also as
follows:
(i) It wears out quickly due to its low resistance to sand
abrasion. As such, a wooden pattern cannot stand a long
constant use.
(ii) It is very susceptible to moisture, which may lead to
its warping or splitting. This needs its careful
storing in a dry place and the application of
preservatives.
(iii) Its life, owing to the above reasons, is short as
compared to other pattern materials. This confines its
use to such cases only when a small number of castings
are required.
2) Metals :- Metals are used with advantage, as pattern
material, only when the number of castings to be made is
very high and a closer dimensional accuracy is desired.
They have a much longer life than wooden patterns and
eliminate the inherent disadvantages of wood to a great
extent. But they also carry the following
Disadvantages :
(i) They are costlier than wood and, therefore, cannot be
used with advantage, where a smaller number of
castings is to be made.
(ii) For giving different shapes and fine surface finish
they need machining. This again adds to their cost.
(iii) Most of them are very heavy and in case of large
castings the weight of the pattern always poses a
problem in its manipulation.
(iv) A large number of them have a tendency to get
rusted.
MP -I Unit - 1 8
3) Plaster :- Plaster of Paris or gypsum cement is
advantageously used as a pattern material since it can be
easily casted into intricate shapes and can be easily
worked also. Its expansion can be easily controlled and it
carries a very high compression strength. Its specific use
is in making small patterns and core boxes involving
intricate shapes and closer dimensional control. A marked
feature of this cement is that contrary to the action of
metals, it expands on being solidified. Thus, if a cement
of proper coefficient of expansion is selected, the effect
of shrinkage of casting can be automatically neutralised.
4) Plastics :- Plastics are gradually gaining favour as
pattern materials due to their following specific
characteristics :
1. Lightness in weight.
2. High strength.
3. High resistance to wear.
4. High resistance to corrosion due to moisture.
5. Fine surface finish.
6. Low solid shrinkage.
7. Very reasonable cost.
The plastics used as pattern materials are thermo-
setting resins. Phenolic resin plastic and foam plastic
suit best for this purpose. For making the pattern, first
the moulds are made, usually from plaster of Paris. The
resin is then poured into these moulds and the two heated.
At a specific temperature, the resin solidifies to give the
plastic pattern.
5) Wax :- Wax patterns are exclusively used in investment
casting. For this a die or metal mould is made in two
halves into which the heated wax is poured. The die is
kept cool by circulating water around it. As the wax
sets on cooling, the die parts are separated and the wax
pattern taken out.
MP -I Unit - 1 9

Q.6. Explain the process of ‘Sand preparation and

conditioning.
Ans.: None of the natural sand possesses the required
qualities to the required extent. They may lack in one or
more of these properties which we have to make up by
artificial means to make the sand suitable for use. Sand
mixing is the process through which we add those materials
to the sand which are rich in such characteristics, which
the sand lacks.
Sand to be used in moulding should be properly
conditioned before use in order to obtain good castings,
since most of the defects, which occur in castings, are due
to improper conditioning of the sand. It holds good
equally for the new as well as old or used sand. Proper
conditioning means the uniform distribution of the clay
bond over the sand grains, even distribution and proper
control of the moisture content in the sand and sorting out
the foreign materials like nails, gaggers and other metal
pieces from the sand by ridding and a thorough mixing of
the entire sand mass.
Even today the above operation is carried out by hand
in most of the small foundries. Since no testing equipment
is normally available in such foundries, the sand condition
is judged by the moulders themselves by virtue of their
practical experience only and the quality of the castings
produced in such foundries entirely depends upon this
factor. A common physical test, which is generally
followed by most of the moulders, for judging the sand
condition is to grip a handful of the prepared foundry sand
and then relieve the pressure of the fingers. The sand
mass thus produced is broken into two pieces by hand and
the edges formed at the broken section are carefully
observed. If there is no deformation in the edges the sand
MP -I Unit - 1 10
is supposed to be properly conditioned. If the upper
surface of the broken pieces appears to be setting down
gradually, as if it is being compressed, it indicates a
high moisture content. Gradual separation of sand grains,
as if they are being sprinkled from the parted surfaces,
indicate a weak bond and low moisture content. Mixing of
sand by hand is performed by first collecting the sand,
together with the other constituents to be mixed in it, in
the form of a help and then pouring adequate amount of
water on to it. After keeping it as such for some time it
is turned upside down by means of a shovel and the
operation repeated several times to ensure through mixing
of different constituents. It is then riddled to remove
the forming material from it and thus it is ready for use.

Q.7. Write short notes on :-

(1) Mould hardness test
(2) Core hardness test
Ans.: (1) Mould hardness test.
The hardness of a sand mould can easily be tested by
means of a hardness tester. It is a very handy instrument
working on the principle of dryness hardness testing
machine. It carries a hemispherical ball or tip at its
bottom, which is penetrated into the mould surface. A
spring-loaded shaft inside the hollow body of the
instrument actuates the needle of the dial gauge fitted at
the top. The dial of this gauge provides direct reading of
the mould hardness.
(2) Core hardness test.
It is also a very simple and handy instrument used for
testing the hardness of dry sand cores, especially of the
dried oil-sand cores. It carries a cutter at its bottom,
which is provided with a pre-determined pressure, by means
of a spring inside the instrument, when it is pressed
MP -I Unit - 1 11
against the surface of the core. Corresponding to the
penetration the hardness is directly given by the scale
provided on the tester.

Q.8. What are crucible furnaces? Where are they preferred

and why?
Ans.: These are the simplest of all the furnaces used in
foundries. They are sparingly used in most of the small
foundries where melting is not continuous and a large
variety of metals is to be melted in small quantities. In
these furnaces the entire melting of metal takes place
inside a melting pot, called crucible, which is made of
clay and graphite. The sizes of these crucibles vary from
No.1 to No.400 each number representing a definite quantity
of metal that can be held conveniently by the crucible.

Q.9. How is the thermal efficiency of cupola is determined?

Ans. The thermal efficiency of the cupola is given by the
ratio of heat actually utilised in melting and superheating
the metal to the heat evolved in it through various means.
This ratio can be expressed mathematically as follows:
ηderecent cupola

= Heat utilised in melting and superheating the metal x 100

Cal. Value of coke + heat evolved due to oxidation of

iron,Si & Mn
In case of a hot blast cupola the above expression will
change as follows:
ηpercent cupola

= Heat utilised in melting and superheating the metal x 100

Cal. Value of coke + Heat evolved due to oxidation of
iron,
Si and Mn + Heat supplied by the air
Blast
MP -I Unit - 1 12
Experiments reveal that the thermal efficiencies of
different cupolas normally range between 30 to 50 per cent.

Q.10. Explain in brief causes and remedies of the following

casting defects
Ans. (1) Blow holes:- They appear as cavities in a casting.
When they are visible on the upper surface of the casting,
they are called open blows. These blows are normally
rounded and have smooth walls. When they are concealed in
the casting and are not visible from outside, they are
known as blowholes. They are due to the entrapped bubbles
of gases in the metal and are exposed only after machining.
Possible causes :
1. Excess moisture content in moulding sand-leading to the
production of too much of steam and thereby
rendering the permeability of the mould as inadequate.
2. Cores not sufficiently baked.
3. Use of rusted or highly moistened chills, chaplets or
other metal inserts-giving rise to the production of a
high amount of steam and gases.
4. Excessive use of organic binders-resulting in the
production of high amount of gases.
5. Cores not adequately vented-resulting in their low
permeability.
6. Moulds inadequately vented resulting in their low
permeability.
7. Moulds rammed very hard-more addition to low
permeability.
Remedies :
1. Moisture content in the moulding sand should be properly
controlled.
2. Cores should be adequately backed.
3. Chills, chaplets and metal inserts used should be clean
and free from rust or any other gas producing substance.
MP -I Unit - 1 13
4. Organic binders should be used with restraint.
5. Cores and moulds should be adequately vented.
Moulds should not be rammed excessively hard.
(2) Shrinkage :- During solidification of metal, there is a
volumetric shrinkage. This should be adequately compensated
by feeding failing which voids will be produced in the
casting. These voids may exist on the surface as
depression, called surface shrinkage, or within the casting
called internal shrinkage. Too much shrinkage may lead to
crack, known as hot tears. This defect occurs on account
of inadequate and improper gating, risering and chilling so
that proper directional solidification does not take place.
As such it can be remedied by adopting corrective measures
in respect of the above factors.
(2) Hot tears :- They are also known as pulls or hot
cracks. The main reasons of their occurrence is the low
strength of metal after solidification, causing the
metal to fail in coping up with the excessively high
stresses set up by the solid shrinkage of the metal.
These cracks may be external or internal. They are
supposed to be more harmful when they are present
internally, because in that case their occurrence is not
revealed without machining or radiographic testing.
Their presence is identified by an oxidised surface
showing an irregular and ragged appearance on fracture.
The main reasons of their occurrence are lack of
collapsibility in the core and mould, faulty design
leading to exceptionally high residual stresses at
certain portions in the casting and very hard ramming of
sand resulting in restricted contraction of casting. An
improvement over these shortcomings will help
elimination of hot tears.
MP -I Unit - 1 14
Q.11. Describe the following types of sands in respect of
their composition, particular properties and uses
Ans: Loam Sand :- It is a mixture of clay and sand with
water to a thin plastic form and from which moulds are
built. It contains moisture 18-20% and the loam is dried
very slowly. It is used for producing larger castings.
A typical mixture of loam sand consists of
Floor coke 10 Vol
Loam sand 10 Vol
New sand 6 Vol 80% mixture + 20% moisture
Silica sand 22 Vol
Clay 5 Vol
Other gradients 5 Vol
1. Parting Sand :- Conventionally, mould is prepared into
two or more boxes. These boxes are to be separated
without adhering to each other’s sand. For this purpose
parting sand is used. One of the parting compounds is
lycopedium, which is used when oil is mixed with moulding
sand. Very fine brick powder can also be used.
2. Green Sand :- It is the sand in green condition and after
preparing the mould, casting (pouring of molten metal) is
done in moist state. While preparing the mould, the
rammed sand is dense but porous and further the structure
is made porous by venting. Green sand is generally used
for small or medium sized casting.
(a) Mixture of green sand for light work purpose contains
Floor sand ...... 80%
New sand........ 13.5% 95% mixture + 5% moisture
Super fine coal dust ... 6.5%
(b) Mixture of grey n sand for general purpose contains
Floor sand………….. 60%
New sand ………… .. 30% 95% mixture + 5% moisture
Coal dust ………….. 10%
MP -I Unit - 1 15
(c) Mixture of green sand for high finish castings
contains
Floor sand ………… 51%
New sand ………… 23%
Coal dust …………… 8.5% 95% mixture + 5% moisture
Carbon blacking … 8.5%
Talc ……… 2.8%
3. Backing Sand :- Backing sand or floor sand is used to
back up the facing sand and to fill the whole volume of the
flask. Old, repeatedly used moulding sand is mainly
employed for this purpose.
The backing sand is sometimes called black sand
because of the fact that old, repeatedly used moulding sand
is black in colour due to the addition of coal dust and
burning on coming in contact with molten metal.

Q.12. Describe the utility of following moulding tools and

give neat sketches of each.
Ans. Bellows :- A hand operated bellow is shown in Fig.

It is used to blow but the loose or unwanted sand from

the surface and cavity of the mould.
Hand Riddle :- It consists of a wooden frame fitted with a
screen of standard wire mesh at its bottom. It is used for
hand ridding of sand to remove foreign material from it.
MP -I Unit - 1 16
Rammer:- A hand rammer is a wooden tool used for
packing or ramming the sand into the mould. One end,
called the peen, is

wedge shaped, and the opposite end, called the butt, has a
flat surface. Floor rammers are similar in construction but
have long handles. Pneumatic rammers are used in large
moulds saving considerable labor and time.

Q.13. What do you understand by casting? List the merits

and demerits of casting process.
Ans. Casting is one of the most versatile form of
mechanical process for producing components; casting is a
replica of pattern, in metal which is obtained by pouring
molten metal into the mould.
Principal of casting consists of introducing the
molten metal into a cavity or mould of the desired shape
and allowing it to solidify. When it is removed from mould,
the casting is of same shape but slightly smaller due to
contraction of metal. The molten metal passes through the
four stages i.e. liquid stage, musy stage, plastic stage,
and solid stage till the solidification takes place.
Today we have a variety of moulding processes and melting
equipments, thus we are capable to produce castings of
different, materials and their alloys. Though, there is a
tremendous improvement in the production methods, but the
basic principles are still the same. One can realise the
importance of castings and their role in modern
MP -I Unit - 1 17
development. It is difficult to visualise any product
which do not have one or more casted parts in different
sizes. Though there are other metal shaping process such
as metal-machining, metal-forging, stamping which can
fulfil the needs of the community. But casting caries
inherent advantages, which have made it as the backbone of
industrial production.
Design Advantages
(a) Size – Casting can be prepared upto 200 weight and the
least size that can be made is weighing few grams. Its
advantage lies with the production of massive objects in
one piece.
(b) Complexity – Most simple/complex shaped products can
be prepared by casting easily. Such production depends
on the preparation of pattern and mould. Complicated
shapes cannot be easily produced by other shaping
methods.
(c) Weight Saving – Since the metal can be placed at the
exact location where it is needed, thus lot of metal can
be saved by adopting this process.
(d) Production of Prototype – It is capable to produce
prototype models/exact product as desired.
(e) Wide Range of Properties – This process offers a large
range of mechanical and physical properties in the
castings as per requirement. Usually the use the metal-
alloys is one variable.
Advantages of Casting Process
(a) Low cost – It is usually found to be the cheapest
method of metal shaping.
(b) Dimensional Accuracy – Tolerances as close as ±0.1 mm
can be achieved depending on metal to be casted, casting
process, shape and size of casting. Surface finish can
also be controlled from 5 microns to 50 microns.
MP -I Unit - 1 18
(c) Versatility in Production – This process is adaptable
to all types of production.
Metallurgical advantages
(i) Fibrous structure.
(ii) Controlled grain size,
(iii) Uniform density.
Merits of casting:-
1. Versatile form of mechanical process for producing
components.
2. There is no limit to the size and shape of the articles
that can be produced by casting.
3. Casting offers one of the cheapest methods and gives high
strength and rigidity even to intricate parts, which are
difficult to produce by other methods of manufacturing.
Demerits :-
1. Casting is not always the best method of the various
production techniques.
2. Metals having good fluidity and small shrinkage can only
be casted in a best way.

Q.14. Which factors need to be considered in selecting a

particular type of pattern? Explain split pattern, sweep
pattern and match-plate pattern with the help of neat
sketches
Ans. Factors affecting selection of a particular tape of
pattern.
The type of pattern to be used for particular casting
depends upon many factors like
1. The bulk of casting i.e. whether a small or large number
of casting is wanted.
2. Ease or difficulty of moulding operation.
3. Type of moulding process.
Split pattern :- Many times the design of casting offers
difficulty in mould making and withdrawal of pattern, if a
MP -I Unit - 1 19
solid pattern is used. For such castings, split or two
piece patterns are employed. They are made in two parts,
which are joined at the parting line by means of dowels.
While moulding one part of the pattern is contained by the
drag and the other by the cope.

Match plate patterns :- These patterns are used where a

rapid production of small and accurate castings is desired
on a large scale. Their construction cost is quite high,
but the same is easily compensated by a high rate of
production, greater dimensional accuracy and minimum
requirement for machining in the casting. These patterns
are made in two pieces; one piece mounted on one side and
the other on the other side of a plate, called match-plate.
The plate may carry only one pattern, or a group of
patterns mounted in the same way on its two sides. The
plate may be of wood, steel magnesium or alluminium. Gates
and runners are also attached to the plate alongwith the
pattern.

Sweep pattern :- Sweeps can be advantageously used for

preparing moulds of large symmetrical castings,
particularly of circular cross-section. This effects a
large saving in time, labour and material. The full
MP -I Unit - 1 20
equipment consists of a base, suitably placed in the sand
mass, a vertical spindle and a wooden template, called
sweep. The outer end of the sweep carries the contour
corresponding to the shape of the desired casting. The
sweep is rotated about the spindle to form the cavity.
Then the sweep and spindle are removed, leaving the base in
the sand. The sweep and spindle are removed, leaving the
base in the sand. The hole made by the removal of spindle
is patched up by filling the sand.

Q.15. What is pattern? How does it differ from the actual

product to be made from it?
Ans. A pattern may be defined as a replica or facsimile
model of the desired casting which, when packed or embedded
in a suitable moulding material, produces a cavity called
mould. This cavity, when filled with molten metal,
produces the desired casting after solidification of the
poured metal. Since it is a direct duplication, the
pattern very closely conforms to the shape and size of the
desired casting, except for a few variations due to the
necessary allowances. The ways in which a pattern differs
from an actual component are :
1. It carries an additional allowance to compensate for
metal shrinkage.
2. It carries additional allowances over those portions,
which are to be machined or finished otherwise.
MP -I Unit - 1 21
3. It caries the necessary draft to enable its easy removal
from the sand mass.
4. It carries additional projections, called coreprints, to
produce seats for cores.

Q.16. What is permeability? What is the effect of Moisture

and clay content permeability?
Ans. It is also termed as porosity. It is that property of
the sand, which allows the gases and steam to escape
through the sand mould. When the hot molten metal is poured
in the mould a very large volume of gases and steam is
formed due to heating to moisture, coal dust, oil and
similar other materials present in the sand. If these
gases are not allowed to go out they will either make the
casting unsound or blast the mould. Therefore, this is
very important property required in the moulding sand. It
largely depends upon the same grain size and shape and the
proportion of moisture and clay present in the sand.
Rounded grains of uniform size lead to a high permeability.
This property is also effected by ramming of sand. A soft
ramming will increase the permeability and hard ramming
will reduce it. In practice it is further increased by
applying vent wires in the prepared mould.

Q.17. Write note on Skeleton pattern

Ans. Skeleton pattern :- When the size of the casting is
very large, but easy to shape, and only a few numbers are
to be made, it is uneconomical to make a large solid
pattern of that size. In such cases, a pattern consisting
of a wooden frame and strips is made, called skeleton
pattern, it is filled with loam sand and rammed. The
surplus sand is removed by means of a strickle. The core
can be prepared separately, either with the help of
MP -I Unit - 1 22
a core box or another skeleton made for that, and assembled
in position in the mould.

Q.18. Give reason for Rat-tails or buckles in casting.

Ans. 1) Continuous large flat surface on casting.
2) Excessive mould hardness.
3) Lack of combustible additives in moulding sand.

Q.19. What care is to be taken in operating cupola?

Ans. The following considerations should be made for
operating the cupola successfully:
1. A superior refractory lining should be used to withstand
high temperature produced inside the furnace.
2. The man who fires the coke and charge should place the
metal charge in the centre.
3. The molten metal should be tapped out well before its
level rises too high in the well.
4. The tap hole should be property closed by means of a
well-prepared clay bolt or plug.
5. In closing the tap hole care should be taken to press the
plug downward in the hole so that the splash of the
molten metal does not fall on the hands.
6. The amount of air supply should be property controlled.
An excess amount of air will result in lowering to
temperature inside.

Q.20. Define
(a) (i) Pattern
(ii) Mould
MP -I Unit - 1 23
(iii)Casting
(b) Write different stages in core making.
(c)Explain non-destructive inspection method of casting -
any three methods.
Ans: (a) (i)Pattern : Pattern is a model of anything which
is used to prepare moulds by placing it in sand.
(i) Mould : A mould is a cavity so prepared that it can be
used to make castings by molten metal into it.
(ii) Casting : The molten metal poured into mould, on
cooling is known as casting.
(b) Core making consists of the following operation.
i) Core sand preparation : The first consideration in
making a core is to mix and prepare the sand properly.
The mixture must be homogeneous so that the core will be
of uniform strength throughout. The core sands are
generally mixed in (1) roller mills, and (2) core mixers.
In the case of roller mills, the action of the mullers
and ploughs gives a uniform and homogeneous mixing.
Roller mills are suitable for core sands containing
cereal binders, whereas the core sand mixer is suitable
for all types of core binders.
ii) Core making : Cores are made separately in a core box
made of wood or metal. The various steps in core making
are ramming of core sand in the box, venting,
reinforcing, removing of core from box, baking, pasting,
sizing etc. This work of producing cores can either be
done by hand or by some machines designed for this
purpose. In machine moulding, the core-sand mixture is
rammed by jolting, squeezing or blowing by means of
suitable machine. Venting, reinforcing and other
operations are carried out by hand.
MP -I Unit - 1 24

iii) Core Baking : Generally baking is carried out in

ovens equipped with drawers, shelves or other holding
devices. The operation is generally continuous and cores
are put either in batches or continuously over or moving
shelves. The heat in oven is produced by burning oil or
coke or by electric resistance. Core-baking time depends
upon the types andTypes
quantity
of cores of binder used, the amount of
moisture used in sand, and size of core. The temperature
for baking depends on the core material used. When cores
are baked, they are more easily supported on a flat
surface, which should be incorporated in the design.
iv) Finishing : After receiving them from ovens, the
cores are properly finished by rubbing or filing, etc. to
bring them to correct dimensions, remove extra sand
projections from their surfaces and provide a good
surface finish. Then only they become suitable for being
placed in the moulds.
(c) (i)Sound test : It consists of suitably suspending the
casting, free of floor and all other abstractions, and then
gently striking it with hammer. The sound produced is
carefully noted. Tapping by the hammer is done at
different points and a change in the pitch and quality of
sound indicates a discontinuity within the mass of the
castings. However, it is difficult to locate the
discontinuity and the extent to which it is present.
MP -I Unit - 1 25
(i) Magnetic particle testing : This method can be used
only for those metals and alloys, which can develop
magnetic properties, e.g. iron and steel. The principle
involved in this test is that in a magnetised metal if
its magnetic field is interrupted by a crack its
continuity is broken. Due to low magnetic permeability
of air some magnetic flux lines leak out of the metal,
and if a magnetic material is spread over that portion
some of it is held there by the flux lines to show the
presence of a crack or void there. So, for this test,
the casting is first magnetised and then fine particles
of iron or steel are spread over its surface. The
presence of cracks is revealed by the help up particles
on the surface.
(ii) Penetrant testing : This method is used to detect
small surface cracks and can be conveniently used for all
metals and alloys. It consists of applying a thin
penetrating liquid over the surface of the casting,
allowing it to penetrate into the cracks by capillary
action and then cleaning the whole surface which draws
back some of the liquid on to the surface. The surface
is then exposed to an ultraviolet light where the
presence of liquid is clearly seen, indicating a crack
there.

Q.21. What do you understand by gravity die-casting?

State its advantages.
Ans. Advantages:
1) It is a very speedy process and each cast takes between
2 to 4 minutes time only.
2) Permanent moulds have a very long life in as much as
one mould can be conveniently used for producing
between 3,000 to 10,000 castings in cast iron and
between 10,000 to 25,000 castings in alluminium.
MP -I Unit - 1 26
3) Surface finish through this method is better than sand
castings but inferior than pressure die-castings.
4) Dimensional tolerances of the order of ±0.508 per 100
mm. can be conveniently obtained.
5) For the same amount of production it requires less
floor area than sand casting.
6) Less skill is required of the operator than in sand
casting.
7) Many of the defects found in sand castings are
eliminated totally.
8) Castings produced through this method are found to have
a finer grain structure.
9) Castings in large quantities can be produced more
economically.
10) A minimum thickness of 2.4 mm. Can be easily cast.

Q.22. Explain with the help of neat cross sectional sketch

of cupola, indicating its various zones.
Ans. Various zones of cupola are shown in Figs.
A number of chemical reaction take place in these zones
which are explained below :
1. Well :- It is the space between the bottom of the tuyeres
and the sand bed. The metal, after melting,, trickles
down and collects in this space before it is tapped out.
2. Combustion zone :- It is also known as oxidising zone.
It is located between the top of the tuyeres and a
theoretical level above it. The total height of this
zone is normally from 15 cm. To 30 cm. The actual
combustion takes place in this zone, consuming all free
oxygen from the air blast and producing a lot of heat,
which is sufficient enough to meet the requirements of
other zones of cupola. More heat is evolved due to
oxidation of silicon and manganese. A temperature of
about 15400C to 18700C is produced in this zone. The
MP -I Unit - 1 27
exothermic reactions taking place in this zone can be
represented thus.
3. Reducing zone :- It is also known as the protective
zone. It is located between the top of the combustion
zone and the top level of the coke bed. CO2 is reduced
to CO in this zone through an endothermic reaction, as a
result of which the temperature falls from combustion
zone temperature to about 12000C at the top of this zone.
The reaction is as follows :
Nitrogen, the other main constituent of the
upward moving hot gases does not participate in the
reaction. This zone, on account of the reducing
atmosphere in it, protects the charge against oxidation.
4. Melting zone :- The first layer of metal charge above the
coke bed constitutes this zone. The solid metal charge
changes to molten state in this zone and trickles down
through the coke to the well. The molten metal picks up
sufficient carbon content in this zone as represented by
the following reaction :
5. Preheating zone :- It extends from above the melting zone
to the bottom level of the charging door and contains a
number of alternate layers of coke and metal charges.
The function of this zone is to preheat the charges from
atmospheric temperature to about 10930C before they
settle downwards to enter the melting zone. This
preheating takes place due to the upward advancing hot
gases, from which the solid metal also picks up some
sulphur content.
6. Stack :- The empty portion of cupola above the preheating
zone, which provides the passage to hot gases to go to
atmosphere, is known as stack.

Q.23. Explain the common allowances provided on patterns.

Ans. Pattern Allowances
MP -I Unit - 1 28
(i) Shrinkage:- When any metal cools, it naturally
shrinks in size. Hence, if the actual object itself is
used for the pattern, the resulting casting would be
slightly smaller than desired. To compensate for this
possibility, a shrink rule is used in laying out of
measurements for the pattern. A shrink rule for cast
iron is 10 mm per meter (the average shrinkage for cast
iron) longer than the standard rule.
When metal patterns are to be cast from the original
patterns, double shrinkage must be allowed.
(ii) Draft :- When a pattern is drawn out from a mould, the
tendency to tear away the edges of the mould in contact
with the pattern is greatly decreased if the surfaces of
the pattern are given a slight taper in a direction
parallel to which it is being withdrawn. This tapering
of the sides of the pattern, known as draft, is done to
provide a slight clearance for the pattern as it is
lifted up. The amount of draft on exterior surfaces is
about 10 to 20 mm per meter. On interior holes, which are
fairly small, the draft should be around 30 mm per meter.
(iii) Finish :- When a draftsman draws up the details of a
part to be made each surface to be machined is indicated
by a finish mark. The mark indicates that additional
metal must be provided at this point so that there will
be some metal to machine. The amount that is to be added
depends upon the size, shape of casting, but in general,
the allowance for small castings and average sized
castings is 3 mm.
(iv) Distortion :- This allowance applies only to those
castings of irregular shapes, which are distorted in the
process of cooling as a result of metal shrinkage. Such
an allowance depends on the judgment and experience of
the pattern maker, who understands the shrinkage
characteristics of the metal.
MP -I Unit - 1 29
(v) Shake :- When a pattern is rapped in the mould before
it is withdrawn, the cavity in the mould is slightly
increased. In an average sized casting this increase in
size can be ignored. In large castings or in one that
must fit without machining, however, shake allowance must
be considered by making the pattern slightly smaller.

Q.24. Discuss the advantages split and multi-piece patterns.

Ans. Following are the advantages of split and multi-
piece patterns.
1. Complicated designs can be constructed in these types of
patterns.
2. They facilitate easy withdrawal from cope and drag box.
3. These pattern are easy to contact as compared to solid or
single piece pattern.

Q.25. Why testing of foundry sand is necessary? What are the

common tests performed on foundry sands?
Ans. In progressive foundries it is recognized that the
foundry sand deserves as much attention as the casting
metal. The foundry sand may account for one-third of the
cost of the finished casting. In modern mass production of
sand castings, the moulding sand, which constitutes the
chief moulding material, is therefore, required to be
tested periodically in order that control of its
composition and properties may be maintained. Test may be
either chemical or mechanical. Chemical tests are used
only to determine the undesirable elements in the sand, and
in most cases mechanical tests are employed.
The essential mechanical tests include fineness,
moisture content, clay content, permeability, strength in
compression, and mould hardness.
MP -I Unit - 1 30
Q.26. What are the factors, which should be considered
before designing a casting?
Ans. The important factors to keep in mind when designing a
casting to obtain maximum strength and minimum casting
include :
1. Design for directional solidification.
2. Design for minimum stresses.
3. Design for metal flow.
4. Cast-well design.
5. Design for minimum casting.
6. Design for expected tolerances.
7. Functional design.

Q.27. Write short notes on the following casting defects.

1) Cuts and washes
2) Drops
Ans. 1) Cuts and washes :- These defects occur due to the
erosion of sand from the mould or core surfaces by the
molten metal. The cavities formed on the mould and core
surfaces due to this erosion are filled by the molten metal
and the same appear on the casting surface as an surface as
an excess metal in the form of ragged spots. These spots
are called scabs. The eroded sand appears as a sand
inclusion some-where else in the casting. These cuts and
washes take place due to insufficient strength of mould and
core, lack of binding material in the facing and core sand
and faulty gating. Obviously, the remedy of the defect
lies in adequate ramming, additional of sufficient binders
in facing and core sands and improved gating system.
2) Drops :- This defect appears as an irregular
deformation of the casting. It occurs on account of a
portion of the sand breaking away from the mould and
dropping into the molten metal. The above breaking takes
place due to low green strength in the sand, too soft
MP -I Unit - 1 31
ramming, insufficient reinforcement of the cope or other
sand projections. Increase in green strength of the sand
by suitable modification in its composition, hard ramming
and adequate reinforcing of cope and other sand projections
by means of bars, nails and gaggers etc. are the principal
remedies of this defect.

Q.28. What are the factors which govern the selection of a

proper material for pattern making.
Ans. Factors effecting the selection of pattern material:-
The selection of a particular material for making the
pattern is influenced by the following factors : -
1. Number of castings to be made.
2. Method of moulding to be used, i.e., hand or machine.
3. Type of casting method to be used.
4. Degree of accuracy in dimensions and the quality of
surface finish required on the castings.
5. Design of casting.

Q.29. How are the patterns classified ? Explain the use of

solid pattern.
Ans: On the basis of material used in construction of
patterns, they are classified as :
(1) Wooden patterns
(2) Metal patterns
(3) Plaster patterns
(4) Plastic patterns
(5) Wax patterns
(1) on the basis of number of pieces used in construction,
patterns are classified as
(1) Solid or single piece pattern
(2) Two piece or split pattern
(3) Multi-piece pattern
(4) plate pattern
MP -I Unit - 1 32

Solid or Single piece pattern :-

A single piece pattern is the simplest of all the
patterns, is made in one-piece and carries no joint,
partition or loose pieces. Depending upon the shape, it
can be moulded in one or two boxes. This pattern is the
cheapest but its use can be done to a limited extent of
production only since its moulding involves a large number
of manual operations like gate cutting, providing runners
and risers and the like.

Q.30. Write short notes on

1) Functions of a pattern
2) Core boxes
Ans. 1) Functions of a pattern :-
The main functions of a pattern are :
(i) To produce the mould cavity of appropriate shape and
size in which the molten metal can be poured to obtain
desired casting.
(ii) To produce seats for cores in the mould in which cores
can be placed to produce cavity in the casting. These
seats in the mould are called coreprints and the
corresponding projections on the pattern, which
produce these seats, are also known as coreprints.
(iii) To establish the parting surfaces and lines in the
mould.
(iv) To establish distinct locating points in the moulds of
which the corresponding points on the casting are used
as reference points, for checking the casting
MP -I Unit - 1 33
dimensions and relative location of machined and other
surfaces.
(v) To minimise defects in castings.
(vi) To enable production of green sand or rammed-up cores
within the mould itself.
(vii) To minimise the cost of casting.

2) Core boxes :-
Core boxes are used for making cores. They are either
made single or in two parts. Their classification is,
generally, according to the shape of the core or the method
of making the core. The common types of core boxes are the
following :-
(i) Half core box :- To prepare the core in two halves
which are later on cemented together to form the
complete core.(See fig. )

(ii) Dump core-box :- Used to prepare complete core in it.

Generally, rectangular cores are prepared in these
boxes.(See fig.)
MP -I Unit - 1 34
(iii) Split core-box :- It is made in two parts, which can
be joined together by means of dowels to form the
complete cavity for making the core.(See fig.)

(iv) Strickle type core-box :- It is used to form cores of

irregular or unsymmetrical shapes, as shown in fig.

(v) Loose piece core-box:- It is used to prepare, in the

same core box, the two halves of a core of which the
halves are not identical in shape and size. (See fig.)

Loose piece core box

Q.31. What are the factors which govern the choice of a

particular type of furnace for melting a particular metal?
MP -I Unit - 1 35
Ans. The choice of a particular type of furnace is largely
based on the following factors :-
1. Rate of melting desired, depending upon the quantity of
metal required to be melted per hour.
2. Type of metal to be melted.
3. Temperature required.
4. Capability of melting medium for absorbing impurities.
5. Method of pouring the molten metal.
6. Economic considerations, i.e. initial investment to be
made as cost of equipment and its installation,
maintenance cost and cost of fuel to be consumed, etc.

Q.32. What is a hot blast cupola? What are its advantages?

Q.33. Explain the causes and remedies of following casting
defects.
Ans.

Sr. Defects Possible courses Remedies

No
1 Fusion a)Low refractoriness in (a)Improve refractoriness.
moulding sand. (b)Modify gating system.
b) Faulty gating. (c)Use lower pouring
c) Too high pouring temperature.
temperature of metal. (d) Improve quality of
d) Poor facing sand. facing sand.
2 Short (a)Too low pouring (a) Use higher pouring
metal temperature. temperature.
a)Excess sulphur (b) Reduce sulphur content.
Content in metal. (c) Modify gating system.
(a) Faulty gating. (d) Reduce moisture
(b)High moisture content.
content in moulding
sand.
MP -I Unit - 1 36
3 Shift (a) Worn-out or bent (a)Repair or replace the
Clamping pins. pins.
(b) Misalignment of (b) Repair of replace
Two halves of pattern. dowels causing
(c) Improper support misalignment.
of core. (c) Provide adequate
(d) Improper location of support to core.
core. (d) Locate the core
(e) Faulty core boxes. properly.
(f) Insufficient (e) Repair or replace
strength of moulding the core boxes.
sand and core. (f) Increase strength
of moulding sand and core.

Note :- There is always a possibility of asking question on

“ Casting defects, their causes and remedies”. Students are
advised to Refer table 11.1 containing total 18 defects in
Workshop technology by B.S.Raghuwanshi.

MEGA OFFER FOR ENGINEERING STUDENTS

LEARN Mechanical Desktop
& AUTO-CAD 2000i
IN JUST RS. 1000/-
PLUS MUCH MORE ONLY AT
SIDDHIVINAYAK COMPUTERS

á MS- WORD

á MS-EXCEL

á POWER POINT

á COREL DRAW

á TV/MULTIMEDIA SOFTWARE

á SCANNER SOFTWARE

á INTERNET(FAX, INTERNET EXPLORER, OUTLK EXPRESS, YAHOO

MP -I Unit - 2 37
UNIT NO.2

Q.1. (a) Define the following terms.

1) Drag
2) Sprue
3) Parting line
4) Gate
(b) Discuss the following casting defects.
i) Sand Spots
ii) Run Out
Ans. 1) Drag:- Sand moulds are prepared in specially
constructed boxes called flasks. The purpose of the flask
is to import the necessary rigidity and strength to the
sand in moulding. They are usually made in two parts, held
in alignment by dowel pins. The top part is called the
cope and the lower part.
2) Sprue :- A vertical passage through the cope and
connecting the pouring basin to the runner and gate is
called Sprue. Conventionally a sprue should be tapered
with larger end to receive the molten metal and to act as
reservoir. Round sprue is preferred upto 20 mm dia, but
longer sprues may be rectangular (less turbulence in
rectangular sprue). The circular sprue has minimum surface
exposed to cooling and offers the least resistance to
flow).
3) Parting line :- It is the line along which the sand
surfaces of the drag and cope join each other.
4) Gate :- It is an opening through which the molten-
mental flows from runner to mould cavity. The size, and
location of gates are so arranged that the mould cavity can
be filled as quickly as possible without cutting the mould
surfaces, further crack in metal after solidification
should not develop.
MP -I Unit - 2 38
(b)i)Sand Spots:- Sand spots on surfaces are generally
developed on iron castings rich in silicon content due to
local chilling of those spots by moulding sand. Due to
this chilling effect white cast iron is formed at those
places, rendering them hard. The main cause of this defect
is a faulty metal composition and a faulty casting design
which results in relatively more rapid cooling of certain
portions than the remaining casting. Changes in metal
composition, addition of suitable amount of nickel and
modification in casting design are the possible remedies of
this defect.
i) Run Out :- A run out occurs when the molten metal
leaks out of the mould during pouring, resulting in an
incomplete casting. The main causes of this defect are
defective moulding boxes, which do not fit properly, and
faulty moulding. Corrective measures in respect of these
two causes will prevent this defect.

Q.2. What is the purpose of die casting? Describe vacuum

die casting with the help of a neat sketch.
Ans. The method of die casting serve the following purpose
:
1) Increasing production rate.
2) Effecting greater economy.
3) Improving quality of casting.
4) Eliminating or minimising the need of further
machining.
5) Provide better dimensional control.
6) Production of better surface finish.
MP -I Unit - 2 39

Vaccum die casting machine :- Complete evacuation of air

from the die prior to metal injection is a vital necessity
for preventing the air entrapment in the casting.
This difficulty is overcome in the vaccum die casting
machine. Some modifications are made in hot chamber die
casting machine to get vaccum die casting machine. The
additional equipment required in this case consist of an
encasement ground the die blocks, compressible seals at
the top and bottom of this encasement and a pipe connecting
the encasement to the vaccum pump through a valve and
vaccum tank. An additional plunger, adjacent to the main
plunger, for elasing the part, when vaccum is applied to
the die to prevent the molten metal
From being drawn into the die.

Q.3. What is the utility of various types of furnaces used

in foundry shops? Describe one widely used furnace with
special reference to its parts, working and other features.
Draw a neat sketch of the furnace also.
Ans. The main utility of various furnaces used in foundries
is for melting of various varieties of ferrous and non-
ferrous metals and alloys.
Describe Cupola furnace for 2nd part of question.

Q.4. Write short notes on the following

(Covering main aspects only).
MP -I Unit - 2 40
(i) Inspection of castings
(ii) Modernisation and mechanisation of foundries.
Ans: Inspection of castings :-
It serves two purposes (1) The rejection of the castings
which do not meet the specifications and (2) maintaining
the quality of workmanship.
There are many methods used to check the quality of
castings. Most of the methods mentioned below.
(i) Visual inspection.
(ii) Dimensional inspection.
(iii) Mechanical testing and chemical testing.
(iv) Defects in internal flows by non-destructive tests.
(v) Metallurgical testing.
(ii) Modernisation and mechanisation of foundries.
The term ‘mechanization’ means substitution of
machinery to perform the operations which were otherwise
performed by hands. Such a substitution can be made of
sand preparation, moulding and core-making, pouring,
material handling and many other similar operations. Such
foundries, where machines have been employed to replace
hand operations, are called mechanized foundries. However,
the decision to switch over to mechanization in any foundry
is largely governed by economic considerations. The extent
to which it can be adopted in any foundry depends
considerably on the quantity and type of production.
Larger the production, more is the scope for mechanization.
This scope is further enhanced if the sad production is of
identical components on mass scale.
Advantages of mechanization
1. From the same floor area much higher production can be
achieved.
2. A large saving in labour and time is effected by doing
away with a number of laborious hand operations, like
sand preparation, mould making and material handling etc.
MP -I Unit - 2 41
3. It creates more hygienic and healthy working conditions
for the shop workers and effects an increase in their
earnings through higher production.
4. It improves the quality of the castings produced by
facilitating closer dimensional tolerances, minimising
defects and providing better surface finish.
5. Overall production cost is reduced due to faster rate of
production and elimination of a large number of laborious
hand operations.

Q.6. What is permanent mould? Specify its advantages and

disadvantages?
Ans. When the mould made from metals like C.I. or steel
then, while casting such mould is not destroyed or rebuilt
after every casting. Since can be use for long period such
mould is known as permanent mould.
Advantages of permanent mould
1) Increases the speed of casting process.
2) Have very long life.
3) Results in better surface finish than sand casting.
4) Castings in large quantities can be produced
economically.
5) Casting method requires less skill and at same time
number of rejections are less.
Disadvantages of permanent mould
1) These moulds are much costlier than sand mould.
2) It can be successfully used for casting very high
temperature alloys
3) Gates, runners and risers can not be shifted and
positioned any where at will.
4) May produced several defects in casting like stress and
surface hardness due to surface chilling effect.
MP -I Unit - 2 42
Q.7. Sketch cross section through permanent mould showing
its principal parts. Describe its construction in detail.
Ans. Construction of permanent mould:
Generally these moulds are made in two halves, parting
surface of which is in a vertical plane. Cores may be
designed as part of the mould itself known as fixed cores
or fitted separately known as movable cores. For easy and
quick removal of movable cores separate mechanism is
incorporated. Clamping arrangement is used to avoid mould
to open under the hydrostatic pressure of molten metal.
Mould generally comprises of several blocks joined together
as shown in figure.
The form block and base block together form the actual
mould cavity whereas the runner block incorporates the
runner and riser. Runner and riser are generally kept on
parting line.

Q.8.What is gravity die casting? Explain with neat sketch.

Q.9. Explain the difference between gravity die casting and
pressure die casting.
Ans.
- In gravity die casting pouring is done simply due to
gravity and no external pressure is applied. But for
pressure die casting external pressure is applied to free
the molten or semi molten metal in to the die cavity.
- In P.D.C. the pressure is applied to the force the fluid
in die cavity. The fluid alloy fills the entire die
MP -I Unit - 2 43
including all minute cavities. Hence intricate can be
produced successfully but as compared to G.D.C.
- We get better dimensional tolerance and better surface
finish in P.D.C. compared to G.D.C.
- P.D.C. can be made fully or semi automatic.
- P.D.C. metal in semi molten state can be cast which not
possible in G.D.C.
- As the arrangement to develop the pressure is needed in
case of P.D.C. it needs some costly equipments which
increases the build up cost for P.D.C. Hence the
equipments use for P.D.C. are costlier than G.D.C.

Q.9. Write short notes on

(i) Repair of castings
(ii) Pressed casting
Ans: (i)Repair of castings:- When casting gets damaged or
found defective particularly in case of large castings, it
is not economical to reject it and recast it. In such case
we can repair it by proper method mostly by welding which
save time as well as money. Depending upon the casting
material, type of defect, we can use proper welding method
to repair defect. In most cases, bend or warped castings,
if slightly out of shape also possible to bring back to
original shape by hammering with soft hammers by hand,
jacks or by presses.
(ii)Pressed casting :- In this type fixed amount of molten
metal poured into the permanent mould and then close
fitting cores are pushed in the cavity, by this molten
metal force into the mould cavity. Cores are removed after
metal sets into cavity. We get thin walled hallow casting.
This method is limited for ornamental articles.

Q.10. Explain Jamming of cupola.

Ans. Jamming of cupola may be permanent or temporary.
MP -I Unit - 2 44
If the molten metal is not taped out before its level
rises to high in the well, the slag which floats on the
surface of molten metal, will start flowing into wind belt
through the tuyeres and air passage will be choked and the
cupola jammed. Thus, the furnace is put to an unusable
condition then it is known as permanent jamming. Iron and
slag around the tuyeres openings get solidify. Due to the
low temperature at the tuyeres openings which results in
the closing of air passage and supply of air is temporarily
stopped termed as temporary jamming. This can be prevented
by frequent poking of this solidified material by poking
bar, through tuyeres.

Q.11. Explain the process of sand preparation and

conditioning.
Ans. Following steps are carried out for sand preparation
and conditioning :-
Sand found in nature doesn’t content all required
qualities in required extent necessary for proper moulding.
Hence some additives are mixed with sand. Generally clay,
lime, magnesia, potash, soda, horse manure, saw dust, cow
dug, coal dust etc. used in small quantities.
This additives are mixed by hand or by mixing machine
which ensures uniform distribution of clay, moisture and
other constituent between sand grains.
Then adequate amount of water is poured over sand,
then the sand turned upside and downside by means of
shovel. This moistens the clay making it adhesive.
This mixture is riddled to remove the foreign
material.

Q.12. State the advantages and disadvantages of die

casting?
Ans. Advantages of die casting are
MP -I Unit - 2 45
1) It requires less floor space as compared to other
casting processes.
2) Rate of production is high. 75 to 150 casts per hour in
cold chamber and 300 to 350 casts per hour in hot
chamber process.
3) Die casting dies retain their accuracy for a very long
time.
4) Very thin sections can be cast and holes upto minimum of
1.6 mm diameter can be easily cored.
5) High surface finish is obtained and often no further
finishing is required.
6) Cost per unit is minimum hence economical.
Disadvantages of die casting
1) All metals and alloys can not be cast.
2) The cost of machines, dies and other equipment used is
high.
3) Not economical for small quantity production.
4) Heavy casting cannot be cast.
5) Special precautions are necessary for evacuation of air
from die cavity, otherwise cause porosity.

Q.12. State the differences between cold chamber die

casting machine and hot chamber machine.
Ans. Following points shows the difference between cold
chamber die casting (machine) and Hot chamber die casting
(machine).
Cold chamber die casting Hot chamber die casting
(Machine) (Machine)
1. Heating chamber is not 1. Heating chamber is integral
integral part of machine part of machine unit.
unit. Metals are melted in
a self contained pot in an
auxiliary furnace.
Non ferrous metals and Metals an alloys having low
MP -I Unit - 2 46
alloys having high melting melting point usually below
point usually above 5000C. 5000C. are cast.
are cast.
Requires operating pressure Requires comparatively low
2
of 300 to 1600 kgf/cm . operating pressure below 150
2
kgf/cm .
Usually 75 to 150 castings Usually 300 to 350 castings
per hour can be produced. per hour can be produced.
Semi solid metals and alloys Semi solid metals and alloys
can be cast. can not be cast.
Usually nickel-chrome steel Usually hardened and tempered
is used for die. chrome-vanadium or chrome-
tungsten steel is used for
die.

Q.13. How permanent mould casting differ from sand casting?

Ans.
Permanent Mould Casting Sand Casting
1. Mould is a permanent one 1. Mould is not permanent.
and is neither destroyed
nor remade after each cast.
2. Requires less floor 2. Requires more floor space
space area. area.
3. Moulds are costly. 3. Cost of mould is less.
4. Rate of production is 4. Rate of production is
high. slow.
5. Economical for large 5. Used for small quantity of
quantity production. production.
6. In order to enable and 6. The runner and riser can
easy and unrestricted be suitably positioned at
removal of casting, the will.
runner and riser are
normally kept on the
parting line.
MP -I Unit - 2 47
7. Better surface finish is 7. Surface finish inferior
obtained. than permanent mould casting.
8. Less skill operator is 8. Comparatively more skill
required. operator is required.
9. Eliminates many defects 9. No need of such precaution
found in sand casting but against chilling effect on
need greater precaution casting surface.
against chilling effect on
the casting surface.

Q.14. What is gravity die casting? Explain with neat

sketch?
Q.15. Sketch and explain the construction and operation of
hot chamber die casting machine.
Ans. In the hot chamber die casting machine the metal
melting unit forms an integral part of machine. It mainly
consist of hot chamber and a goose neck type metal
container made of cast iron.
Construction
This type of machine having goose neck type container
which always remains immersed in the metal pot.
Cylindrical shape is formed at the end of goose neck, a
plunger acts inside the cylinder. A port is provided near
the top of the cylinder. Goose neck injector is connected
to stationary die by nozzle and movable die can move to
from die casting and injecting the casting. Die is
provided with proper injecting mechanism.
Operation
As the plunger move upward the port get open and
molten metal enters into cylinder. Downward movement of
plunger closes the port and forces the molten metal inside
die cavity through nozzle. After solidification plunger
moves upward at the same time movable die move away from
stationary die to inject the casting.
MP -I Unit - 2 48

Injecting mechanism cause to inject the casting. Plunger

starts downward movement and movable die moves towards the
stationary die to form required casting. The cycle
is further repeated.
Q.16. Write short notes on
1) Slush casting
2) Pressed casting
Ans: Slush casting :- Slush casting is a method of
producing hallow casting by using permanent moulds without
the use of cores. In this method the molten metal poured
in to the mould and allowed to solidify upto the required
thickness, then remaining molten metal made to fall out.
Because of this we cannot precisely control the thickness
of casting, hence this method is adopted for ornaments,
statues, toys and other novelties were controlled thickness
is not too important.
Pressed casting :- In this type fixed amount of molten
metal poured into the permanent mould and then close
fitting cores are pushed in the cavities, by this molten
metal force into the mould cavity. Cores are removed after
metal sets into the cavity and we get thin walled hallow
casting. This method is limited for ornamental articles.

Q.17. Explain with neat sketch, the construction and

operation of a die casting die?
Ans. Construction :-
MP -I Unit - 2 49
Die castings are made into halves, one is stationary
and other is movable. These two halves when closed have
vertical parting surface. Dowel pins are provided for
perfect alignment. Provision of vent for escape of air
into parting surface is usually provided. A proper
ejecting mechanism is provided. The die is so designed
that after solidification the casting will always cling to
the ejector die.
Operation :- Movable die moves and comes in contact with
stationary die. Movable die perfectly aligned with
stationary die, which forms the required die cavity. This
cavity is usually the required casting. Then the molten
metal is injected into the die cavity. After
solidification, inserted cores are firstly withdrawn. Then
the die opens, casting cling to the movable die.

Then either the movable half is slighted backward

over the ejector pins or the ejector plate attached to this
is advanced to project the ejector pins beyond the movable
die to eject the casting from the die.

Q.18. What are the common forms in which the die casting
dies are designed? Describe.
Ans. Die casting dies are generally designed in three
forms.
1) Single impression dies :- In this form die have single
cavity by this die only one casting at a time can
produce.
MP -I Unit - 2 50
2) Multi impression dies :- In this form die have more than
one die cavities. These die cavities are alike. By this
die, castings equal to the number of cavities in them can
be produced at a time.
3) Combination dies :- In this form die have more than one
die cavities, but these die cavities are not alike. By
this die, casting equal to the number of cavities in
them can be produced.

Q.18. Explain the working of a cold chamber machine with

the help of a diagram.
Ans. The working principle of a cold chamber machine is
illustrated in Fig.15.3. The word ‘cold chamber’ is used
to denote horizontal cylinder into which the injection
plunger work. For these machines the metal is melted
separately in a furnace and transferred to these by means
of a small hand ladle. After closing the die the molten
metal is poured into the horizontal chamber through the
metal inlet. The plunger is pushed forward hydraulically
to force the metal into the die. After solidification, the
die is opened and the casting is ejected. The plunger is
again drawn back and the cycle repeated as usual for next
casting. These machines are widely used for casting a good
number of alluminium alloys and brasses which cannot be
cast in hot chamber machines as they require higher melting
points. Moreover, the chances of iron pick up by
alluminium are almost finished in these machines as it
takes place only at elevated temperatures, and also because
the molten alloy remains in contact with the steel cold
chamber and plunger for a very small period.

Q.19. State the advantages and disadvantages of die

casting?
Ans. Advantages of die casting are
MP -I Unit - 2 51
1. It requires less floor space as compare to other casting
processes.
2. Rate of production is high. 75 to 150 casts per hour in
cold chamber. 300 to 350 casts per hour in hot chamber
process.
3. Die casting dies retain their and more accuracy for a
very long time.
4. Very thin sections can be cast and Holes upto minimum of
1.6 mm.
5. High surface finish is obtained and often no further
finishing is required.
6. Cost per unit is minimum hence economical.
Disadvantages of die casting are
1. All metals and alloys cannot be cast.
2. The cost of machine dies and other equipment used is
high.
3. Not economical for small quantity production.
4. Heavy castings cannot be cast.
5. Special precautions are necessary for evacuation of air
from die cavity, otherwise cause porosity.

Be a Certified Autocad 2000i & Mechanical

Desktop Professional at SIDDHIVINAYAK
computer
VIST US AT http://business.vsnl.com/siddhivinayak_akola
Mail us at : dipak_shirbhate@hotmail.com
For this note contact at
siddhivinayak computers, renuka nagar dabki road akola
ph 0724- 422684
for coaching in thermal power engg contact er. Rajesh
jarudkar ph 453117
OUR OTHER PUBLICATION FOR THIRD YR DESIGN OF MATERIAL
HANDLING SYSTEM (Rs 50/-)AND MEASUREMENT SYSTEM(FIFTH SEM)
MP -I Unit - 3 52

UNIT NO.03

Q.1. (a) Explain the method of carbon dioxide moulding with

its neat sketch.
Ans. In this method silica sand and 3.5 to 5 % Sodium
silicate liquid base binder, mixed for 3 to 4 minutes in a
muller. Silica sand should be clean, dry and free from
clay. To obtain collapsibility property some additives
like, wood, coal dust, flour, graphite etc are added.
Moisture content should not exceed 3%. This prepared
sand is put in to the mould (around the pattern) by any
convenient method.
After packing CO2 gas is forced into mould at a
pressure of about 1.41 kg/cm2, called gassing. CO2 reacts
with sodium silicate, following reaction takes place and
silica jel is formed.
Na2SiO3 +H2O+CO2 Na2CO3 +(SiO2+ H2O)
(Sodium silicate) (Sodium (Silica jel)
carbonate)
Silica jel binds the sand grains together to provide
the strength and hardness to the Mould. Steps of carbon
dioxide moulding shown below.

Q.2.Describe the process of true centrifugal casting with

the help of neat diagram.
MP -I Unit - 3 53
Ans. In this process, the castings are made in a
hollow, cylindrical mould rotated about an axis, common to
both casting and mould, the axis may be horizontal,
vertical or inclined. The mould used may be either of
permanent type or a sand lined mould usually end cores are
used to prevent the molten metal, thrown out from end.

Fig shows horizontal true centrifugal casting machine.

Having a large cylindrical mould for casting cast iron
pipes. The mould consists of an outer metallic flask
provided with rammed sand lining inside. The mould is
rotated between two sets of rollers, mounted on a shaft
driven by a variable speed motor. Pouring basin is formed
on the body of a trolley.
Molten metal is poured while Mould is rotating,
due to the centrifugal force metal is directed towards the
periphery. While pouring Mould is rotated at slower speed,
after pouring, speed is increased to effect even
distribution of the metal all along the inside surface of
the mould and proper directional solidification. After
solidification flask is replaced by new one and the process
is repeated.
The use of this process is limited only for
symmetrical shaped objects, such as pipes, rolls, cylinder
sleeves and liners, piston-ring stock, bearings bushing
etc.

Q.3. Explain the ‘core’ with the use. What are the
characteristics of a good core?
MP -I Unit - 3 54
Ans. A core can be defined as a body of sand,
generally prepared separately in a core box, which is used
to form a cavity of desired shape and size in a casting.
However, there are some exceptions to this definition. For
example in a pattern can be used to form a core as a part
of the mould, this being known as a green sand core.
Similarly, in permanent moulds or dies, the cores are
formed by the metallic moulds themselves as an integral
part of them. Cores which are prepared separately in core
boxes are called dry sand cores, and held and located in
the moulds in the seats formed by the core prints provided
on the patterns. The main characteristics required in a
good core are the
following :
1. It must be sufficiently permeable to allow an easy
escape to the gases formed.
2. It should be highly refractory to withstand the intense
heat of molten metal.
3. It should be enough hard and strong to bear its own
weight and the force of molten metal.
4. It should have high collapsibility i.e.; it should be
able to disintegrate quickly after the solidification of
the metal is complete.
5. It should not carry such constituents, which will give
rise to excessive gases on coming in contact with the
molten metal.
(The main ingredients of core sand mixtures
and their essential characteristics have already been
discussed in the last chapter.)

Q.4. What is investment costing? What are its main

advantages and disadvantages?
Ans. Following are the steps of investment casting:
1.First of all master pattern is made from wood or metal.
MP -I Unit - 3 55
2 By using gelatin or an alloy of low melting point and
master pattern, master mould is formed.
3.The master Mould is filled with liquid wax or by thermo
plastic polystyrene resin which when solidified forms a wax
pattern.
4. The wax pattern is coated with slurry consisting of
silica flour and small amounts of kaolin and graphite
mixed with water. This process referred to as the
investment of the pattern.
5. The pattern is then used to make up moulds similar to
those used in the conventional moulding process, but the
pattern within the mould is not taken out of the mould,
which is not opened after this moulding process.
6. Finished mould is dried in air for 2 to 3 hrs. and then
baked in an oven about 2 hrs. to melt out the wax or
remove the wax with the help of a solvent degreaser.
7. After this the mould is sintered at about 10000C to
improve its resistivity. Finally it is cooled down to a
temp. between 800 and 7000C for casting. The castings
are obtained by gravity, pressure vacuum or centrifugal
operations. After the metal is cooled the plaster is
broken away and gets feeders are cut out. The castings
so obtained are finally cleaned by sand blasting,
grinding or other finishing processes.
Advantages
1. Better dimensional accuracy, the normal tolerance being
± 0.005 mm.
2. Better surface finish
3. Thin sections of the order of 0.75 mm can be cast
4. Intricate machining of the casting is avoided
5. Castings are sound and have large grains as the rate of
cooling is slow.
MP -I Unit - 3 56
Disadvantages
1. Moulds used are single purpose, i.e.they can be used only
once.
2. It is expensive process and hence is adopted only where
small number of intricate and highly accurate parts are
to be manufactured.
3. This process is suitable for small size parts.
4. They present the same difficulty where cores are to be
used.
5. Process is slow.

Q.5. Which are the moulding machines used in practice?

Describe any one with the help of sketch if required?
Ans. Types of moulding machines:
The large variety of moulding machines that are
available in different designs can be classified as:
1. Jar or Jolt machine. This machine consists of an air-
operated piston and cylinder. The air enters from the
bottom side of the cylinder and acts on the bottom face
of the piston to raise it up. At the top of the piston
is attached the platen or table of the machine which
carries the pattern and moulding flask with sand over it.
When the piston, and hence the table, has been raised to
a certain height the air below the piston is suddenly
released, resulting in an even packing of sand around the
pattern in the flask. The operation is repeated several
times and quite rapidly. It is known as jolting.
2. Squeezer machine: These machines may be hand operated
or power operated. The pattern is placed over the machine
table, followed by the moulding flask. In hand-operated
mechanism whereas in power machines it is lifted by the
action of air pressure on a piston in the cylinder in the
same way as in jolt machine. The difference is that the
table is not dropped from height but is raised gradually.
MP -I Unit - 3 57
On the top of the machine column is provided an overhead
plate and the sand in the flask is squeezed between this
plate and the upward rising table. This enables a uniform
pressing of sand in the flask. A specific advantage of
power operated machines over hand-operated ones is that
more pressure can be applied in the former which
facilitates handling of a wider range of jobs.
Pin lift or push-off type machines. In these machines
the mechanism is almost similar to the above except that
the supporting ram is stationary and four pins are suitably
incorporated passing through the machine platen and the
pattern plate. No stripping plate is, however, required.
After the ramming is over the moulding flask is lifted off
the pattern by the four pins which are mechanically
operated by a mechanism suitably incorporated in the
machine.

Q.6. Describe centrifugal casting and state its advantages

and limitations. Draw a sketch of the same.
Ans. Centrifugal casting is casting method in which, molten
metal is poured while mould is rotating, due to the
centrifugal force metal is directed towards the periphery.
The cold metal is forced towards the outer side of the
casting by the centrifugal force, where as the hotter metal
remains on the inner side of the casting to provide the
required feeding of metal during solidification.
Although many different shapes can be cast through
this process, but those with symmetrical shapes are best
suited for it.
Centrifugal casting methods can be classified as
follows: -
a) True centrifugal casting
b) Semi centrifugal casting
c) Centrifuging
MP -I Unit - 3 58
Advantages: -
1. Due to the forced movement of the molten metal castings
are dense sounds and free from porosity.
2. The use of gates, feeders and central core is
eliminated, making the method less expensive
3. Mass production is possible with less rejection.
4. Mechanical and physical properties of castings are
improved.
5. Parts are produced closer to finished dimensions with
consequent saving in machining.
Disadvantages: -
1. Need heavy initial investment.
2. Need skilled labour.
3. Economical only for mass production.
4. Expensive maintenance cost.
5. The process is limited to only cylindrical and circular
parts with a limited range of sizes.

Q.7. What is meant by felting and why is it required?

Explain in brief
Ans. Castings, when taken out of the mould, are not in the
same condition in which they are desired since they have
sprue, risers, gates, etc. attached to them. Besides, they
are not completely free of sand particles. This operation
of cutting off the unwanted parts, cleaning and finishing
the casting is known as felting. This includes:
1. Removal of cores from the castings.
MP -I Unit - 3 59
2. Removal of gates, risers, runners, etc. from the
castings.
3. Removal of fins, and other unwanted projections from the
castings.
4. Removal of adhering sand and oxide scale from the surface
of the castings (surface cleaning).
5. Repairing castings to fill up blowholes, straightening
the warped or deformed castings.

Q.8. What do you understand by design of casting? 2

Ans. Design of casting includes following: -
1. Design for directional solidification.
2. Design for minimum stresses
3. Design for metal flow.
4. Cast-well design.
5. Design for minimum casting.
6. Design for expected tolerances.
7. Functional design.

Q.9. Describe shell moulding in terms of the following :-

(i) Its principal
(ii) Patterns for it.
(iii) Materials used in making shell
(iv) Steps in the process
Use sketches at appropriate places.
Ans. Shell moulding :- Shell moulding is a method of metal
casting, in which conventional rammed sand moulds are
replaced by relatively thin, rigid shells of approximately
uniform wall thickness. By the same technique, hollow
cores can be made to replace the traditional solid rammed
and baked cores normally used in green sand moulds.
The main steps in shell moulding are as follows :-
1. A metal pattern usually of cast iron having the same
profile as that of the required casting is heated to
MP -I Unit - 3 60
1500-2500C in an oven. It is taken from the oven and a
stripping agent, usually silicon 5 to 10 % solution in
paraffin or water, is sprayed on the pattern to
facilitate the subsequent withdrawal of the shell from
the pattern.
2. As shown in figure,(b),the pattern is clamped to the dump
box which is mounted on trunions. In the box, the dry
sand resin mixture is the shell forming medium.
3. The dump box is inverted, as shown in figure (c), so that
the dry sand mixture falls on to the hot pattern face.
The hot pattern face causes the resin to soften and flow.
After about 30 seconds, the resin component of the sand-
resin mixture softens and fuses to form a fairly uniform
shell about 60 cm thick on the pattern face.
4. The dump box is returned to its original position as
shown in figure (d), and excess of sand-resin mixture
falls back to the bottom of the box leaving a shell
adhering to the hot pattern surface. The partly cured
shell is then placed in an oven for final curing. This
is carried out at about 4000C and may take about two
minutes.
5. When curing is complete, the shell becomes rigid and is
stripped from the pattern by spring loaded ejector pins,
which pan through the pattern plate as shown in figure
(e).
6. Two such shells are fixed together to form the complete
mould, with the help of bolts, clips or glue and placed
in a suitable box with proper backing and to receive the
molten metal as shown in figure (f).
Sand for shell moulding.
MP -I Unit - 3 61

Usually zircon sand of rounded grain shape, free from

organic impurities and having a grain size of 100 to 150
mesh (B.S.) is used. Coarser sands increase shell strength
but lower surface finish. Finer sands improve the surface
finish but weaken the shell. Although zircon sand is
costlier than silica sand, it gives, a stronger shell for a
given percentage of resin binder and a good surface finish.
Binder for shell moulding:
The binders used are resins of thermosetting type and
the most common resin are phenol formaldehyde, urea
formaldehyde, and polysters. The resins are used in the
powdered form and when subjected to about 2000 to 2500C,
they melt instantly and turn into a rubbery state and
harden after one or two minutes. The usual amount of
resins in the sand moisture varies from 3 to 10 per cent.

Q.10. Explain the method of CO2 moulding with its neat

sketch.
Ans. In this method silica sand and 3.5 to 5% Sodium
silicate liquid base binder, mixed for 3 to 4 minutes in a
muller, silica sand should be clean, dry and free from
clay. To obtain collasibility property some additives
like, wood, coaldust, flour graphite etc. are added.
MP -I Unit - 3 62
Moisture content should not exceed 3%. This prepared
sand is put in to the mould (around the pattern) by any
convenient method.
After packing, CO2 gas is forced into mould at a
pressure of about 1.41 kg/cm2, called gassing. CO2 reacts
with sodium silicate, following reaction takes place and
silica jel is formed.
Na2SiO3+H2O+CO2 Na2CO3 + (SiO2+H2O)
(Sodium (Sodium (Silica
Silicate) Carbonate) jel)
Silica jel binds the sand grains together to provide
the strength and hardness to the Mould. Steps of carbon
dioxide moulding shown below.

Q.11. What is centrifuguring ? Describe the process stating

its differences with other centrifugal casting method?
Ans. This is also sometimes known as pressure casting. It
mainly differs from true centrifugal or semi-centrifugal
casting methods in that unlike the latter two, the axis of
rotation and that of the moulds do not coincide with each
other, as the moulds are situated at a certain distance
from the central vertical axis or rotation all around the
same. Shapes of castings do not carry any limitations in
this method and a variety of shapes can be cast. A number
of small mould cavities are made around a common central
sprue and connected to the same through radial gates. For
MP -I Unit - 3 63
a higher rate of production the stacked moulds can be used
with advantage. As in semi-centrifugal force used to force
the molten metal from the central sprue into the mould
cavities through the radial gates. Sectional view through
a typical mould for centrifuging is shown in Fig.

Q.12. What are the factors to be considered while selecting

the method of casting?

Q.13. Specify and explain the method of casting used to

manufacture pipes. 7
Ans. ** Write the process of centrifugal casting**

Q.14. Explain in detail investment casting?

Q.15. What is mercast process of casting?

Ans. In this process frozen mercury is used for the
production of precision castings. In this case, the metal
mould is prepared of the necessary shape with gates and
sprue-holes. It is then placed in cold bath and filled
MP -I Unit - 3 64
with acetone (which acts as a lubricant). Mercury is
poured into it and freezing of mercury takes place at 200C
after about 10 minutes of pouring. The patterns are then
removed and are given dippings in a cold ceramic slurry
bath, until a shell of about 3 mm is built up. Mercury is
then melted and removed at room temperature. The shell is
dried and heated at high temperature to form a hard
permeable shape. The shell is then placed in a flask,
surrounded by sand, preheated and filled with metal. After
solidification of metal, the castings can be removed.

Q.16. What is core? What is its use? What are the

characteristics of a good core?
Ans. A core can be defined as a body of sand, generally
prepared separately in a core box, which is used to form a
cavity of desired shape and size in a casting. However,
there are some exceptions to this definition. For example
in a pattern can be used to form a core as a part of the
mould, this being known as a green sand core. Similarly,
in permanent moulds or dies, the cores are formed by the
metallic moulds themselves as an integral part of them.
Cores which are prepared separately in core boxes are
called dry sand cores, and held and located in the moulds
in the seats formed by the core prints provided on the
patterns. The main characteristics required in a good core
are the following:
1. It must be sufficiently permeable to allow an easy
escape to the gases formed.
2. It should be highly refractory to withstand the intense
heat of molten metal.
3. It should be enough hard and strong to bear its own
weight and the force of molten metal.
MP -I Unit - 3 65
4. It should have high collapsibility i.e., it should be
able to disintegrate quickly after the solidification of
the metal is complete.
5. It should not carry such constituents which will give
rise to excessive gases on coming in contact with the
molten metal.
The main ingredients of core sand mixtures and their
essential characteristics have already been discussed in
the last chapter.

Q.17. Explain hot chamber die casting machine?

Ans. The main parts of a hot chamber machine are shown Fig.
This is operated by a hydraulic plunger. This plunger acts
inside a cylinder formed at on end of the goose-neck type
casting submerged in the molten metal. A port is provided
near the top of the cylinder to allow the entry of the
molten metal into it. When the bottom of the plunger is
above the port the cylinder is connected to the melting pot
through this port. The down stroke of the plunger closes
this port, cuts off the metal supply and applies pressure
on the molten metal present in the goose neck to force the
same into the die cavity through the injecting nozzle.
After a certain period of time the plunger is raised up,
causing the remaining molten metal in the nozzle and
channel to fall back into the goose neck casting. Just
before the end of its upward stroke the plunger uncovers
the port, through which more molten metal enters into the
cylinder. The dies are then opened and the casting
ejected. Zinc based low melting point alloys are generally
cast in these machines.

Q.18. State its advantages and disadvantages?

Ans. Advantages
1. Surface finish a good
MP -I Unit - 3 66
2. Dimensional accuracy is high
3. Thin sections upto 2 mm can be cast
4. Sand handling is minimum
5. Permeability of the shell is high
6. Surface chilling of the castings is absent and the
castings are free from skin hardening
7. Less floor area is required
8. It is highly adaptable for mechanisation.
9. Cost of cleaning the casting is low
10.Casting defects are minimum
11.Shells can be stored
12.It allows for greater detail and less draft
13.Unskilled labour can be employed.
Disadvantages
1.Higher pattern cost
2.Higher resin cost
3.Not economical for small runs
4.Dust-extraction problem
5.Complex jobs cannot be shell moulded.
Shell moulding machines are of two types, (1) Semi
automatic (2) Automatic.

Q.19. Illustrate and desirable the process of Semi-

Centrifugal casting.
Ans. This process, which is also known as profiled
centrifugal casting is widely used for relatively large
castings which are symmetrical in shape, such as discs,
pulleys, wheels and gears etc. In this method the mould is
rotated about vertical axis and the metal poured through a
central sprue. It is not necessary to cast only one mould
at a time. Several moulds can be stacked together, one
over the other, and fed simultaneously through a common
central sprue, as shown in Fig. This provision increases
the rate of production considerably. The centrifugal force
MP -I Unit - 3 67
is used to feed the metal outwards to fill the mould
cavities completely. The centre of the castings is usually
solid, but, if required, a dry sand central core may be
used to produce the central hole. The speed of rotation of
these moulds is much lower than that in true centrifugal
casting. With the result the pressure developed is too low
and the impurities are not directed towards the centre as
effectively as in true centrifugal casting. The speed of
rotation of these moulds is such that a linear speed of
about 180 meters per minute is obtained on the outer edge
of the casting. The moulds used may be of green sand, dry
sand, metal or any other suitable material.

Q.20. Describe the complete procedure of investment

casting. What are the main advantages and disadvantages?
Ans. INVESTMENT CASTING :- It is also known as Lost was or
Precision casting. The castings produced by this method
are within very close tolerances and do not require
subsequent machining. The procedure adopted for investment
casting is as follows.
1. First of all, a metal die for casting the wax pattern is
made.
2. The wax patterns and gating systems are produced from the
metal dies by injection. The wax is injected into the
mould at 50 C to 80 C and at pressure of 35 kg/cm2 to kg/cm2.
0 0
MP -I Unit - 3 68
3. The wax assembly is dipped into a slurry of a refractory
coating material. A typical slurry consists of silica flour
suspended in ethyl silicate solution of suitable viscosity
to produce uniform casting after drying. After dipping,
the assembly is coated by sprinkling it with silica and
allowed to dry.
4. The coated wax assembly is now invested in the mould.
This is done by inverting wax assembly on a table,
surrounding it with a paper-linked steel flask and pouring
the investment moulding mixture consisting of either sand
95%, water 27 to 31% and 5% alumina cement. The mould
material settles by gravity and completing surrounds the
pattern as the work table is vibratech the moulds are then
allowed to dry in air for 2 to 3 hours.
5. The wax is melted out of the hardened mould by heating it
in an invested position at 900C to 1800C. The melted wax
may be collected and re-used.
6. The mould is again heated at the rate of 400C to 700C per
hour from about 1500C to 10000C for ferrous alloys and 6500C
for alluminium alloys. The temperature is controlled so
that the mould is at a temperature desirable for pouring
the particular alloy. The investment moulds may be poured
under simple gravitational force or under the force of
applied out pressure or by centrifugal force.

(a)

(b) (c) (d)

MP -I Unit - 3 69

HEAT

(e) (f)
Following are the advantages and disadvantages
investment casting.
Advantages :
1. The close tolerances (±0.05 mm) are easily maintained in
average work.
2. It produces extremely smooth surfaces.
3. It eliminates post machining operations including thread
cutting and gear tooth ferming.
4. It is adaptable to all metallic alloys.
Disadvantages :
1. The investment moulds as well as the materials from
which they are made an single purpose, therefore they
can not be reused. This increases cost of production.
2. The larger objects are impractical for investment
casting due to equipment size limits.
Steps involved in making investment casting.
(a) Wax injected into die to make pattern.
(b) Pattern have been gated to central sprue.
(c) Placing a metal flask around the pattern assembly.
(d) Investing the wax pattern assembly.
(e) Removing wax pattern from investment mould.
(f) Pouring molten metal into the mold.
(g) Removing casting from the mold by breaking the mold
material.
MP -I Unit - 3 70
Q.21. What do you understand from ‘Centrifugal castings’?
How are the centrifugal casting methods classified?
Ans. The process of centrifugal casting is also known as
liquid forging. It consists of rotating the mould at a
high speed as the molten metal is poured into it. Due to
the centrifugal force the molten metal is directed outwards
from the centre, towards the inside surface of the mould,
with considerable pressure. As a result of this a uniform
thickness of metal is deposited all along the inside
surface of the mould, where it solidifies, and the
impurities being lighter remain nearer to the axis of
rotation. This process enables the production of castings
with greater accuracy and better physical properties as
compared to sand castings. It also enables the production
of distinct surface details and dense metal structure.
Although many different shapes can be cast through this
process, but those with symmetrical shapes are best suited
for it. The better physical properties of the castings are
the result proper directional solidification of the metal
inside the mould. It is achieved because the denser(or
cold)metal is automatically forced towards the outer side
of the casting by the centrifugal force, whereas the hotter
metal remains on the inner side of the casting to provide
the required feeding of metal during solidification. The
centrifugal casting methods can be classified as follows:
1. True centrifugal casting.
2. Semi-centrifugal casting.
3. Centrifuging.

Q.22. What are the main methods of casting applied to

investment casting?
Ans.
1. Gravity casting method.
2. Centrifugal casting method.
MP -I Unit - 3 71
3. Vaccum casting method.

Q.23. What are the materials commonly used for making the
moulds for centrifugal casting?
Ans. The moulds used in centrifugal casting methods are
made of sand, metal or graphite. Sand moulds are generally
preferred for slender castings where the metal has to flow
a long distance. The use of these moulds minimises
chilling effect. For quantity production metal moulds are
preferred. Metal moulds are made from cast iron, high
carbon steel or alloy steel. Graphite moulds are largely
used for non-ferrous castings.

Q.24. With the help of neat diagram describe the process of

true centrifugal casting. How this method can be used for
production of pipes?

Q.25. Describe step by step, the process of shell moulding.

What are its advantages and disadvantages?

Be a Certified Autocad 2000i & Mechanical Desktop

Professional at siddhivinayak computer education,
renuka nagar dabki road akola

MASTER IT TODAY THAT THE WORLD WILL LEARN TOMORROW

AUTOCAD-2000I
MECHANICAL DESKTOP
PRO-ENGINEERING
I-DEAS
CATIA V-5
SOLID WORKS

FOR NOTES CONTACT MR. HARISH CHEDE OR 0724-422684

MP -I Unit - 4 72
UNIT NO. 4

Q.1. What is hot working ? State its principles,

advantages and disadvantages.
Ans. Mechanical working of metals above its
recrystallisation temperature is known as hot working.
Advantages :
1. Larger deformation can be accomplished and more rapidly
by hot working since the metal is in plastic state.
2. Porosity of the metal is considerably minimised.
3. Concentrated impurities, if any in the metal are
disintegrated and distributed throughout the metal.
4. Grain structure of the metal is refined and physical
properties improved.
Disadvantages :
1. Due to high temperature a rapid oxidation or scale
formation takes place on the metal surface, leading
to poor surface finish and loss of metal.
2. On account of the lost of carbon from the surface of
the steel piece being worked the surface layer loses
its strength, which is a disadvantage when the part
is put to service.
3. This weakening of the surface layer may give rise to
a latigue crack which may ultimately result in
fatigue failure of the part.
4. Close tolerances cannot be maintained.
5. It involves excessive expenditure on account of high
cost of tooling. This, however, is compensated by the
high production rate and better quality of products.
MP -I Unit - 4 73

Q.2. Describe the procedure of hot extrusion of tubes.

Ans. A common method of hot extrusion of tubes is shown in
figure. It is actually a forward extrusion method using a
mandrel to form the bore of the tube. First the mandrel is
pushed through the centre of the billet and the die,
followed by applying pressure on the billet by advancing
the plunger. The metal is forced to flow through the
opening between the die and the mandrel. The operation is
performed quite rapidly. Most of the metals and alloys are
hot extruded, although some of these are cold extruded
also, for production of seamless tubes.

Q.3. Write short notes on

Ans. 1. Hot Spinning :-
The process consist of heating the metal to forging
temperature and then forming it into the desired shape on a
spinning lathe which is similar to an engine lathe.
Usually shapes of circular cross-section which are
symmetrical about the axis of rotation, are formed by this
process. The workpiece is shaped over a formed revolving
metal holding device, called chuck, with the help of
spinning tools. It very well compares with drawing of
stamping in so far as the production in small quantities is
concerned, since the cost of dies for such small quantities
will lead to uneconomical production through the latter
MP -I Unit - 4 74
methods. Hot spinning is generally used for thicker plates
and sheets which cannot be shaped through cold spinning.
In operation it is similar to cold spinning and, therefore,
the details of equipment, tools and procedure, etc., will
be given later under 'cold spinning’.
2. Hot Forging
These process basically consists of heating the metal
to plastic state and then applying pressure to form it into
different shapes and sizes. Unlike rolling, the pressure
in this case is not continuous but intermittent. The hot
metal piece may be compressed along its length to increase
its cross-section, along its cross-section to increase its
length, within a closed cavity to acquire the shape of that
cavity or in different directions to bend it into different
shapes. The pressure may be applied by hand hammer called
hand or smith forging, by power hammers, called hammer
forging, by presses (press forging) or upset forging
machines.

3. Hot drawing
This process is widely used for the production of
thicker walled seamless tubes and cylinders. It is usually
performed in two stages. The first stage consists of
drawing a cup shape out of a hot circular plate with the
help of a die and a punch. The second stage consists of
reheating the drawn cup and drawing is further to the
desired length having the required wall thickness. The
second drawing operation is performed through a number of
dies, which are arranged in a descending order of their
diameters, so that the reduction in wall thickness is
gradual in various stages. The farther end of the drawn
object is always blind, which may be cut off to produce a
through hole, if required.
MP -I Unit - 4 75
Q.3. What are the specific advantages and limitations of
cold working?
Ans. Advantages and limitations:
1.Better dimensional control than hot working is possible
because the reduction in size is not much.
2.Surface finish of the component is better because no
oxidation takes place during the process.
3.Strength and hardness of the metal are increased.
4.It is an ideal method for increasing hardness of those
metals which do not respond to the heat treatment.
5.Only ductile metals can be shaped through cold working.
6.Over-working of metal results in brittleness and it has
to be annealed to remove the same.
7. Subsequent heat treatment is mostly needed to remove the
residual stresses set up during cold working.

Q.5. What are the main characteristics of the hot working

of metals or compared with cold working process?
Ans. (1) Above the re-crystallisation temperature, the
metal becomes plastic and causes the growth of grains. By
hot working, the grains are broken up and their parts are
deformed into small and more numerous crystals or in other
words the refinement of grain occurs. Metals possess
little elasticity and low load is required to shape the
metal as the strength and hardness decrease at elevated
temperatures.
(2)The porosity of the steel ingot can be eliminated to a
greater extent.
(3)Great latitude in shape and size of form is possible due
to reduction of elastic limit.
(4)A uniformity is established either by squeezing other
impurities into fiber slags or distributing them throughout
the mass.
MP -I Unit - 4 76
(5)Directional property resulting from a fiber structure is
obtained.
(6)Due to refinement of grains, mechanical properties such
as toughness, ductility, elongation and reduction in area
are improved.
(7)The power required to finish the part ingot is less.
(8)It can be used on most of the metals, because it is a
rapid and economical process.

Q.6.Why forging generally preferred for those components

which require high strength and resistance to shock?
Explain briefly.
Ans. Characteristics of the Forged Parts
(1)It refines the structure of metal by closing up the
cavities and by smashing up large grain formations.
(2)Forged parts have directional properties and hence have
good strength.
(3)Mechanical properties such as percentage elongation,
percentage reduction of area and resistance to shock and
vibration are improved.
(4)Cracks and blow holes are minimised.

Q.7. For various methods of forging known to you give the

application areas.
Ans.
(1) Hand forging :- Hand forging is emplayed only to shape
a small number of light forgings chiefly in repair
shops.
(2) Hammer forgings :- Usually used for small item forging.
(3) Press forging :- Usually used for heavy item forging.
(4) Machine forging :- For medium sized and large articles
requiring very heavy blows.
(5) Drop forging :- For mass production of identical parts.
MP -I Unit - 4 77
Q.8. Define up setting, edging, drawing, piecing and
punching operations as applied to not working of metals.
Ans.
Upsetting :- This is just opposite to drawing and involves
increasing of the cross-sectional area usually by pressing
or hammering in a direction parallel to the original ingot
axis. In the process of upsetting, the shaft or rod is
generally gripped in dies, and the head or flange upset
either by a plain flattened ram or with further dies,
shaped to give the desired contour.
Edging :-
Drawing :- Refer – (Hot drawing)
Piercing :- This process is employed for the production of
seamless tubes. It offers the most economical mechanical
working, process for the manufacture of seamless tubes. It
consists of passing the hot rolled billet at 11000C. between
two conical rollers and over a mandrel which helps in
piercing and controlling the size of bore as the billet is
forced over it.

Q.9.Define the following terms related to cold working of

metals.
Ans.
(1) Blanking :- This is the operation carried out on presses
and consists of cutting the outside contour of a
stamping. Production of sheet-metal blanks of flat
MP -I Unit - 4 78
shapes requires a single-action press equipped with
tools comprising a punch, a corresponding die, a
stripper to keep the sheet from following the punch on
its upstroke and means for aligning the sheet or strip
of material and for spacing successive cuts. Cutting
inside contours, i.e. holes and slots is called
piercing. All these operations will be dealt in detail
under the chapter of presses. However pressed-metal
parts, or stampings are recommended for mass production.
Stampings combine the virtues of lightness, a high
degree of uniformity, and surfaces well adopted to
receive protective and decorative finishes.
(2) Swaging :- This operation consists of applying
compressive or impact forces on the metal below the
recrystallisation temperature. It causes the metal to
flow in the predetermined shape according to the design
of the dies. Rotary swaging and cold heading are the
two important processes of swaging.
(3) Lancing :- It is a special form of piercing operation in
which the entire contour is not cut, the blanked
material remains attached with the sheet. It is
achieved by bending down one side of partially punched
hole.
(4) Embossing :- It is also like a drawing or stretching
operation and does not require much pressure like
drawing and coining. It consists of producing, projected
or raised designs in relief on a surface of sheet. It
is done with the help of two mating dies. The sheet is
first blanked and then little more force is applied by
the punch which forces the metal against a mating die
conforming to the same configuration as the punch. In
this way very little metal is squeezed in the operation
and the words are printed on the sheet in projected
form.
MP -I Unit - 4 79
Q.10. Explain extrusion process as used for production of
tubes. Draw sketches for various stages in it.

Q.11. In what way does shear spinning differ from spinning

process?

Q.12. What are the various methods of tube manufacturing?

Explain any one in detail.
Ans.
1.Tube drawing
2.Roll piercing
3.Tube manufacturing by lap welding.
4.Tube extrusion.
Roll piercing :-
It is a method of producing seamless tubes. The
piercing machine used in the process consists of two
tapered rolls called piercing rolls. Round heated billet
of steel is passed between these rolls over a mandrel.
Both the rolls rotate in the same direction. The billet is
centre punched or provided with a small drilled hole at one
end and heated to proper temperature. It is then pushed
forward into the rolls. The rolls grip the billet and pull
it further into them. The axes of the rolls are crossed,
therefore they revolve the billet as well as draw it
forward to force it on to the mandrel. The mandrel can
also revolve in its own position. This combination of the
revolving motions of the billet, and mandrel, together with
the axial advancement of the billet, provide a helical
rolling effect on the material. Production of a 12 meter
length of upto 150 mm diameter rough tubing will take about
10 to 30 seconds through this method. If tubing of larger
bore (say upto 350 mm) are to be made a second piercing
operation is necessary after the first. Still larger sizes
will need a third piercing operation.
MP -I Unit - 4 80
The rough tubing produced as above is further
subjected to rolling, reeling and sizing etc. to bring it
to the correct shape and size and to provide a fine surface
finish. Such tubes are produced in various metals and
alloys like steel alloys, alluminimum, brass and copper
etc.

Q.13. What do you mean by cold working of methods ? Explain

any two cold working process with neat sketch.
Ans. The processes which are done on the metals by
keeping the temperature below recrystallisation temperature
are known as cold working processes. The force required for
these processes is high as compared to hot working
processes. Cold working processes are also applied for soft
materials otherwise the work piece will crack. In cold
working processes strength & hardness is increased but
grain structure is distorted.

Q.14. Write short notes on

1.Hot spinning (described earlier)
2.Hot drawing (described earlier)
3.Roll piercing (described earlier)

Q.15. Explain principle of rolling showing its effect on

granular structure.
Ans. The process of rolling basically consists of
passing the hot ingot through two rolls rotating in
opposite direction at a uniform peripheral speed. The space
between the rolls is adjusted to conform to the desired
thickness of the rolled section, and the same is always
less than the thickness of the ingot to reduce its cross-
section and increase its length.
The process is illustrated in figure, which shows the
changes that take place in the grain structure of the metal
MP -I Unit - 4 81
as it passes through the rolls. As a result of squeezing
the grains are elongated in the direction of rolling and
the velocity of material at exit is higher than that at the
entry. After crossing the stress zone the grains start
refining. But this is the case only in hot rolling. In cold
rolling they tend to retain the shape acquired by them
during rolling.

Q.16.Describe the types of rolling mills. Explain their

arrangements, specific uses in detail.
Ans. The different types of rolling mills are
described below:
1)Two high mill-
It consists of two heavy horizontal rolls, placed
exactly one over the other. The rolls are supported on
bearings housed in sturdy upright side frames, called
stands. The space between the rolls can be adjusted by
raising or lowering the upper roll. The position of the
lower roll is fixed. Both the rolls rotate in opposite
directions to one another, as shown in figure. Their
direction of rotation is fixed and cannot be reversed.
Thus, the work can be rolled by feeding from one direction
only. There is another type of two high mill which
incorporates a drive mechanism that can reverse the
workpiece continuously through back-and-forth passes
between the rolls. This type of rolling mill is known as a
two-high
MP -I Unit - 4 82

reversing mill. They are normally employed for the initial

rolling of an ingot.
2)Three high rolling mills-
It consists of three horizontal rolls, positioned
directly one rotation of the upper and lower rolls are the
same, but the intermediate roll rotates in a direction
opposite to both of these. All the three rolls continuously
revolve in the same fixed directions and are never
reversed. The work piece is fed in one direction between
the upper and middle rolls and in the reverse direction
between the middle and lower rolls. Many pieces may be
passed through the rolls simultaneously. This results in a
higher rates of production than the two-high mill. This
mill may be used for blooming, billet rolling or finish
rolling.
MP -I Unit - 4 83
3)Four-high rolling mills-
It consists four horizontal rolls, two of smaller
diameter and two of larger diameter, arranged directly one
over the other as shown in figure. The larger diameter
rolls are called back-up rolls and their main function is
to prevent the deflection of the smaller rolls, which
otherwise would result in thickening of rolled plates or
sheets at the centre. The smaller rolls are known as
working rolls and they are the rolls which concentrate the
total rolling pressure over the metal. These mills are

generally used for subsequent rolling of slabs. The common

products of these mills are hot or cold rolled sheets and
plates.
4)Cluster mill-
It consists of two working rolls of smaller
diameter and four or more back-up rolls of larger diameter.
The arrangement of rolls for this mill is shown in figure.
The number of back-up rolls may go up as high as 20 or
more, depending upon the amount of support needed for the
working rolls during the operation. This type of mill is
generally used for cold rolling.
MP -I Unit - 4 84

5)Continuous rolling mills-

It consists of a number of nonreversing two-high
mills arranged one after the other, so that the material
can be passed through all of each successively. The
millstand rotate at a faster speed than that of the
preceding rolls in order to accommodate the increasing
length of the metal piece being rolled. This arrangement
facility facilitates a very rapid production, because the
component passes continuously from one stand to the other
until it reaches the final pass. But it is suitable for
mass production work only, because for smaller quantities
quick changes of set-up will be required and they will
consume a lot of time and labour. As the speed of rolls on
each successive stand varies it is necessary that their
respective surface speeds should be properly calculated and
adjusted.

Q.17.Write short notes on

1)Cold spinning
2)Roll bending
Ans. Cold Spinning-
The process is similar to hot spinning, described
earlier. The metal is pressed on to the surface of a wooden
or metallic form, called chuck, attached to the lathe
spindle. An adapter fitted in the barrel of the tailstock
MP -I Unit - 4 85
holds the work against the form. The tools used, called
spinning tools, are provided with blunt edges and are
supported on the toolrest fitted on the cross slide, as
shown in figure.
Alluminium and other soft metals are best suited for cold
spinning. A few commonly used spun articles out of
Alluminium and its alloys are processing kettles, cooking
utensils, liquid containers and light reflectors etc.
Various other ductile metals, particularly non-ferrous
ones, are quite successfully spun into various typical
shapes. The thickness of the metal is reduced during
spinning, and proper allowance should be made for this in
the blank to be cut. At the end of the operation the
unwanted material is trimmed off to bring the product to
required size. The form or chuck may be in single piece or
composed of many sections attached together, depending upon
the possibility of the spun part from it. Where the space
of the part does not permit its removal from chuck, off-
centre chuck are used.

This process of spinning is generally used for:

1.Limited production.
2.Keeping the tool costs low.
3.Production such peculiar shapes which are difficult to be
produced through other forming methods.
MP -I Unit - 4 86
2) Roll bending-
It is also s kind of roll forming operation
through which metal sheets and bent into cylindrical
shapes. The roll bending machines carries three rolls; two
being fixed and the third adjustable. Diameter of all the
same. By adjusting the position of the adjustable roll the
plates or sheets can be bent in different curvatures.

Q.18. Define cold bending.

Ans. It is employed for bending into desired shapes
various stock materials like rods, wires, bars, pipes,
tubes and various structural shapes. Formed dies are used
for bending these articles and the operation is usually
performed in many stages. Well designed fixtures are also
used where mass bending of such components is required.

Q.19. Discuss extrusion of a seamless tube.

Q.20. Sketch and describe the types of rolls used in

rolling mills.
Ans. The rolls used in rolling mills essentially
consists of three parts, namely body, neck, and wabbler.
The main rolling operation is performed by the body. It is
therefore made to have different shapes on its periphery,
according to the desired shapes of the rolled products,
such as smooth for flat and grooved for other sections. The
rolls vary in diameters from a few centimeters to about 1.5
meters. The extent to which the reduction in cross-section
can be made in a single pass depends upon the weight and
size of the rolls. The neck is that part of the roll on
which it rotates in the bearing. The wabbler is the star-
shaped construction at both ends of the roll which engages
the hollow cylinder to connect it to the driving shaft to
receive power. The advantage of providing the wabblers is
MP -I Unit - 4 87
that the main body of the roll is not directly connected
with the driving shaft. Thus, in case of too heavy
loading, if there is any damage, it will occur only in the
wabbler, which is a much weaker section, and the main body
will remain absolutely free from it. The rolls are
generally made from cast or forged steel or cast iron.

Q.21. Describe the process of cold spinning stating its

advantages and specific uses.
Ans. Advantages of cold spinning
(1) This is very cheap process.
(2) It does not require much investment.
(3) The production of in cylindrical shape by spinning is
less economical.
Specific uses of cold spinning:
Cold-spinning process is frequently used in the
making of bells on musical instruments and also for light
fixtures, kitchen-ware, reflectors, funnels, and large
processing kettles.

Q.22. What is continuous rolling mill? What are its

advantages?
Ans. This consists of several stands of two high mills
arranged one after the other. As the metal comes out of
one set of rolls, it enters second, third and so on and
finally comes out in required size and shape. The speed of
every stage goes on increasing in comparison to preceding
roll in order to accommodate the increasing length of the
metal and thereby making it a continuous process. The
MP -I Unit - 4 88
operation is thus very fast and space requirement for mill
is less. The production is economical and at the same time
mass production is possible.

Q.23. Write short notes on

Ans. Cold rolling:
Cold rolling is generally employed for providing
a smooth and bright surface finish to the previously hot
rolled steel. It is also used to finish the hot rolled
components to close tolerances and improve their toughness
and hardness. The items generally subjected to cold
rolling for this purpose are bars, rods, sheet plates,
strips and wires etc. Before being put to cold rolling the
hot rolled articles are cleaned through pickling and other
operations. The same types of rolling mills, described
earlier in connection with hot rolling, are used in cold
rolling. In order to obtain a smooth surface finish the
roll surfaces are polished and scratches, if any, removed.
The part being rolled is usually annealed and pickled
before the final pass is made, so as to bring it to
accurate size and obtain a perfectly clean surface.

Q.24.What is hot working? What are the common hot working

processes?
Ans. The principal hot working processes generally
applied to various metals, are the following:
1.Hot rolling.
2.Hot forging.
3.Hot spinning.
4.Hot extrusion.
5.Welded pipe and tube manufacturing.
6.Roll piercing.
7.Hot drawing.
MP -I Unit - 4 89
Q.25.Explain the following cold working process.
Ans. Cold hobbing:
It is a process for producing cavities of various
shades in a blank of soft metal by pressing a hardened
steel form into it. This form is known as a hob. The
operation may require several pressings and annealings in
between. Hydraulic presses are used for providing the
required pressure. The main advantages of this process is
the economical production of identical cavities in large
number. Moulds for plastic moulding can be produced
through this method.

Q.26. What principles are involved in hot rolling? Explain.

Q.27. What is hot extrusion? In how many ways it can be

performed?
Ans. The process of extrusion consists of compressing
a metal inside a chamber to force it out through a small
opening called die. Any plastic material can be extruded
successfully. Most of the presses used for extruding
metals are hydraulically operated horizontal presses. A
large number of extruded shapes are in common use such as
tubes, rods, structural shapes and lead covered cables.

Q.28. What is roll piercing and for what purpose it is

used?

Q.29. Describe the process of cold spinning stating its

advantages and disadvantages and specific uses.

Visit dept of production engineering on web at

http://coeta-production.tripod.com
MP -I Unit - 5 90

UNIT NO:5
Q1. Describe with the help of neat sketch the principle of
spot welding.
Ans. The principle of spot welding is illustrated in
fig, where a transformer core is shown having primary and
secondary windings P and C respectively. One end of the
secondary windings is connected to the upper electrode E1
carried in the movable copper or bronze arm A and the other
end to the lower electrode E2 mounted on the fixed arm B. In
operation the metal sheets S1 and S2 are held and pressed
between the electrodes and a strong current at low voltage
is switched on. Due to the resistance offered by the sheet
metal to the flow of this current the temperature at the
contact surfaces rises to fusion point and the weld is
completed under the contact pressure of the electrodes.

Q2. Write shorts on

1)Welding rods
2)Fluxes
3)Gas flames
Ans: 1)Welding rods:
Sufficient care should be taken in selecting a
suitable welding rod or filter rod for welding a particular
material. Always the best available quality of the rods
should be selected as the cheaper qualities are likely to
contain more impurities and they will result is the
MP -I Unit - 5 91
production of an unsound joint. Welding rods suitable for
welding different metals are produced by various standard
manufacturers under their own trade names and it is
advisable, at least for a beginner, to be guided by the
manufacturer’s instructions in the selection and use of
these rods. However, it is reckoned that a welding rod will
posses the same or nearly same composition of its
constituents as that of the metal which is to be joined.

2)Fluxes:
The chemicals, which deoxidize the metal surface
and provide inert atmosphere around the molten, are known
as fluxes.
FUNCTION:
1)To prevent oxides from the hot surfaces.
2)To reduce the viscosity of molten metal.
3) It maintains a steady arc in case of arc welding
Fluxes are available as liquid, powder, paste and
gas. Powder flux is sprinkled on the surfaces to be welded
or the filter rod is dipped into the powder. Liquid &
paste fluxes are sprayed on the surfaces to be welded. Gas
fluxes are used to form inert atmosphere around the joint
to be welded.
1) Gas flames
There are three types of gas flames :
1.Oxidising Flame 2. Carburising Flame 3. Neutral Flame
MP -I Unit - 5 92
Q.3. Briefly explain seams welding and butt welding.
Ans. Seam Welding:
Seam welding is used for making continuous welds
between two overlapping pieces of sheet metals. In this
process the current is not passed continuously but is
regulated by a timer. The work to be welded is placed
between the two wheels, which apply sufficient pressure
between the sheets and also carry sufficient current or
producing continuous welds. The heat is generated due to
passing of the current through the resistance in the
welding circuit. The heat generated can be controlled by
either varying the current or pressure between the sheets,
which varies the contact resistance. If the heat rate is
high then the speed of rollers in increased thereby
reducing the weld time and vice versa. The electrodes are
made of copper alloys and are water circulated in order to
dissipate heat from them. In high speed seam welding using
continuous current, the frequency of the current acts as an
interrupter. In seam welding, a series of over-lapping
spot welds are formed as shown in Fig and these have
sufficient overlap to provide a pressure-tight joint.
However the spacing of these spots can be regulated also.
Butt Welding :
In butt-welding, the two pieces of metal of same
cross-section are gripped together and pressed while heat
is generated in the contact surface by electrical
resistance when the current is passed. As pressure keeps
on acting continuously, the joint is upset slightly which
has to be rounded up by machining or grinding. It is
desirable that both parts are of same resistance in order
to have uniform heating at the joint. In order to have
good weld, first the pressure must be less and then
increased steadily to the value sufficient to effect weld.
In this process there is no flashing or arcing at the joint
MP -I Unit - 5 93
during the operation. This process is best suited to rods,
pipes and many other parts of uniform cross-section.
Butt-welding can be sub-divided into two groups,
i.e. upset butt-welding and flash butt welding. In the
first type, the parts to be welded are clamped edge to edge
in clamps of the machine and brought together with light
contact while current flows to heat the joint. The
pressure applied upsets the joint. Upset butt-welding is
used principally for non-ferrous metals.
In the flash butt welding, the parts are brought
together in a vary light contact. A high voltage starts a
finishing action. The parts keep on moving against each
other till forging temperature is reached and then
sufficient pressure is applied to effect the weld. In this
process it is very important to have proper timing and
current for the size and section of parts used. Usually
large areas are welded by flash welding process. This
process requires less current and is quite rapid. Most of
the non-ferrous metals except those containing high
percentages of lead, zinc, tin and copper can be welded
satisfactorily.

Q.4. What is resistance welding?

Ans. Resistance Welding :
MP -I Unit - 5 94
It is the process of joining metal pieces
together by raising the temperature of the pieces to fusion
point and applying a mechanical pressure to join them. In
this the pieces to be joined are held together and a strong
electric current(A.C.) of high amperage and low voltage is
passed through them. This current comes across a certain
resistance in passing from one piece to the other and it is
this resistance offered to the flow of current which
results in raising the temperature of the two pieces to
fusion of melting point at their junction. The mechanical
pressure applied at this movement completes the weld. This
method of welding is widely used in modern practice for
making welded joints in sheet metal parts and bars and
tubes etc.

Q.5. How welded joints are tested? Explain any two methods
of it.
Ans. Welds may be inspected and tested in a variety of
ways depending on the nature and type of a given welded
structure. In most cases weldment are :-
1) Inspected visually defects which can be defected by
examination.
2) Tested for tightness.
3) Tested for mechanical strength.
4) Examined for hidden flows by physical method.
Overall two types of tests are performed.
Destructive testing
1) Macro-Crack test.
2) Weld tensile test.
3) Transverse tensile test.
4) Impact test
Non destructive tests
1) Visual inspection.
2) Dye penetrants test.
MP -I Unit - 5 95
3) Electro-magnetic test.
4) Magnetic particle test
5) Radiographic test ( X-ray production)
6) Ultrasonic detection of flows
Magnetic testing :
This type of test is limited to those materials
which can be magnetized i.e. ferrous materials. This test
is used to detect surface faults only.
If a ferrous component is magnetized and if the
metal is sound the lines of force pass smoothly through the
test piece as shown in figure. If a fault is present the
lines of focus tend to become distorted as they try to by-
pass or circumvent the fault. If the fault is at or near
the surface, the distortion of the magnetic field may cause
the lines of force to break the surface. At this point on
the surface, a region of comparatively intense magnetism
exists. A magnetic link composed of iron powder suspended
in oil can then be sprayed over the surface. The particles
of iron are attracted to the region over the fault and
hence mark its site.
Any unevenness on the surface to be tested gives
the same effect as a surface fault. Surfaces
should therefore be reasonably smooth and clean.

Ultrasonic testing :
Sound waves above 20,000 vibrations sec, are
inaudible to humans. This is the ultrasonic range used for
testing. Ultrasonic sound waves travel very rapidly
MP -I Unit - 5 96
through liquids and solids and are reflected from any
discontinuity. The waves do not travel smoothly through
air.
In order to reveal the internal condition of a
metal by the use of high frequency sound a method must be
adopted whereby sound can be generated, passed into the
metal and any echoes that are reflected from inside the
metal are subsequently recorded.

No Fault

Before the commencement of the test a film of oil

is coated on to the specimen to be tested. The transducers
A & B (crystals of quartz and barium titanate) are placed
as shown in figure.
A high frequency alternating current is applied
to “A” in short pulses. Crystal “A” vibrates and sends outs
shorts waves of ultrasonic sound via the air film into the
metal. They pass through the metal, reflect off the bottom
face and return to the top face again. The reflected
vibration strikes the crystal “B” is connected a cathode
ray tube similar to that used in an ordinary television
set. Each time a voltage passes from crystal “B” a blip
appears on the tube face.
If there is no fault in the metal, only two
echoes are recorded as shown in figure. If a fault is
present, a third “blip” is visible on the screen. By
relating the distance “D” to the known thickness, the
position of the flaw can be estimated. This is a more
sensitive device and hence difficult to distinguish between
a potentially dangerous fault and unimportant one
MP -I Unit - 5 97
The method can be used to revel all the usual
weld faults.

Q.5. Write short notes on the following highlighting the

principal, application in industries and limitations if
any.
Ans. Brazing :
The term brazing implies the use of brass as the
filter material but nowadays a number of other alloys are
also in use. The filter metal is called, ‘spelter’. In
brazing, metal parts are joined by coalescence at
temperatures above 5600C. However, non-ferrous filter metal
is used which has a melting temperature below that of the
base metals. Consequently, the base metals are never
melted. The filter metal is distributed in the joint
between the base metals by capillary attraction and the
coalescence is between the base metals and the filter metal
and not between the base metals.
Application :
Brazing is used for electrical items, radiators,
heat exchangers, pipes & pipe fittings and tool tips.
Disadvantages :
1. Low strength.
2. Not applicable for hardened steel and aluminium alloys.
SOLDERING
Soldering is a process of joining two metals by
using another low temperature metal alloy. The metal used
for the joining purpose is called solder. Solders are of
two types :
1. Hard Solder
2. Slot Solder
Hard solder is an alloy of copper and zinc where
as the soft solder is an alloy of tin and lead.
Process/Procedure :
MP -I Unit - 5 98
The surfaces to be joined are cleaned and are
placed on each other. A flux s employed to prevent
oxidation. Zinc chloride is commonly used for this
purpose. The soldering iron(shown in the figure) is heated
either electrically or by some external heat. Then the hot
end is dipped into the flux and solder is pressed against
the surfaces to be joined. A joint is formed by melting the
solder.
Applications :
Soldering in widely used for sheet metal work and
in radio and television work for joining wires.
Advantages :
1. Joining cost is low
2. Equipment is very simple and cheap
3. Good sealing in fabrication as compared to other
processes like rivet, spot weld and bolts
4. It provides a positive electrical connection.
5. Due to low operating temperature, the properties of
base metal are not affected.
Disadvantage :
1. Joints formed are weak.
Riveting : It is a permanent fastening process in which the
end of the metal pin is pressed over or spread out by
hammering operation Riveting can be cold riveting for
light work. Wrought iron and steel are used for hot
riveting and copper, brass and aluminium are used for cold
riveting.
Application :
In engineering practice, there are many items,
which are built up of a number of separate pieces rigidly
attached together by means of permanent joints. For
example, boilers, water-tanks and various other vessels,
which are subjected to internal pressure, are constructed
out of separate steel sheets joined together permanently.
MP -I Unit - 5 99
Further, steel structures, such as cranes, bridges, beams,
trusses, etc., are also built up of separate steel sections
rigidly fastened together. Riveting is one o the most
commonly used methods of producing rigid and permanent
joints in all such cases.

Q.7. Describe the Thermit welding process.

Ans. Thermit Welding :-
Thermit welding is the application of a filler
material or the joining of two pieces of metal, usually
steel, through the use of heat supplied by a chemical
reaction. The chemicals used for the heating process are a
mixture of aluminium and iron oxide. The thermit, as the
mixture is called, requires an igniter of some type to set
of the reaction. The chemical formula for this process is
8Al + 3Fe3O4 = 9Fe + 4Al2O3
The heat released is approximately 30000C,
causing the iron, remaining in the charge, to charge and
melt.The thermit is mixed in a suitable crucible and the
igniter is placed on top. It is then lit with a red hot
metal rod. As the igniter burns, temperatures around 11500C
are reached before another reaction begins. At this point
the metal begins to melt.
MP -I Unit - 5 100
The reaction carries burning throughout the mixture for 25
to 30 seconds. The heat released causes the iron to change
from a solid to a liquid. This steel then becomes molten
and reaches the desired fusion temperature. It is channeled
into a prepared mould. The fracture or two pieces to be
joined together, have been preheated to the high
temperature of the liquid steel, and thus the parts are
welded together.

Q.8. What are the advantages of welding over other

processes of similar purposes? Why is inspection necessary
after welding?
Ans. Replacing Casting :
A wide variety of machine parts, which were
manufactured by casting, are now being designed and
fabricated as weldments. Machinery base, frames and
brackets are made up of standard steel shapes and rolled
plates and joined by any one of the welding processes.

Replacing Riveting and Bolting :

Welding is gaining importance day by day in the
joining of metals as it gives speedy and sound joints and
at the same time, the joined structure is lighter in
weight.
Welding as the only means of fabrication :
Welding is the only solution in cases where the
equipment is to be constructed of steel plates, the
thickness of which is greater than those joined by means of
riveting and caulking.
Testing and Inspection of Welds :
It is very important that for satisfactory
operation and working, welds are properly tested and
inspected as their failure may result into hazards and
great losses. The tests can be either of destructive or
MP -I Unit - 5 101
non-destructive nature. The former type gives the
quantitative information and is used in laboratories,
whereas the second type gives the idea of quality of weld.

Q.8. Write brief note on welding defects and remedies

Sr. Defect Causes Remedies

No
1. Porosity 1)Inherent (1)Some electrodes produce
properties inherently sound welds. Ensure
of that proper electrodes are used.
electrodes (2)Puddling keeps the weld metal
2)Improper molten longer and often ensures
welding welds.
procedure (3)A weld made of a series of
3)Insuffici strong beads is apt to contain
ent pudding minute pin holes. Weaving will
time to often eliminate this trouble.
allow (4)Do not use excessive welding
entrapped current.
gases to (5)In some cases the base metals
escape are at fault. Check this for
(4) Poor segregation and impurities.
base metal
2. Poor or 1)Improper (1)Ensure allowance of proper
incompl preparation space at the bottom of the weld.
ete- of joint (2)Use small diameter electrodes
penetra 2)Use of in narrow welding groove.
tion too large (3)Use sufficient welding current
arc to obtain proper
3)Insuffici penetration. Do not weld too
ent welding rapidly.
current (4)Use a backup bar if possible.
4)Too fast (5)Chip or cut out the back of
MP -I Unit - 5 102
welding the joint and deposit bead of
speed weld metal at this point.
3. Warping 1)Shrinkage (1)Select electrode with high
deposited welding speed and moderate
weld metal penetrating properties.
2)Excessive (2)Weld rapidly to prevent
local excessive local heating of the
heating at plates adjacent to the weld.
the joint (3)Do not allow excessive space
3)Improper between the parts to be welded
preparation (4)Properly clamp the parts
of joint adjacent the joint.
4)Improper
clamping of
parts

Q.9. Give two applications of the following :-

(1) Resistance Welding
(2) Oxy-acetylene Welding
(3) Atomic Hydrogen Welding
(4) Gas cutting
Ans: (1) Resistance welding:
Resistance welding is a group of welding
processes where in coalescence is produced by the heat
obtained from resistance of the work to the flow of
electric current in a circuit of which the work is a part
and by the applications of pressure used for
i) Joining sheets, bars, rods and tubes
ii) Welding aircraft and automobile parts.
iii) Making cutting tools
iv) Making fuel tanks of cars, tractors etc.
v) Making wire fabric, grids, grills, mask weld, containers
etc.
MP -I Unit - 5 103

2) Oxy-acetylene Welding:
It is a process in which acetylene is mixed with
oxygen in correct proportion in the welding torch. It is a
furion welding process. It joins metals using the intense
heat of combustion.
Uses:
1)For joining thin materials
2)For joining materials in whose case excessively high
temperature or rapid heating and coating of the job would
produce unwanted or harmful changes in the metals.
3)For joining materials in whose case extremely high
temperature would cause certain demerits in the metals to
escape into atmosphere.
4)For joining most ferrous and non-ferrous metals. e.g.
carbon steels, alloy steel, cast iron, Alluminium, copper,
nickel, magnesium and its alloys etc.
5)In automotive and aircraft industries, in sheet metal
fabricating plants etc.
3)Atomic hydrogen Welding:
It is a welding process where in coalescence (furion) is
produced by heating the job with an electric arc maintained
between two tungsten electrodes in an atmosphere of
hydrogen which also acts as a shielding gas.
Uses:
1) The process can be used for the welding of most of the
metals and alloys like plain carbon steel, alloy steel,
stainless steel, Alluminium, copper, nickel and their
alloys.
2)For surfacing dies and tools.
3) Gas cutting:-
Gas cutting is a group of cutting processed where the
severing or removing of metals is effected by means of the
chemical reaction of oxygen with the base metal at elevated
MP -I Unit - 5 104
temperatures in the case of oxidation resistant metals,
their reaction is facilitates by use of a chemical flux or
metal powder.
Uses:
1) To prepare edges of plates for bevel and groove weld
joint designs.
2) To cut small sized work-piece from bigger plates for
further processing.
3) To cut rivets, gates and risers from castings.
4) To cut many layers of thin sheets at same time(stack
cutting) to reduce both time and cost for production work.
5) To pierce holes and slots in steel plates
6) For salvage work.

Q.10.What is mean by bright dipping? Explain briefly.

Ans: Bright dipping:- The purpose of bright dipping is to
remove all dirt and oxides from the metal surface and
produce a highly reflective surface on non ferrous metals
and alloys, like copper, alluminium, bronze etc. This is
quite necessary as nonferrous metals can be easily
dioxidised. Such a process of cleaning the surface makes
the metals more attractive. In this process the metals are
dipped in acids such as Sulphuric & followed by Nitric acid
in different concentration in water. In case of Alluminium
metal Phosphoric acid and nitric acid with water is mainly
used. This solution mixtures can be changed for different
metals.

Q.11.What are the various factors to be considered while

selecting the joining process? (O.P.Khanna)
Ans:- Various factors are to be considered while selecting
the joining process:-
a) Safety recommendation for installation and operation of
gas welding and cutting equipment
MP -I Unit - 5 105
b) Safety recommendation for installation and operation of
arc welding and cutting equipment.
c) Explosion of fire and other hazards and protection
against them.
d) Protection of welders
e) Ventilation and health protection.

Q.12.What is resistance welding? Explain spot welding in

detail with the sketch.

Q.13.State various differences between branzing and

soldering.
Ans. DIFFERENCE BETWEEN SOLDERING AND BRAZING
Sr. Brazing Soldering
No.
1. Filter metal has the Filter metal has the melting
melting point above point below 4000C.
4000C.
2. More stable joints can Less stable joints can be
be made. made.
3. High pressure & Joints are affected by high
temperature do not temperature & pressure.
affect the joint.
4. Equipment cost is more. Equipment cost is very low.

Q.14. What is weldability?

Ans. Weldability of Metals :
It may be defined as the capacity of the metals
to be welded into inseparable joints having specified
properties such as definite weld strength, proper structure
etc.
This means, if a particular metal has
weldability, then it should be readily suitable for
welding. If the metal has poor weldability, it can be
MP -I Unit - 5 106
improved by the use of proper (a) shielding against
atmospheric action,(b)flux,(c)filter metal,(d)welding
procedure and, in some cases,(e)proper heat-treatment of
the metal before and after deposition.

Q.15.What are the various methods of testing welded joints?

Explain any two in detail.
Ans :- Testing of welded joints is necessary to asses the
properties and qualities of welded joints and asses the
suitability of the weldment (as assembly whose component
parts have been joined by welding) for the intended
purpose. There are two main forms of testing and inspection
of welds.
(1) Destructive testing :- This test is applied to samples
representative of the welded joints under review, often
made especially for test purposes. In a destructive test,
the test piece or specimen is destroyed, in most cases by
fracturing. After the test the specimen remains no longer
useful for further use.
Destructive tests as applied to welds are:-
a) The tensile test,
b) The bend test,
c) The impact test
d) The Nick-break test
e) The hardness test and
f) The etch test
2) Nondestructive test : Such tests are applied to welded
components to determine their suitability for the service
conditions to which they will be subjected. These tests
neither break nor alter the structure or appear on the
welded component. These tests have the ability to detect
invisible subsurface defects. And make components more
reliable and safe. These tests are applied to welds are:
MP -I Unit - 5 107
1) Visible inspection 2) Stethoscope tests 3) X-ray and Y
rays radiography 4) Magnetic particle inspection
5)Fluorescent penetrate inspection 6) Ultra Sonic
inspection 7) Eddy current testing

Q.16.Describe resistance seam welding. Also mention its

limitations.
Ans. Limitations :It cannot be applied to those portions
when abrupt change in contour occurs along the path of
electrode wheels, such as on sharp corners.
1) In longitudinal seam welding machines the maximum length
of the seam joint that can be made equals the throat
depth of the machine.
2) It is necessary to avoid obstructions in the path of
electrode wheel or else a corresponding recess should be
provided on the wheel periphery to accommodate these.
3) It is necessary that the weld should proceed along a
straight line or a uniform curve.
4) Stock thickness above 3 mm cannot be welded with normal
case.
5) For successful welding and production of defect free
welds it is essential that the work surfaces should be
perfectly clean and free from grease, paint, oil, rust
and scale.

Q.17. Write short notes on

1) Left ward welding
2) Bronze Welding
Ans. 1) Left ward welding :
It this welding the tip of the torch is held at 60 to 70
degrees to the plates. And the filter rod is inclined at 30
to 40 degrees in opposite direction. In this method the
plate edges are heated immediately after the molten metal.
The torch tip and filter rod are moved
MP -I Unit - 5 108
slowly in the direction towards left.

2) Bronze Welding :
Bronze welding, also called braze welding, is a
process which is intermediate between true welding and true
brazing. In brazing process, the edges or surfaces are not
melted. Instead, a low melting alloy is introduced between
them and a joint is produced by adhesion. In welding, the
edges or surfaces are melted and a stronger joint is made
of two similar metals.
In bronze welding, the edges or surfaces of the
materials to be joined are only heated to a temperature
which corresponds to the melting point of the bronze-
filling rod used. The filter rod used for bronze-welding
usually contains 60 per cent copper and 40 per cent zinc, a
combination giving high tensile strength and ductility.
Additional elements are silicon and tin which act as
deoxidisers.
Q.18. Explain Tungsten Inert gas arc welding with its
specific application.
Ans. This process has popularly been called TIG since
it is based on a tungsten electrode working in the presence
of inert gas. This process consists of a torch with a
tungsten electrode. The use of filler material depends on
the material composition, thickness, etc. and is fed either
MP -I Unit - 5 109
with hand (for manual operations) or by means of a feeding
mechanism (for semi-automatic and fully automatic). Details
have been shown in Figure.

The tungsten electrode may range in diameter from 0.15mm to

9.25 mm and may be made of pure tungsten, Thoriated
tungsten or Zirconiated tungsten. The oxides of
Thorium/Zirconium held in easy electron emission and easy
starting. Very little tungsten is lost, during welding
process, since its boiling point is very high (58600C). If
the electrode touches the base metal, some tungsten may be
deposited on the weldment.
MP -I Unit - 5 110
While welding stainless steels and other steels, electrode
of 0.35mm to 0.75mm diameter and A.C. high frequency
current are used to help stablise the arc and to ease
starting. G.T.A. process is conventionally useful on
stainless steels, nickel-cobalt alloys, aluminium and
copper alloys, and titanium or highly alloyed metals where
weld purity is essential. There is hardly any need to
finish the weld. The welds are hard.
Advantages – Useful for welding those metals which tend to
oxidise rapidly (primarily for non-ferrous metals).
Disadvantages – The process is relatively slow in
operation.

Q.19. Describe the process of welding used for :

Ans. 1. Cast Irons :-
This metal needs special care in welding because
of its extreme brittleness and weakness. The endeavor in
welding cast iron should be to prevent the occurrence of
contraction stresses during welding and thus produce a
strong joint free from fractures at the junction of the
parent metal and the weld. Cast iron components are
generally preheated to a dull red heat and then welded. It
should be carefully noted that once the cast iron has
melted it should be cooled slowly so as to allow time to
carbon to turn into graphitic state. If the cooling is
rapid the carbon will be retained in the metal in combined
state to form white cast iron. This, being a hard and
brittle substance, will render the iron harder and more
brittle and reduce the tensile strength and its
machinability. The object, therefore, should be to produce
Grey iron except when a very hard metal is required, which
of course is a very rare need. Cast iron can be welded both
by arc welding as well as gas-welding. In arc welding a
MP -I Unit - 5 111
flux coated electrode should be used. Sometimes annealing
may be needed after are welding process.
2. Aluminium :
Pure aluminium can easily be welded by gas and
arc welding. Resistance welding and atomic hydrogen welding
methods can also be successfully employed for welding
aluminium. Aluminium and its alloys have their melting
points ranging from 6000C to 7000C. At elevated temperatures
aluminium forms its oxide and it remains on the metal in
the form of a thick layer. It is a very refractory
material so much so that its melting point is above 27500C.
Another difficulty is that the specific gravity of this
oxide is higher than that of aluminium. With the result,
if it is not removed, it will be disbursed throughout the
weld rendering it unsound. It is necessary, therefore,
that the said oxide should always be removed by using a
suitable flux. In arc welding D.C. is usually preferred
for welding aluminium. A positive polarity, or a reserve
polarity as we call it, is a recommended practice. The size
of electrode will be determined by the thickness of the
metal. Edge preparation can be needed in thicker sections
only.

Q.20. Define arc cutting process.

Ans. Arc cutting is based on melting the metal at the
cut by the heat of an electric are and blowing molten metal
by a jet of air. The air is continually supplied under a
pressure of at least 4 atm.(400 kN/m2) into the torch
(electrode holder), along the electrode and into the cut.
In some torches air is supplied from the side. Both carbon
and metal electrodes are employed in the arc cutting of
metals.
A more recent addition is the oxy-arc cutting
process using carbon electrodes. By this method, a jet of
MP -I Unit - 5 112
oxygen is passed on the molten metal some distance from the
arc, and the oxygen readily oxidises the metal and removes
both the oxidised and molten metal from the cut. The action
is similar to that of gas cutting except that the preheat
is supplied by an arc instead of a flame. A plasma-arc
operation without the addition of filler metal is an
effective means of cutting metal. The current is supplied
by a de welding generator.

Q.21. Describe MIG type of welding with its specific

application.
Ans. In this reference, Metal Inert Gas(MIG) shielded
arc welding is very common. Wire, acting as consumable
bare electrode, is fed through the welding head with the
help of wire feed rolls. Inert gases are used for welding
the jobs. Electric arc is developed between a continuously
fed consumable electrode and the work piece. Metal is
transferred through protected arc column to the work. A
fixed relationship exists between the rate of wire burn-off
and the welding current such that the stabilised arc is
maintained. Current depends on the electrode wire diameter,
speed of melting the wire, composition of parent metal, and
its thickness.
MP -I Unit - 5 113
In case of using high amperage, the gun or welding torch
may either be air cooled or water cooled. During welding,
the welding area is flooded with inert gas which does not
react with metal and the rate of flow of inert gas is kept
enough to keep oxygen of air away from the hot molten pool
and hot area.
For welding non-ferrous (A1-alloys; Cu-alloys,
high nickel alloys) argon or argon-helium gas mixture may
be used. Titanium needs only argon gas shielding. No flux
is needed. It gives high welding speed. This process can be
easily made automatic.

Q.22. What do you understand by gas welding?

Ans. Gas welding process consists of joining the
metals with the help f high temperature flame and filler
rod. High temperature flame is generated by combusting a
mixture of two gases (Oxygen + Acetylene) and the flame is
used to heat the work pieces and filler rod fills the gap.
The filler rod melts along with the parent metal and fills
the parent metal cavity.
The mixture of these two gases (oxygen and
acetylene) is commonly used for gas welding purpose.
However, the mixture of other combustible gases can also be
used. The production of gases in this reference is very
important.
MP -I Unit - 5 114
Q.23. Explain the procedure of soldering. How it differs
from brazing?

Q.24. Write short notes on

Ans. 1) Forge Welding :-
This is the oldest of all the methods of welding-
processes. Generally this process is used in the
blacksmith shop. In it, the work pieces are placed in a
forge or other appropriate furnace and heated within the
area to be joined, to the condition of plasticity, on the
surface. The parts are then quickly super-imposed and
worked into a complete union by hand or power hammering or
by pressing together. The quality of the weld depends to a
great extent upon the amount of heating. If the ends to be
joined are not heated enough, they will not stick together;
if overheated, the metal becomes burned, brittle and has
spongy appearance.
Wrought iron and low carbon steel are the
materials most commonly joined by the forge welding. The
oxidise very rapidly when exposed to the atmosphere after
being heated to high temperature. Therefore, very little
oxygen should be permitted to contact the metal being
heated. The most commonly used forge-welding processes are
hammer welding, die-welding and roll-welding. The
principal difference between these processes is the manner
in which pressure is applied. In case of hammer welding,
the pressure is applied at high velocity in the form of
blows. In die-welding, the pressure is exerted either by
means of a bell or a mandrel and tube rolls. In roll-
welding the work is forced longitudinally between plate-
rolls, which supply required pressure.
(2) Polarity in arc welding :
Conventionally, in case D.C. welding set, one can
have straight polarity or reversed polarity. Polarity
MP -I Unit - 5 115
indicates the direction of current flow. In straight
polarity, the work is kept positive, whereas the electrode
is negative and electrode as positive. The significance of
polarity is that there is a direct relationship between the
points where the heat is to be liberated. Most of the heat
is liberated in the positive side of the arc. Thus, the
total heat generated by flow of current is divided into two
parts (66% at the +ve pole and 33% at the -ve pole). In
conventional way, the electrons flow from –ve pole to +ve
pole, and these electrons bombard at the +ve pole. Due to
this bombardment of electrons, the heat developed at the
striked end is always higher. This phenomenon has been
explained. This is the reason for having higher amount of
heat liberated at positive pole in straight polarity.
Straight polarity is used because it is preferable to have
most of the heat at the work-piece rather than at the
electrode, since it is desired to have more heat at work-
piece.
If light coated electrode is connected to
positive pole, it will become red-hot and so welding will
be impossible. If the light coated electrode is connected
to negative pole and the work to the positive pole, so the
molten pool at work will become a source of higher heat
content and the electrode will not be affected. So welding
the thin sheets, the work is made negative. Carbon
electrode is always made negative, so change of polarity is
not applicable in this case.
In case of A.C.welding, the heat generated at
each pole is the same owing to cyclic nature of current.
MP -I Unit - 5 116

Electrodes used in arc welding :

Electrodes, the filler material rods, can broadly
be classified into two categories.
Non consumable electrodes are made of carbon,
graphite or tungsten, which do not consume during welding
process.
Consumable electrodes are made of different
metals depending on the chemical composition of metal to be
welded. These electrodes are of two types.
(a) Plain or bare electrodes are made of various metals and
alloys, which do not have any coating of flux. The
globules of metal pass from the electrode to work, they are
exposed to atmospheric air and thereby the molten metal
oxidises which does not float at the top of pool. Pool
after solidifying contains the oxidised metal also which
ultimately decreases the strength and develops
discontinuities in the weldment. So the use of bare
electrode is limited to minor repair of poor quality work
of welding.
MP -I Unit - 5 117
(b) Coated electrodes are conventionally used in industries.
These electrodes are called as conventional electrodes. A
conventional electrodes forms a molten pool in the joint
area which must be protected from being oxidised. On
solidification, the presence of these oxides makes the
joint weaker and less efficient. So the molten pool must
be protected from oxidation by gaseous shield and
slag(Ref.Fig 13.lb). Thus rapid loss of heat is also
prevented. This gaseous shield and the slag is produced by
the flux coating on the electrode, hence called Coated
Electrode.

Q.25. Explain, what is an electric arc welding.

Ans. Metal are welding process is the most extensively
employed method of joining metal parts. The source of heat
is an electric arc. When two conductors of an electrical
circuit (AC or DC) are brought together and separated by a
small air-gap (2 to 4 mm) such that the current continues
to flow through the gaseous medium, an electric arc is
produced. Electrical energy at the arc is converted into
heat energy producing a temperature of about 3700oC at the
centre of the arc. The intense heat given out by the arc
raises the temperature of the parent metal, which forms a
pool of molten metal. The metal at the end of metal
electrode is melted and transferred into the pool in the
shape of globules. The added molten metal fills the gap
between the parts of the parent metal and forms a permanent
joint.

Q.26. Describe the following methods and their

applications.
(1) Tig welding
(2) MIG Welding
MP -I Unit - 5 118
Q.27. Describe in brief the equipment required for oral
acetylene welding.
Ans. Oxy-acetylene gas welding equipment comprises of the
following :
1. Oxygen cylinder : It is used to store the compressed
oxygen gas. It is black in colour and is made of steel.
2. Acetylene cylinder : It is used to store acetylene gas.
It is maroon in colour and is made of steel.
3. Blow-pipe : It is used to mix oxygen and acetylene gases
and then to supply the gas mixture to a nozzle connected
to its end. The blow-pipe (also sometimes known as
welding torch) has two controlling devices, one for
controlling the flow of acetylene and the other for
oxygen entering a chamber, called mixing chamber.

4. Nozzle : It is a device screwed to the end of the blow-

pipe. It is used to permit the flow of oxy-acetylene gas
mixture from the mixing chamber of the blow-pipe to the tip
of the nozzle to facilitate burning. The nozzles are
interchangeable, as it is the size of the nozzle outlet,
which determines the gas consumption, and so the size of
the gas flame. A nozzle having small-bore diameter is used
for fast melting.
5. Pressure-reducing valve : Pressure-reducing valve is
located on the top of the gas cylinder. Its function is to
reduce the pressure of the gas inside the cylinder to a
pressure suitable for welding. The regulator located on
MP -I Unit - 5 119
the top of the oxygen cylinder is called oxygen pressure-
reducing valve and the one located on the top of the
acetylene cylinder is called acetylene pressure-reducing
valve.
6. Pressure gauges : Each gas cylinder is provided with two
pressure gauges, one for registering the pressure of the
gas inside the cylinder and the other for indicating the
pressure of the gas supplied to the blow-pipe.
7. Hose and hose-fittings : The hose, connecting the outlet
of the pressure-reducing valve and the blowpipe, should be
strong, durable, flexible, non-porous and light. The hose
for the supply of oxygen is green in colour and that for
the supply of acetylene is red in colour. The hoses are
made of piles of rubber covered with fabric. Hose-fittings
are provided at the ends of the hoses for attachment to the
blowpipe and the outlet of the pressure-reducing valves.
8. Welding goggles : Goggles with tinted glasses is used
during welding to protect the eyes from injury.
9. Welding gloves : It is used to protect the hands from
the heat and metal splashes.
10. Spark lighter : It is used to provide a convenient and
instant means for lighting the blowpipe.
11. Chipping hammer : It is made of steel and is used to
remove metal oxides from welded bead.
12. Wire-brush : Its function is to clean surfaces of a
joint before and after welding.

Q.28. How are the different parts prepared before riveting

and how is riveting done to join those parts?
Ans. In preparing the joint the primary requirement is
the correct drilling of holes in the plates. Of course in
thin plates they may be punched. If the holes are punched
their edges get hardened and may result in cracks all round
the periphery. The safer practice is therefore, to punch
MP -I Unit - 5 120
the holes slightly smaller in size than required and then
enlarge them to the correct size by means of drilling and
reaming. Drilling of holes is preferably carried out, as
for as possible, by holding the plates together in
position. For this a fairly high degree of skill is
required of the marker, as the correct drilling of holes
will be possible only when the holes will be accurately set
out and marked. A common practice, therefore, is to first
mark and drills all the holes in one plate and one hole in
the other plate. The two plates are then secured either by
riveting or bolting in this common hole and the other end
is suitably clamped. The plate containing the holes is
kept on the top and the other one under it. Holes in the
lower plate are then drilled through these holes which act
as guides for correct location and drilling of holes in the
lower plate. If countersunk rivets are to be used, the
holes should be provided with proper chamber to accommodate
the counter-sunk head. The operation is known as counter-
sinking.
After the above operation is over the rivets are
heated up, passed into the drilled holes and the head
formed at the free end. Care should be taken in selecting
the correct length of the rivet as too large a rivet will
bend during hammering and if it is too short in length the
head formed will be undersize. The rivets should be heated
sufficiently so that they attain the forging heat and then
the operation performed quickly. During riveting a snap
should be used to support the rivet by accommodating its
head inside the cavity at its end and then a similar tool
should be used on the other side of the rivet to form the
head. However, if a counter-sunk head rivet is being used
it should be performed at the other end.
MP -I Unit - 5 121
Q.29. Describe with the help of neat sketch the principal
of spot welding.

Q.30. Describe fully the method of oxy acetylene cutting?

Ans. It is a chemical process in the sense that the
metal, at the portion where it is to be cut, is actually
made to oxidise under the action of the flame. All ferrous
metals can be cut by means of an oxy-acetylene flame. The
metal to be cut is heated up to red heat by means of the
flame and then a sharp stream of oxygen is made to this
electrode and the work-piece and shielding is provided by
the gas evolved during combustion of flux plus the CO2 gas
fed around the arc for this purpose.
While welding with flux coated electrode a
magnetized granular flux is fed into the arc through the
gun nozzle, and there it attaches itself to the electrode.
The coating so provided protects the electrode against the
atmospheric contamination by the shield of CO2 gas. The
method of feeding the electrode wire into the arc is again
similar to that in standard MIG welding process described
in Art.22.37.above. Thus, it will be observed that the CO2
MIG welding process is exactly similar to the standard MIG
welding process except the electrode wire uses either
magnetized flux of as its core.
Main advantages of CO2 MIG welding process are :
1.It is a fast welding process.
2.The deposition rate is quite high.
3.Penetration of the arc is deep.
4.Minimum edge preparation is required, particularly in
butt joints.

Q.31. Explain the process of soldering and brazing.

Ans. Soldering :-
MP -I Unit - 5 122
Brazing :- The process of joining two metal surfaces
by heating and adding a non-ferrous alloy with melting
point above 4000C is known as brazing.
Process :- The surfaces to be joined are cleaned from all
oil, dirt or oxides. Then both the surfaces are placed in
joining position. Flux is sprinkled or placed on it. The
heat is given to the surface and the filler metal. The
molten filler metal flows to the surfaces to be joined. On
cooling brazing joint is formed. The filler metals used
are copper, copper alloy, silver alloy and aluminium
alloys. In brazing the filler metal melts but the surfaces
to be joined remain un-melted. The various methods used to
melt the filler metal and flux are
(i) Gas torch brazing : It is a commonly used process in
which oxy-acetylene torch is used.
(ii) Furnace brazing : The surfaces to be joined are placed
in a furnace already hot.
(iii) Dip Brazing : The surfaces to be joined are dipped in
molten filler metal.
(iv) Electrical brazing : In electric brazing heat is
produced by resistance or induction method.
Applications:
Brazing is used for electrical items, radiators,
heat exchangers, pipes & pipe fittings and tool tips.

Q.32. What are the common causes of failure of riveted

joints? Explain.
Q.33. In which type of welding, the electrodes are used and
why? How do you identify electrodes?
 MP -I Unit - 5 123
SIDDHIVINAYAK COMPUTERS
RENUKA NAGAR,DABKI ROAD, AKOLA 6422684
GET YOUR VALUABLE PRINTOUTS
AT MOST ECONOMICAL RATES IN AKOLA
PRINTING RATES FOR PROJECT & SEMINAR REPORTS
ALL COPIES :- Rs 2.00/PAGE(SPECIAL OFFER)
• ABOVE RATES INCLUDE PAPER, TYPESETTING/FEEDING.
• SCANNING Rs. 5/-
• ABOVE RATES DO NOT INCLUDE ROUGH PRINTOUTS
• COLOUR PRINTING: Rs 30/PAGE (TEXT ONLY)
• COLOUR PRINTING: Rs 40/ PAGE (BACKGROUND)
INTERNET : Rs 40/hour (eth & vsnl)
e-mail : diapk_shirbhate@hotmail.com
LOOKING FOR YOUR VALUABLE ORDER
Be a Certified Autocad 2000i & Mechanical Desktop
Professional at SIDDHIVINAYAK computer education, Akola
MASTER IT TODAY THAT THE WORLD WILL LEARN TOMORROW
AUTOCAD-2000I , MECHANICAL DESKTOP , PRO-ENGINEERING
I-DEAS , CATIA V-5 , SOLID WORKS

OUR OTHER PUBLICATION FOR THIRD YR

DESIGN OF MATERIAL HANDLING SYSTEM
AND
MEASUREMENT SYSTEM(FIFTH SEM

FOR COACHING IN THERMAL POWER ENGG AND THEORY

OF MACHINE CONTACT ER RAJESH JARUDKAR (B.E. M.E.)
PH 0724-453117
MP -I Unit - 6 124

UNIT NO : 06

Q.1. What factors govern the selection of a particular

cleaning process for metallic surfaces
Ans. Selection of cleaning process is mainly influenced by
(a) Type of contaminants
(b) Degree of cleanliness required
(c) Composition of metal
(d) Condition of metal
(e) Thickness of rust and scale
(f) Allowable metal loss
(g) Surface finish tolerances
(h) Shape and size of workpieces
(i) Production requirement
(j) Available equipment
(k) Cost involved.

Q.2. Describe the process ‘Electro-forming’ in detail.

Ans. This is the process of forming metals. The parts of
various shapes are produced by electrolytic deposition of
metal upon a conductive removable mould. The difference
between electroplating and electro-forming being that in
the former case the metal permanently sticks to the
cathode, whereas in later case a solid shell is produced
around the cathode which can be separated from it. The
cathode (mould) can be made of any shape depending upon the
shape required for the part. The finish of part produced
depends upon the surface smoothness of mould. The metal
for electroforming the part on the mould is supplied from
an electrolytic solution in which a bar of pure metal acts
as an anode for the plating current.
This process is very useful for thin walled parts
where high accuracy and surface finish are desirable. This
MP -I Unit - 6 125
is also suited to complicated internal shaped parts which
are difficult to machine. The process is also very
advantageous for production of small number of parts for
which other methods will be very expensive.
Process. In electroforming process, first a negative image
of part, called matrix, mould or pattern is prepared. This
can be either permanent or expendable type depending upon
the shape of part to be produced. Permanent moulds can be
easily machined from metal and are very economical. These
can be used only when there is sufficient draft to withdraw
them without any damage to the formed part. The expendable
type of cores can be either of low melting temperature
alloy or of some chemically soluble substance. In case of
expendable type of moulds, the substance used may be non-
conducting e.g., plastic etc. In such cases they must be
coated with some metallic film by spraying, brushing or
chemical reduction. Wax mould can be coated with graphite.
After the desired forms are prepared, the moulds
are placed in the electrolytic solution and proper current
is passed in the solution. The mould keeps on receiving
the metallic ions from the metallic rod and finally a layer
of sufficient thickness is formed around the mould. It is
then removed from the bath, rinsed and then stripped from
the mould. The various metals used for electroforming
include copper, nickel, iron, silver, zinc, lead, tin
cadmium, gold, Alluminium and others having conducting
nature. Out of these copper, nickel, iron and silver are
best suited for electroforming as they have the properties
of good reproductibility, resistance to corrosion, good
bearing surface and adequate strength for small thickness.
The properties of the electroformed parts depend upon the
characteristics of the metal used, rate of deposition of
metal and plating temperature etc. Some changes in
MP -I Unit - 6 126
properties of electroformed parts can also be achieved by
proper heat treatment.
Q.3. What is ‘Abrasive cleaning’?
Ans. This method is widely used for removing all
classes of scale and rust from forgings, castings,
weldments, and heat treated parts. Depending on the finish
requirements, blasting may be the sole means of scale
removal or it may be used to remove the major portion of
scale, with pickling employed to remove the remainder.
In this process the parts are generally cleaned
by the use of abrasive particles such as sand, steel grit,
or shot, impelled against the surfaces to be cleaned.
Some cleaning is performed by means of a high-
velocity air blast, with the blast directed by hand. In
many cases, an air less blast machine that cleans by impact
is also used. The abrasive is fed from an overhead storage
hopper to the centre of a radially rotating wheel,
whereupon the metallic shot or grit is hurled in a
controlled stream upon the work to be cleaned. All traces
of sand, scale, oxides, and other material are removed
right down to the virgin metal, providing an excellent
surface for bonding final finishes.
The airless blast machine is used for cleaning
engine blocks, crankshafts, castings of different shape and
size, railroad cars, car wheels, oil and gas pipes, steel
strip, and many other purposes.

Q.4. What are ‘Anodic Coatings’ and what for are they
provided?
Ans. It is an oxidising process used for Alluminium
and magnesium articles. The article to be anodised is made
anode and sulphuric, oxalic and chromic acids are used as
an electrolyte. The coating is produced entirely by the
oxidising process and not by plating. The coating so
MP -I Unit - 6 127
produced is hard but at the same time it is porous enough
and hence advantageous from decorative point of view. Such
oxide coatings enable organic coatings and dyes to be
successfully used on Alluminium article surfaces. Modern
Alluminium glasses and pitchers are the examples of this
class.

Q.5. Write short notes on

(1) Parkerizing
(2) Tumbling
Ans. (1) Parkerizing : It is a process used for making thin
phosphate coatings on steel to act as a base or primer for
enamels and paints. In this process steel articles are
dipped in a heated solution of magnesium dihydrogen
phosphate at temperature of 88oC for about 45 minutes.
During the dipping period, the phosphate from magnesium
dihydrogen phosphate decompose and phosphate separates out
and forms a thin coating on the steel articles.
(2) Tumbling :- Tumbling, often, is the least expensive
process for removing rust and scale from metal parts.
Parts configuration and size are the primary limitations of
the process. Tumbling in dry abrasives (deburring
compounds) is effective for removing rust and scale from
small parts of simple shape. However, parts of complex
shape, with deep recess and other irregularities, cannot be
descaled uniformly by tumbling. It may require several
hours of tumbling, if the method is used. The addition of
descaling compounds instead of deburring compounds will
often decrease the tumbling time by 75 percent.
The operation is accomplished by placing
workpieces in a drum or barrel, together with stars, jacks,
slugs, or abrasive materials. The abrasive materials can
be sand, granite chips, slag, or Alluminium oxide pellets.
In operation, the barrel is rotated, and the movement of
MP -I Unit - 6 128
the workpieces and the accompanying slugs or abrasive
material against each other produces by friction a fine
cutting action which remove the fins, flashes, and scale
from the products.

Q.6. What is buffing ?

Ans. Semi-automatic machines are mostly used for doing
this jobs. These machines carry a series of polishing and
buffing wheels, which can be adjusted to different
positions so that all surfaces of the part can either be
polished or buffed as required. The compounds and wheels
selected are governed by the shape of the part, the
material of which it is fabricated, and the appearance of
the product. For ordinary polishing and buffing
operations, polishing and buffing wheels are mounted on
floor polishing lathes.
Commonly used polishing wheels are constructed of
canvas, muslin, felt, and leather, while buffs are flexible
wheels made of cotton cloth, canvas, linen, flannel or wool
discs.
Polishing and buffing compounds, like wheels, are
usually divided in two broad categories : (1) cutting down,
the removing of scratches and grain lines from previous
operations, and (2) colouring, which gives the product the
final, bright, deep luster.
Buffing compounds can either be greaseless or
have a grease base. A mixture of glue base, a softening
agent, and a mineral make up a greaseless compound. Grease
buffing compounds use oil, tallow, and other bonds. Many
abrasive elements are used for the colouring compounds,
such as red rouge, green rouse, crocus, and white colouring
compounds.
MP -I Unit - 6 129
Q.7. Highlight the specific difference between Electro
plating and Electroforming?
Ans. The difference between electroplating and
electroforming being that in electroplating, the metal
permanently sticks to the cathode, whereas in a solid shell
is produced around the cathode which can be separated from
it.

Q.8. Write short note on metal spraying covering mainly the

following :-
1) Surface preparation
2) Methods of spraying
Ans: Metal spraying or metallizing literally means to
treat with or coat with a metal or metallic compound.
Metallizing as a process normally includes the preparation
of base material, the spraying on the metal and finally
finishing the surface by grinding.
1) Surface preparation : The surface of parent metal is
properly prepared as the bond between the sprayed metal
parent metal is purely mechanical. The surface is cleaned
by blasting with sharp silica sand or angular steel grit.
Cylindrical objects are prepared by machining small grooves
on the surface followed by rolling over the tops of these
grooves with a tool similar to the knurling tool. Both of
the methods roughen the surface and provide the necessary
interlocking surfaces, so that the plastic material can be
easily adhered to the surface.
MP -I Unit - 6 130

The molten material is blown with considerable force, which

causes the interlocking with surface irregularities. The
sprayed metal itself provides a suitable surface for
successive coatings and permits the building up a layer of
considerable thickness.

2) Methods of spraying : Basically, there are two types of

equipments used for metal spraying. On is the metallic-gun
which consists of a gas torch with a hole in the centre of
the tip for the wire, a small air turbine and gears to feed
in the wire through the tip into the flame as fast as it
melts and an air cap around the torch tip and nozzle which
supplies a blast of air to atomise the molten metal and
deposit in on the prepared surface. In other method,
powdered metal is fed from a container through a rubber
hose to the spray-gun and out through the centre of the
flame, similar to the wire gun. In this case metal is
already in the atomised form and hence air needed is just
sufficient to deposit the molten metal on the surface being
coated.
The applications of both the methods are
important in their respective fields. The powder-gun
having no turbine or gears, costs less, is lighter to
handle and without the blast of atomising air, can be used
more effectively to heat the base metal when such heat is
needed. On the other hand, metal is less expensive in wire
form than in powder form; metal in wire form is more
readily available, and more easily handled.
3)Applications in manufacturing :-
(1) Corrosion-Protection:- The most extensive use of metal
spraying is the application of Alluminium and zinc into
iron and steel. Calorising is frequently accomplished by
MP -I Unit - 6 131
spraying of 0.125 mm Alluminium on steel and then heating
the part to form iron Alluminium compound on the surface.
(2) Hard and noble surface:- One big application of
metallizing is the application of special metal surface
on large masses of less costly metal e.g., a big shaft
required to be corrosion resistant need not be made
completely of stainless steel. It might be made first of
any metal and then metallized with the noble metal.
Similarly the metallizing may be applied for abrasion or
wear resistance, corrosion protection and electrical or
magnetic properties etc. Most of the regular hard
surfacing materials are available in powdered form and
can be sprayed when thin coatings are prepared.
(3) Soldering surfaces:- Sprayed copper is frequently used
on non-metallic parts when it is desired to attach parts
by soldering. The procedure may also be adopted on hard
solder metals such as magnesium, when galvanic corrosion
is not a consideration.
(4) Electrical conductivity:- Conductive coating of copper
and silver can be obtained on poor conductor e.g., by
spraying copper on most of carbon brushes for motors and
generators for better electrical connection.
(5) Thermal conductivity:- Sometimes it is desirable to
have surface to carry away heat from hot spots on poor
conductors. In this case copper can be sprayed and it
has further advantage of perfectly fitting into the non-
conducting part and gives best efficiency.
(6) Its other applications are in having decorative films,
reflecting surface and special metal forms.

Q.9. Describe the following processes.

Ans. 1) Anodising:
2)Shot-peening.
MP -I Unit - 6 132
Shot-peening has been developed recently to
improve the fatigue resistance of metal by setting up
compressive stresses in the surface. The process is
carried out by blasting or hurling a rain of small shots
pneumatically or mechanically at high velocity against the
worked surface. Small indentations are produced due to
striking of shots, which causes the metal to flow
plastically to a depth of few tenths of mm. This process
is adopted to remove stress concentrations on parts of
irregular shapes or at local areas.

Q.11. What is Anodising? Give its applications.

Q.12. What is pickling? What processes must be carried out

before it?
Ans. The most common method of removing unwanted
pigmented compounds which are mostly oxides of metal is by
acid pickling. Either diluted sulphuric, hydrochloric or
phosphoric acid is sprayed on the part, or the part is
dipped into a tank, agitated, and then washed and rinsed
thoroughly. Muriatic acid can also be used either hot or
cold as a pickling solution. Alkaline cleaning of the part
should be used first to remove all dirts and oils in order
to obtain an even removal of the oxides during the pickling
process. Sometimes it is necessary to add pickling
inhibitors such as detergents, liquid glycol, ether, etc.
to decrease the action of acid upon the metal particularly
Alluminium and other non-ferrous metals.

Q.13.What is shot peening? What properties does it impart?

Ans :- Short peening :- It is a mechanical process used to
improve the fatigue resistance of metal by setting up
compromise stresses in the surface. It is carried out by
blastion or hurling of metal shots on to the surface of a
MP -I Unit - 6 133
component by air prom are or with the help of a wheel
revolving at high speed.
This process impart some important properties to
the metal, such as to remove stress concentration on parts
of irregular shapes, increases strength and hardness of the
surface and also makes it fatigue resistant.

Q.14. Explain the method of parkerising stating its

importance.
Ans: Parkerising: Parkerising in nothing but a phosphate
coating on metal surfaces. Phosphate coating are provided
on metal surface. Phosphatic coating are provided on metal
surface to give the metals large durability. This process
is mainly used for steel. Thin coating of phosphate on
steels acts as primer or base coat for paints and enamels.
Steels is coated by dipping it in hot bath of manganese
dihydrogen phosphate at constant maintained temperature of
88oC for about one third hour. A corrosion resistant film on
steel is deposited during this process.
Such type of coating is provided on metal surface
to make them wear resistant surface, providing a protective
coating against the effects of weather and humidity,
providing coloured coatings in different shades, providing
a premier base for proper adhesive of organic coating. It
also reduces friction to the metal.
Q.15. Write note on :
1) Barrel finishing (tumbling)( given earlier)
2) Barrel blasting.

Q.16. What are the special features of electroforming for

which it is preferred in industries?
Ans. This process is very useful for thin walled parts
where high accuracy and surface finish are desirable. This
is also suited to complicated internal shaped parts which
MP -I Unit - 6 134
are difficult to machine. The process is also very
advantageous for production of small number of parts for
which other methods will be very expensive.

LEARN AUTO-CAD 2000i+mechanical desktop

IN JUST Rs 1000/-
PLUS MUCH MORE ONLY AT SIDDHIVINAYAK COMPUTERS
Address : Siddhivinayak Computers, Near Wadekar Kirana
Shop, Renuka Nagar, Near water tank, Dabki Road, Old
City, Akola-2. Ph. 422684
Best of Luck
Visit us at : http://business.vsnl.com/siddhivinayak_akola
Second Year B.E. Production / Mech.(3rd semester)

Manufacturing Process – 1(MP-1) Rs. 60 /-

Third Tear Production/Mechanical(5th Semester)

DESIGN OF MATERIAL HANDLING SYSTEM(D.O.M.H.S) Rs 50/-

Rs 50/-
MEASUREMENT SYSTEM(M.S.)

Final Year B.E. Production / Mechanical(7th and 8th sem)

PRODUCTION PLANNING& CONTROL(P.P.C.) Rs. 50 /-

ADVANCE PRODUCTIVITY TECHNIQUES(A.P.T.) Rs. 40 /-
INDUSTRIAL ORAGANISATION& MANAGEMENT(I.O.M.) Rs. 30 /-
First yr. Polymer & 2nd Year Textile

MECHANICAL TECHNOLOGY / MATERIAL Rs. 100 /-

TECHNOLOGY(MECH. TECH)

ARE YOU LOOKING FOR COACHING IN SUBJECTS LIKE

¾ DESIGN OF MACHINE ELEMENTS (D.O.M.E.)
¾ MACHINE TOOL DESIGN (M.T.D.)
¾ AUTOMATIC CONTROL (A.C.)
¾ THEORY OF MACHINE (T.O.M.)
¾ THERMAL POWER ENGINEERING

CONTACT Er. RAJESH JARUDKAR

B.E.(PRODUCTION) M.E. 6 453117
Visit dept of prod. Engg on web at
http://coeta-production.tripod.com