(Freestudy1.blogspot - Com) Metal Casting PPT With Q A PDF

8/28/2011
Sand casting
y Sand casting uses ordinary sand as the primary
mould material.
y The sand grains are mixed with small amounts of
other materials, such as clay and water, to improve
M t l C ti
Metal Casting mouldability and cohesive strength,
packed around a pattern that has the shape of the
desired casting.
strength and are then
y The pattern must be removed before pouring, the

mold is usually made in two or more pieces.
y An opening called a sprue hole is cut from the top of
By S K Mondal the mold through the sand and connected to a
Compiled by: S K Mondal Made Easy system of channels called runners.
Compiled by: S K Mondal Made Easy Contd….
y The molten metal is poured into the sprue hole, flows

through the runners, and enters the mold cavity
through an opening called a gate.
y Gravity flow is the most common means of
introducing the metal into the mold.
y After solidification, the mold is broken and the
finished casting is removed.
y The casting is then “fettled” by cutting off the ingate
and the feeder head.
y Because the mold is destroyed, a new mold must be
made for each casting.
Compiled by: S K Mondal Made Easy Contd… Compiled by: S K Mondal Made Easy
Sequential steps in making a sand casting y The mold is opened, the pattern board is drawn

y A pattern board is placed between the bottom (drag) (removed), and the runner and gate are cut into the
and top (cope) halves of a flask, with the bottom side up. surface of the sand.
y Sand is then packed into the drag half of the mold. y The mold is reassembled with the pattern board

removed,
d and
d molten
l metall is poured
d through
h h the
h
sprue.
y A bottom board is positioned on top of the packed sand,
and the mold is turned over, showing the top (cope) half
of pattern with sprue and riser pins in place. y The contents are shaken from the flask and the metal
segment is separated from the sand, ready for further
processing.
y The cope half of the mold is then packed with sand.
1
8/28/2011
Compiled by: S K Mondal Made Easy Compiled by: S K Mondal Made Easy
Casting Terms
y Pattern: Pattern is a replica of the final object to be
y Flask: A moulding flask is one which holds the sand
made with some modifications.
mould intact. It is made up of wood for temporary
y Parting line: This is the dividing line between the two
applications
pp or metal for long‐term
g use.
moulding
ld fl k that
flasks h makes
k up the
h sand
d mould.
ld
y Drag: Lower moulding flask.
y Bottom board: This is a board normally made of wood,
y Cope: Upper moulding flask.
which is used at the start of the mould making.
y Cheek: Intermediate moulding flask used in three‐
piece moulding.
Compiled by: S K Mondal Made Easy Contd… Compiled by: S K Mondal Made Easy Contd…
y Moulding sand: The freshly prepared refractory

y Pouring basin: A small funnel‐shaped cavity at the top
material used for making the mould cavity. It is a
of the mould into which the molten metal is poured.
mixture of silica, clay and moisture in appropriate
y Sprue: The passage through which the molten metal
proportions.
from the pouring basin reaches the mould cavity.
cavity
y Backing sand: This is made up of used and burnt
y Runner: The passage ways in the parting plane through
sand. which molten metal flow is regulated before they reach
y Core: Used for making hollow cavities in castings. the mould cavity.
y Gate: The actual entry point through which molten
Compiled by: S K Mondal Made Easy metal enters the mould cavity in a controlled rate. Contd…
Compiled by: S K Mondal Made Easy
2
8/28/2011
Padding
y Chaplet: Chaplets are used to support cores inside the y Tapering of thinner section towards thicker section
mould cavity. is known as 'padding'.
y This will require extra material.
y Chill: Chills are metallic objects, which are placed in
y If p g is not p
padding g or
provided, centre line shrinkage
the
h mould
ld to increase
i the
h cooling
li rate off castings.
i porosity will result in the thinner section.
y Riser: It is a reservoir of molten metal provided in the
casting so that hot metal can flow back into the mould
cavity when there is a reduction in volume of metal due
to solidification
IES‐2001 IES‐1996
Which of the following methods are used for
The main purpose of chaplets is obtaining directional solidification for riser design
(a) To ensure directional solidification 1. Suitable placement of chills
(b) To provide efficient venting 2. Suitable placement of chaplets

3. Employing padding
(c) For aligning the mold boxes
Select the correct answer.
(d) To support the cores
(a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1, 2 and 3
Ans. (d) Ans. (b)
IES 2007 GATE‐2009
Match the items in Column I and Column II.
Which one of the following is the correct Column I Column II
statement? P. Metallic Chills 1. Support for the core
Gate is provided in moulds to Q. Metallic Chaplets 2. Reservoir of the molten metal
(a) Feed the casting at a constant rate R. Riser 3. Control cooling of critical
(b) Give passage to gases sections
S. Exothermic Padding 4. Progressive solidification
(c) Compensate for shrinkage
(a) P‐1,Q‐3, R‐2, S‐4 (b) P‐1,Q‐4, R‐2, S‐3
(d) Avoid cavities (c) P‐3, Q‐4, R‐2, S‐1 (d) P‐4, Q‐1, R‐2, S‐3
Ans. (a) Ans. (d)
3
8/28/2011
GATE‐1992 GATE 2011
In a green‐sand moulding process, uniform Green sand mould indicates that
ramming leads to (a) polymeric mould has been cured
(a) Less chance of gas porosity (b) mould has been totally dried
(b) Uniform flow of molten metal into the mould ((c)) mould is g
green in colour
cavity (d) mould contains moisture
(c) Greater dimensional stability of the casting
(d) Less sand expansion type of casting defect Ans. (d)
Ans. (c)
Pattern Pattern Allowances
A pattern is a replica of the object to be made by the 1. Shrinkage or contraction allowance
casting process, with some modifications.
The main modifications are 2. Draft or taper allowance
y The addition of pattern allowances,
allowances 3. Machining or finish allowance
M hi i fi i h ll
y The provision of core prints, and
4. Distortion or camber allowance
y Elimination of fine details, which cannot be obtained
by casting and hence are to be obtained by further 5. Rapping allowance
processing
Shrinkage allowance Liquid shrinkage and solid shrinkage
y All metals shrink when cooling except perhaps y Liquid shrinkage refers to the reduction in
volume when the metal changes from liquid to
bismuth. solid state at the solidus temperature. To account
y This is because of the inter‐atomic vibrations which for this, risers are provided in the moulds.
are amplified by an increase in temperature.

y Solid shrinkage is the reduction in volume
y The shrinkage allowance is always to be added to the caused, when a metal loses temperature in the
solid state. The shrinkage allowance is provided to
linear dimensions. Even in case of internal dimensions. take care of this reduction.
4
8/28/2011
y Pattern Allowances IES‐1995

Cast Iron 10 mm/m
Which one of the following materials will require
Brass, Copper, Aluminium 15 mm/m
Steel 20 mm/m the largest size of riser for the same size of casting?
Zinc, Lead 25 mm/m ((a)) Aluminium
(b) Cast iron

y In grey cast iron and spheroidal graphite iron, the
amount of graphitization controls the actual (c) Steel
shrinkage. When graphitization is more, the
shrinkage would be less and vice versa. (d) Copper
Ans. (c)
GATE‐1999 IES‐1999
In solidification of metal during casting,
Which of the following materials requires the
compensation for solid contraction is
largest shrinkage allowance, while making a
pattern for casting? (a) Provided by the oversize pattern
(a)
( ) Aluminium
l
(b) Achieved by properly placed risers
(b) Brass
(c) Cast Iron (c) Obtained by promoting directional
(d) Plain Carbon Steel solidification
Ans. (d)
(d) Made by providing chills
Ans. (a) Compiled by: S K Mondal Made Easy
GATE‐2001 GATE‐2004
Shrinkage allowance on pattern is provided to
Gray cast iron blocks 200 x 100 x 10 mm are to be
compensate for shrinkage when
cast in sand moulds. Shrinkage allowance for
(a) The temperature of liquid metal drops from pattern making is 1%. The ratio of the volume of
pouring to freezing temperature pattern
tt t that
to th t off the
th casting
ti willill be
b
(b) The metal changes from liquid to solid state at (a) 0.97 (b) 0.99 (c) 1.01 (d) 1.03
freezing temperature
Ans. (d)
(c) The temperature of solid phase drops from
freezing to room temperature
(d) The temperature of metal drops from pouring
to room temperature
Ans. (c) Compiled by: S K Mondal Made Easy Compiled by: S K Mondal Made Easy
5
8/28/2011
GATE‐2008 GATE 2011
A cubic casting of 50 mm side undergoes volumetric
While cooling, a cubical casting of side 40 mm solidification shrinkage and volumetric solid
undergoes 3%, 4% and 5% volume shrinkage contraction of 4% and 6% respectively. No riser is
during the liquid state, phase transition and solid used. Assume uniform cooling in all directions. The
state,
t t respectively.
ti l The
Th volume
l off metal
t l side of the cube after solidification and contraction is
compensated from the riser is (a) 48.32 mm
(a) 2% (b) 7% (c) 8% (d) 9% (b) 49.90 mm
Ans. (b) (c) 49.94 mm
(d) 49.96 mm
Ans. (a)
IAS‐1995 IAS‐2003
Assertion (A): A pattern is made exactly similar to the Match List I (Material to be cast) with List II
part to be cast. (Shrinkage Allowance in mm/m) and select the
Reason (R): Pattern is used to make the mould cavity correct answer using the codes given below the lists:
for pouring in molten for casting. List‐I List‐II
(a) Both A and R are individually true and R is the correct (Material to Cast) (Shrinkage Allowance in mm/m)
explanation of A (A) Grey cast iron 1. 7 ‐ 10
(b) Both A and R are individually true but R is not the (B) Brass 2. 15
correct explanation of A (C) Steel 3. 20
(c) A is true but R is false (D) Zinc 4. 24 [Ans. (c)]
(d) A is false but R is true Codes:A B C D A B C D
Ans. (d) (a) 1 2 3 4 (b) 3 4 1 2
(c) 1 4 Compiled by: S K Mondal Made Easy
3 2 (d) 3 2 1 4
Draft
y To reduce the chances of the damage of the mould
cavity at the time of pattern removal, the vertical faces
of the pattern are always tapered from the parting line.
This provision is called draft allowance.
y Inner surfaces of the pattern require higher draft than

outer surfaces.
y Draft is always provided as an extra metal.
DRAFT ALLOWANCE
6
8/28/2011
Shake Allowance Distortion Allowance
y At the time of pattern removal, the pattern is rapped y A metal when it has just solidified is very weak and
therefore is likely to be distortion prone.
all around the vertical faces to enlarge the mould
cavity slightly to facilitates its removal.
removal y This is particularly so for weaker sections such as long
flat portions, V, U sections or in a complicated casting
y It is a negative allowance and is to be applied only to which may have thin and long sections which are
those dimensions, which are parallel to the parting connected to thick sections.
plane.
y The foundry practice should be to make extra
material provision for reducing the distortion.
Pattern Materials The pattern material should be
y Wood patterns are relatively easy to make. Wood is not
y Easily worked, shaped and joined
very dimensionally stable. Commonly used teak, white
pine and mahogany wood. y Light in weight
y Metal patterns are more expensive but are more
y Strong, hard and durable
dimensionally stable and more durable. durable Commonly used
CI, Brass, aluminium and white metal. y Resistant to wear and abrasion
y Hard plastics, such as urethanes, and are often preferred
y Resistant to corrosion, and to chemical reactions
with processes that use strong, organically bonded sands
that tend to stick to other pattern materials. y Dimensionally stable and unaffected by variations in
y In the full‐mold process, expanded polystyrene (EPS) is temperature and humidity.
used.
y Investment casting uses wax patterns. y Available at low cost.
IES‐1994 GATE‐2000
Which of the following materials can be used for
Disposable patterns are made of
making patterns?
(a) Wood
1. Aluminium 2. Wax 33. Mercuryy 4
4. Lead
(b) Rubber
Select the correct answer using the codes given below:
(c) Metal
Codes:
(d) Polystyrene
(a) 1,3 and 4 (b) 2,3 and 4 (c) 1, 2 and 4 (d) 1, 2 and 3
Ans. (d)
Ans. (d)
7
8/28/2011
Types of Pattern Types of Pattern
Single Piece Pattern Split Pattern or Two Piece Pattern
These are inexpensive and the simplest type of This is the most widely used type of pattern for intricate
patterns. As the name indicates, they are made of a castings. When the contour of the casting makes its
single piece. withdrawal from the mould difficult, or when the depth
of the casting is too high,
high then the pattern is split into two
parts so that one part is in the drag and the other in the
Gated Pattern cope.
Gating and runner system are integral with the
pattern. This would eliminate the hand cutting of
the runners and gates and help in improving the
productivity of a moulding.
y Cope and Drag Pattern
y Match Plate Pattern
These are similar to split patterns. In addition to
splitting the pattern, the cope and drag halves of The cope and drag patterns along with the
the p
pattern alongg with the g
gating
g and riser systems
y gating and the risering are mounted on a single
are attached separately to the metal or wooden matching metal or wooden plate on either side.
plates along with the alignment pins. They are
called the cope and drag patterns.
y Follow Board Pattern
y Loose Piece Pattern This type of pattern is adopted for those
This type of pattern is also used when the castings where there are some portions, which
contour of the part is such that withdrawing the are structurally weak and if not supported
pattern from the mould is not possible.
possible properly are likely to break under the force of
ramming.
8
8/28/2011
IES‐2008 Types of Pattern
y Sweep Pattern
The pattern adopted for those castings where there It is used to sweep the complete casting by means
are some portions which are structurally weak and of a plane sweep. These are used for generating
are likely to break by the force of ramming are large shapes, which are axi‐symmetrical or
called:
ll d prismatic
i ti ini nature
t such
h as bell‐shaped
b ll h d or
(a) Loose piece pattern cylindrical.
(b) Follow board pattern
(c) Skelton pattern
(d) Single piece pattern
Ans. (b)
Types of Pattern Cooling Curve
y Skeleton Pattern
A skeleton of the pattern made of strips of wood
is used for building the final pattern by packing
sand around the skeleton. After packing the
sand,
sand the desired form is obtained with the help
of a strickle. This type of pattern is useful
generally for very large castings, required in
small quantities where large expense on
complete wooden pattern is not justified.
Fluidity Core
The ability of a metal to flow and fill a mold is known
as fluidity. y Used for making cavities and hollow projections.
Pouring Temperature
y The most important controlling factor of fluidity is the y All sides of core are surrounded by the molten metal
p
pouringg temperature
p or the amount of superheat.
p and are therefore subjected to much more severe
y Higher the pouring temperature, the higher the fluidity. thermal and mechanical conditions and as a result the
y Excessive temperatures should be avoided, however. At core sand should be of higher strength than the
high pouring temperatures, metal‐mold reactions are moulding sand.
accelerated and the fluidity may be so great as to permit
penetration.
y Penetration is a defect where the metal not only fills the
mold cavity but also fills the small voids between the sand
particles in a sand mold.
9
8/28/2011
Desired characteristics of a core y Permeability: Gases evolving from the molten metal

and generated from the mould may have to go
y Green Strength: A core made of green sand should through the core to escape out of the mould. Hence
be strong enough to retain the shape till it goes for cores are required to have higher permeability.
baking. y Permeability Number: The rate of flow of air passing
y Dry Strength:
h It should
h ld have
h adequate
d dry
d strength h through
th h a standard
t d d specimen
i under
d a standard
t d d pressure is
i
so that when the core is placed in the mould, it termed as permeability number.
should be able to resist the metal pressure acting on y The standard permeability test is to measure time
it. taken by a 2000 cu cm of air at a pressure typically of
y Refractoriness: Since in most cases, the core is 980 Pa (10 g/cm2), to pass through a standard sand
surrounded all around it is desirable that the core specimen confined in a specimen tube. The standard
material should have higher refractoriness. specimen size is 50.8 mm in diameter and a length of
Compiled by: S K Mondal Made Easy Contd… 50.8 mm. Compiled by: S K Mondal Made Easy
y Then, the permeability number, R is obtained by

VH y Calculate the permeability number of sand if it takes 1 min
R= 25 s to pass 2000 cm3 of air at a pressure of5 g/cm2 through
pAT
the standard sample.
Where V= volume of air = 2000 cm3
H = height of the sand specimen = 5.08 cm p = 5.0 g / cm 2
p p , g/ 2
p = air pressure, g/cm T = 1 min 25 s = 11.417
417 min
A = cross sectional area of sand specimen = 20.268 cm2 501.28
R= = 70.75
T = time in minutes for the complete air to pass through 5 × 1.417
Inserting the above standard values into the
expression, we get
501.28
R=
p.T
Core Sands
y Collapsibility: At the time of cooling, casting shrinks,
and unless the core has good collapsibility (ability to y Used clay free silica sand.
decrease in size) it is likely to provide resistance against y Binders used are linseed oil, core oil, resins, dextrin,
shrinkage and thus can cause hot tears. molasses, etc.
y Friability: The ability to crumble should be a very
y Core oils are mixtures of linseed, soy, fish and
important consideration at the time of removal.
petroleum oils and coal tar.
y Smoothness: Surface of the core should be smooth for
good finish to the casting. y The general composition of a core sand mixture could
y Low Gas Emission be core oil (1%) and water (2.5 to 6%).
10
8/28/2011
Carbon Dioxide Moulding
y The compressive strength of the bond increases with
y Sodium silicate (water glass, SiO2:Na2O) is used as a binder.
This is essentially a quick process of core or mould standing time due to dehydration.
preparation.
y Because of the high strength of the bond, the core need not
y The mould is prepared with a mixture of sodium silicate and
sand and then treated with carbon dioxide for two to three be p
provided with anyy other reinforcements.
minutes such that a dry compressive strength of over 1.4
MPa is arrived. y It does not involve any distortions due to baking and also
y The carbon dioxide is expected to form a weak acid, which better dimensional accuracies are achieved.
hydrolyses the sodium silicate resulting in amorphous silica,
which forms the bond. y The sand mixture does not have good shelf life and
y The introduction of CO2 gas starts the reaction by forming therefore should be used immediately after preparation.
hydrated sodium carbonate (Na2CO3 + H2O).
IES‐2002 Moulding Sand Composition
Assertion (A): In CO2 casting process, the mould or y Sand: Ordinary silica Sand (SiO2), zircon, or olivine
core attains maximum strength.
Reason (R): The optimum gassing time of CO2 sands.
through the mould or core forms Silica Gel which
y Clay: Acts ss binding agents mixed to the moulding
imparts sufficient strength to the mould or core.
core
(a) Both A and R are individually true and R is the sands
correct explanation of A
Kaolinite or fire clay (Al2O3 2SiO2 2H2O), and
(b) Both A and R are individually true but R is not the
correct explanation of A Bentonite (Al2O3 4SiO2 H2O nH2O).
(c) A is true but R is false
(d) A is false but R is true y Water: Clay is activated by water.
Ans. (a) Compiled by: S K Mondal Made Easy Compiled by: S K Mondal Made Easy
Other Additives Moulding Sand Properties
y Porosity or Permeability: Permeability or porosity of
y Cereal binder up to 2% increases the strength.
the moulding sand is the measure of its ability to
y Pitch if used up to 3% would improve the hot permit air to flow through it.
y Strength: It is defined as the property of holding
strength.
g
t th off sand
together d grains.
i A moulding
ldi sand
d should
h ld have
h
y Saw dust up to 2% may improve the collapsibility by ample strength so that the mould does not collapse or
get partially destroyed during conveying, turning over
slowly burning, and increase the permeability. or closing.
y Other materials: sea coal, asphalt, fuel oil, graphite, y Refractoriness: It is the ability of the moulding sand
mixture to withstand the heat of melt without showing
molasses, iron oxide, etc. any signs of softening or fusion.
Compiled by: S K Mondal Made Easy Compiled by: S K Mondal Made Easy Contd…
11
8/28/2011
y Plasticity: It is the measure of the moulding sand to flow Other Sands

around and over a pattern during ramming and to uniformly y Facing sand: The small amount of carbonaceous
fill the flask. material sprinkled on the inner surface of the mold
y Collapsibility: This is the ability of the moulding sand to cavity to give a better surface finish to the castings.
decrease in volume to some extent under the compressive y Backing sand: It is what constitutes most of the
p y g g
forces developed by the shrinkage of metal during freezing g refractory material found in the mould. mould This is made
and subsequent cooling. up of used and burnt sand.
y Adhesiveness: This is the property of sand mixture to y Green Sand: The molding sand that contains
adhere to another body (here, the moulding flasks). The moisture is termed as green sand. The green sand
moulding sand should cling to the sides of the moulding
should have enough strength so that the constructed
boxes so that it does not fall out when the flasks are lifted
and turned over. This property depends on the type and
mould retains its shape.
amount of binder used in the sand mix. y Dry sand: When the moisture in the moulding sand is
Compiled by: S K Mondal Made Easy completely expelled, it is called dry sand.
IES‐2008 Grain size number
y ASTM (American Society for Testing and Materials)
Small amount of carbonaceous material sprinkled grain size number, defined as
on the inner surface of mould cavity is called n-1
N 2
(a) Backing sand
y Where N is the number of grains per square inch
(b) Facing sand visible in a prepared specimen at 100X and n is the
(c) Green sand ASTM grain‐size number. Low ASTM numbers mean a
(d) Dry sand few massive grains; high numbers refer to many small
Ans. (b) grains.
IES‐2002 Casting Yield
In the grain ‐size determination using standard The casting yield is the proportion of the actual
charts, the relation between the given size casting mass, w, to the mass of metal poured into the
number n and the average number of grains 'N' mould, W, expressed as a percentage.
per square inch at a magnification of 100 X is
(a) N = 2n w
(b) N = 2n‐l Casting yield = × 100
W
(c) N = 2n + 1
(d) N = 2n + 1
Ans. (b)
12
8/28/2011
Gating System Gating System
y Pouring basin: A small funnel shaped cavity at the
top of the mould into which the molten metal is
poured.
y Sprue:
S The
Th passage through
th h which
hi h the
th molten
lt metal,
t l
from the pouring basin, reaches the mould cavity. In
many cases it controls the flow of metal into the
mould.
y Runner: The channel through which the molten

metal is carried from the sprue to the gate.
Types of Gate or In‐gate
y Ingate: A channel through which the molten metal
enters the mould cavity. Top gate: Causes turbulence in the mould cavity, it is prone
y Vent: Small opening in the mould to facilitate escape to form dross, favourable temperature gradient towards the
of air and gases.
gate, only for ferrous alloys.
Bottom gate: No mould erosion, used for very deep moulds,

higher pouring time, Causes unfavourable temperature
gradients.
Parting Gate: most widely used gate, easiest and most
economical in preparation.
Step Gate: Used for heavy and large castings, size of ingates
Compiled by: S K Mondal Made Easy are normally increased from top to bottom.
IES 2011
IES 2011 Match List –I with List –II and select the correct answer using
In light metal casting, runner should be so designed that: the code given below the lists :
1. It avoids aspiration List –I List –II
2. It avoids turbulence
A. Top gate 1. Heavy and large castings
3. The path of runner is reduced in area so that
unequal volume of flow through each gate B. Bottom gate
g 2. Most widely used and economical
y
takes place
C. Parting gate 3. Turbulence
(a) 1 and 2 only
(b) 1 and 3 only D. Step gate 4. Unfavourable temperature gradient
(c) 2 and 3 only Codes [Ans. (a)]
(d) 1, 2 and 3 A B C D A B C D
Ans. (a) (a) 3 4 2 1 (b) 1 4 2 3
Compiled by: S K Mondal Made Easy (c) 3 2 4 1 (d) 1
Compiled by: S K Mondal Made Easy 2 4 3
13
8/28/2011
IES‐1998 GATE‐2002
A sand casting mould
assembly is shown in The primary purpose of a sprue in a casting
the above figure. The mould is to
elements marked A (a)Feed the casting at a rate consistent with the rate
and B are respectively of solidification
(a) Sprue and riser (b)Act as a reservoir for molten metal
(b) Ingate and riser (c)Feed molten metal from the pouring basin to the
(c) Drag and runner gate
(d) Riser and runner (d)Help feed the casting until all solidification takes
Ans. (a) place
Ans. (c)
The goals for the gating system IES‐1998
y To minimize turbulence to avoid trapping gasses into Which of the following are the requirements of an ideal
the mold gating system?
1. The molten metal should enter the mould cavity with as
y To get enough metal into the mold cavity before the
high a velocity as possible.
metal starts to solidify
2 It should facilitate complete filling of the mould cavity.
2. It should facilitate complete filling of the mould cavity
y To avoid shrinkage
3. It should be able to prevent the absorption of air or gases
y Establish the best possible temperature gradient in the from the surroundings on the molten metal while
solidifying casting so that the shrinkage if occurs must flowing through it.
be in the gating system not in the required cast part. Select the correct answer using the codes given below:
y Incorporates a system for trapping the non‐metallic (a) 1, 2 and 3 (b) 1 and 2 (c) 2 and 3 (d) 1 and 3
inclusions.
Ans. (c)
IES‐2009 Types of Gating Systems
Consider the following statements:
1.The actual entry point through which the molten The gating systems are of two types:
metal enters the mould cavity is called ingate.
g
2.Bottom gate in case of a mould creates unfavourable y Pressurized gating system
temperature gradient.
3.Sprue in case of a mould is made tapered to avoid air
inclusion. y Un‐pressurized gating system
Which of the above statements is/are correct?
(a) 1 only (b) 1 and 2 (c) 2 and 3 (d) 1 and 3
Ans. (d)
14
8/28/2011
Pressurized Gating System Un‐Pressurized Gating System
y The total cross sectional area decreases towards the y The total cross sectional area increases towards the
mold cavity
mold cavity
y Back pressure is maintained by the restrictions in the
metal flow y Restriction only
y at the bottom of sprue
p
y Flow of liquid (volume) is almost equal from all gates
y Flow of liquid (volume) is different from all gates
y Back pressure helps in reducing the aspiration as the
sprue always runs full y Aspiration in the gating system as the system never
y Because of the restrictions the metal flows at high runs full
velocity leading to more turbulence and chances of
mold erosion. y Less turbulence.
Sprue Design
y Sprue: Sprue is the channel through which the molten
metal is brought into the parting plane where it enters the
runners and gates to ultimately reach the mould cavity.
y The molten metal when moving from the top of the cope to
the p
partinggpplane g
gains in velocityy and some low‐pressure
p
area would be created around the metal in the sprue.
y Since the sand mould is permeable, atmospheric air would The exact tapering can be obtained by the equation of
be breathed into this low‐pressure area which would then continuity. Denoting the top and choke sections of The sprue by
be carried to the mould cavity. the subscripts’t’ and 'c' respectively, we get
y To eliminate this problem of air aspiration, the sprue is
tapered to gradually reduce the cross section as it moves Vc
A t Vt = A c Vc At = Ac
away from the top of the cope as shown in Figure below (b). Vt
Since the velocities are proportional to the square of
the potential heads, as can be derived from
GATE‐2001
Bernoulli's equation,
The height of the down‐sprue is 175 mm and its
hc cross‐sectional area at the base is 200 mm2. The
At = Ac
ht cross‐sectional area of the horizontal runner is
l 200 mm2. Assuming
also A i no losses,
l i di t the
indicate th
correct choice for the time (in seconds) required to
fill a mould cavity of volume 106 mm3. (Use g = 10
m/s2).
Where H = actual
sprue height
(a)2.67 (b)8.45 (c)26.72 (d)84.50
and ht = h + H
Ans. (a)
15
8/28/2011
GATE‐2007
A 200 mm long down sprue has an area of cross
section of 650 mm2 where the pouring basin meets the
down sprue (i.e. at the beginning of the down sprue).
A constant head of molten metal is maintained by the
p
pouringg basin. The Molten metal flow rate is 6.55 × 105
mm3/s. Considering the end of down sprue to be open
to atmosphere and an acceleration due to gravity of
104mm/s2, the area of the down sprue in mm2 at its end
(avoiding aspiration effect) should be
(a)650.0 (b)350.0 (c)290.7 (d)190.0

Ans. (c)
Gating ratio IES‐2003
A gating ratio of 1: 2: 4 is used to design the gating
y Gating ratio is defined as: Sprue area: Runner area: system for magnesium alloy casting. This gating ratio
Ingate area. refers to the cross∙ section areas of the various gating
elements as given below:
y For high quality steel castings, a gating ratio of 1: 2: 2 or 1. Down sprue 2. Runner bar 3. Ingates
1: 2: 1.5 will produce castings nearly free from erosion, The correct sequence of the above elements in the
ratio 1: 2: 4 is
will minimize oxidation, and will produce uniform (a) 1, 2 and 3
flow. (b) 1,3 and 2
(c) 2, 3 and 1
y A gating ratio of 1: 4: 4 might favour the formation of (d) 3, 1 an 2
oxidation defects. Ans. (a)
IES‐2005 GATE‐2010
The gating ratio 2: 8: 1 for copper in gating system In a gating system, the ratio 1:2:4 represents
design refers to the ratio of areas of:
(a) Sprue: Runner: Ingate (a) Sprue base area: runner area: ingate area
(b) Runner: Ingate: Sprue (b) Pouring basin area : ingate area : runner area
(c) Runner: Sprue: Ingate
(d) Ingate: Runner: Sprue (c) Sprue base area : ingate area : casting area
(d) Runner area : ingate area : casting area

Ans. (a)
Ans. (a)
16
8/28/2011
IAS‐1999 Risers and Riser Design
Assertion (A): The rate of flow of metal through sprue y Risers are added reservoirs designed to feed liquid
is NOT a function of the cross‐sectional areas of metal to the solidifying casting as a means of
sprue, runner and gate. compensating for solidification shrinkage.
Reason (R): If respective cross‐sectional areas of
sprue, runner and gate are in the ratio of 1: 2: 2, the y To perform this function, the risers must solidify after
system is known as unpressurised gating system.
system the casting.
casting
(a) Both A and R are individually true and R is the correct y According to Chvorinov's rule, a good shape for a riser
explanation of A
would be one that has a long freezing time (i.e., a small
correct explanation of A surface area per unit volume).
(c) A is true but R is false y Live risers (also known as hot risers) receive the last
(d) A is false but R is true hot metal that enters the mold and generally do so at a
Ans. (d) time when the metal in the mold cavity has already
Compiled by: S K Mondal Made Easy begun to cool and solidify.
IES‐1994 Chvorinov’s rule

Assertion (A): In a mould, a riser is designed and placed y Total solidification time (ts) = B (V/A) n
so that the riser will solidify after the casting has solidified.
where n = 1.5 to 2.0
Reason (R): A riser is a reservoir of molten metal which
will supply molten metal where a shrinkage cavity would [Where, B = mould constant and is a function of (mould
have occurred. material, casting material, and condition of casting]
(a)
( ) Both
B h A and d R are individually
i di id ll true and d R is
i the
h correct n = 2 and triser = 1.25 tcasting
explanation of A
2 2
(b) Both A and R are individually true but R is not the ⎛V⎞ ⎛V⎞
correct explanation of A or ⎜A⎟ = 1.25 ⎜ ⎟
⎝ ⎠riser ⎝ A ⎠casting
(d) A is false but R is true For cylinder V = πD2H / 4
( )
Ans. (a) of diameter D 2
A = πDH + 2 πD
Compiled by: S K Mondal Made Easy and height H 4
IES 2011 IES‐1998
The relationship between total freezing time t,
volume of the casting V and its surface area A, A spherical drop of molten metal of radius 2 mm
according to Chvorinov’s rule is :
was found to solidify in 10 seconds. A similar drop
⎛V ⎞
(a ) t = k ⎜ ⎟ of radius 4 mm would solidify in
⎝ A ⎠
⎛ A ⎞
(b ) t = k ⎜ ⎟ (a) 14.14 seconds
⎝V ⎠
2
⎛ A ⎞ (b) 20 seconds
(c ) t = k ⎜ ⎟
⎝V ⎠
⎛V ⎞
2
(c) 28.30 seconds
(d ) t = k ⎜ ⎟
⎝ A ⎠
Where K is a constant [Ans. (d)] (d) 40 seconds [Ans. (d)]
17
8/28/2011
GATE‐2003 IES‐2006
According to Chvorinov's equation, the
With a solidification factor of 0.97 x 106 s/m2, the
solidification time (in seconds) for a spherical solidification time of a casting is proportional to:
casting of 200 mm diameter is
(a) v2
(a) 539 (b) 1078 (c) 4311 (d) 3233 (b) v
(c) 1/v
[Ans. (b)]
(d) 1/v2
Where, v = volume of casting [Ans. (a)]

GATE‐2007
Volume of a cube of side 'l' and volume of a sphere of
radius ‘r’ are equal. Both the cube and the sphere are
solid and of same material. They are being cast. The
ratio
ti off the
th solidification
lidifi ti time
ti off the
th cube
b to
t the
th same
of the sphere is:
3 6 2 2 3 2 4
⎛ 4π ⎞ ⎛ r ⎞ 4π ⎞ ⎛ r ⎞ 4π ⎞ ⎛ r ⎞ 4π ⎞ ⎛ r ⎞
(a ) ⎜ 6 ⎟ ⎜l⎟ ( b ) ⎛⎜ ⎟⎜ ⎟ ( c ) ⎛⎜ ⎟ ⎜ ⎟ ( d ) ⎛⎜ ⎟ ⎜ ⎟
⎝ ⎠ ⎝ ⎠ ⎝ 6 ⎠⎝ l ⎠ ⎝ 6 ⎠ ⎝l⎠ ⎝ 6 ⎠ ⎝l⎠
Ans. (d)
Conventional Question ESE 2003: Modulus Method
y It has been empirically established that if the modulus
Compare the solidification time of two of the riser exceeds the modulus of the casting by a

optimum side – risers of the same volume factor of 1.2, the feeding during solidification would be
with one has cylindrical shape and other is
i h h li d i l h d h i satisfactory.
parallopiped. MR = 1.2 Mc
[30 Marks]
y Modulus = volume/Surface area
y In steel castings, it is generally preferable to choose a

riser with a height‐to‐diameter ratio of 1.
Compiled by: S K Mondal Made Easy Compiled by: S K Mondal Made Easy Contd…
18
8/28/2011
Conventional Question IES‐2008
y Calculate the size of a cylindrical riser (height and diameter
πD 2
equal) necessary to feed a steel slab casting of dimensions
+ π D2
4 30 x 30 x 6 cm with a side riser,
riser casting poured horizontally
into the mould.
[Use Modulus Method]
[10 ‐ Marks]
Caine’s Method Table: Constants in Caine’s Method

Freezing ratio = ratio of cooling characteristics of casting to
the riser. (A ) x=
V casting
(A V) riser
The riser should solidify last so x > 1
Th i h ld lidif l
a
According to Caine X = Y − b + c
V riser
Y = and a, b, c are constant.
Vcasting
Chills
Conventional Question IES‐2007 y External chills are masses of high‐heat‐capacity, high‐thermal‐
conductivity material that are placed in the mould (adjacent to
the casting) to accelerate the cooling of various regions.
y Calculate the size of a cylindrical riser (height and Chills can effectively promote directional solidification or
increase the effective feeding distance of a riser. They can often
diameter equal) necessary to feed a steel slab b used
be d to reduce
d the
h numberb off risers
i required
i d for
f a casting.
i
casting of dimensions 25 x 25 x 5 cm with a side y Internal chills are pieces of metal that are placed within the
mould cavity to absorb heat and promote more rapid
riser, casting poured horizontally into the mould. solidification. Since some of this metal will melt during the
operation, it will absorb not only the heat‐capacity energy, but
[Use Caine’s Method] also some heat of fusion. Since they ultimately become part of
the final casting, internal chills must be made from the same
alloy as that being cast.
19
8/28/2011
IES‐1995 GATE‐1998,2007
Directional solidification in castings can be improved Chills are used in moulds to
by using
(a) Achieve directional solidification
(a)
( ) Chills
Chill and
d chaplets
h l t
(b) Reduce the possibility of blowholes
(b) Chills and padding
(c) Reduce freezing time
(c) Chaplets and padding
(d) Chills, chaplets and padding (d) Smoothen metal flow for reducing splatter
[Ans. (b)] [Ans. (a)]

IAS 1994 Cupola
Chills are used in casting moulds to y Steel can be melted in hot blast cupola.
(a) Achieve directional solidification
y In hot blast cupola, the flue gases are used to preheat
(b) Reduce possibility of blow holes
(c) Reduce the freezing time the air blast to the cupola so that the temperature in
p p
(d) Increase the smoothness of cast surface the furnace is considerably higher than that in a
conventional cupola.
Ans. (a)
y Cupola has been the most widely used furnace for
melting cast iron.
IES‐1997 Electric Arc Furnace
Assertion (A): Steel can be melted in hot blast cupola. y For heavy steel castings, the open‐hearth type of
Reason (R): In hot blast cupola, the flue gases are used to furnaces with electric arc or oil fired would be generally
preheat the air blast to the cupola so that the temperature in
the furnace is considerably higher than that in a suitable in view of the large heat required for melting.
conventional
i l cupola.
l
y Electric arc furnaces are more suitable for ferrous
(a) Both A and R are individually true and R is the correct
explanation of A materials and are larger in capacity.
(d) A is false but R is true [Ans. (a)]
20
8/28/2011
Crucible Furnace
Ladles
y Smaller foundries generally prefer the crucible furnace. y Two types of ladles used in the pouring of castings.
y The crucible is generally heated by electric resistance
or gas flame.
Induction Furnace
y The induction furnaces are used for all types of
materials, the chief advantage being that the heat
source is isolated from the charge and the slag and flux
get the necessary heat directly from the charge instead
of the heat source.
Casting Cleaning (fettling) GATE‐1996
Impurities in the molten metal are prevented from
reaching the mould cavity by providing a Light impurities in the molten metal are prevented
(i) Strainer from reaching the mould cavity by providing a
(ii) Button well (a) Strainer
(iii) Skim bob (b) Button well
(c) Skim bob
(d) All of the above
Ans. (c)
Pouring time GATE‐2005
Time taken to fill the mould with top gate
Where A = Area of mould A mould has a downsprue whose length is 20 cm
A.H
tA = H = Height of mould and the cross sectional area at the base of the
A g 2gh m
Ag = Area of Gate downsprue is 1cm2. The downsprue feeds a
Hm = Gate height h i
horizontal
t l runner leading
l di into
i t the
th mould ld cavity
it off
volume 1000 cm3. The time required to fill the
mould cavity will be
Time taken to fill the mould with bottom gate
(a)4.05 s (b)5.05 s (c)6.05 s (d)7.25 s
tB =
2A
A g 2g
( hm − hm − H ) Ans. (b)
21
8/28/2011
GATE‐2006 Expression for choke area
In a sand casting operation, the total liquid head is
maintained constant such that it is equal to the mould m
CA = mm2
height. The time taken to fill the mould with a top gate cρt 2gH
is tA. If the same mould is filled with a bottom gate,
then the time taken is tB. Ignore the time required to Where m = mass of the casting, kg
fill the
h runner and d frictional
fi i l effects.
ff Assume
A ρ = Density of metal, kg / m3
atmospheric pressure at the top molten metal surfaces. t = pouring time
The relation between tA and tB is
(A) tB = 2 t A c = Efficiency factor and is the function of gate
system used
(B) tB = 2 t A
H = Effective head of liquid metal
tA
(C) tB = = h for top gate
2 Ans. (b)
(D) tB = 2 2 t A Compiled by: S K Mondal Made Easy Compiled by: S K Mondal Made Easy Contd…
Casting Defects
h
H=h‐ m for bottom gate The following are the major defects, which are likely to
2
hc2 occur in sand castings:
=h‐ for parting line gate
2h m
y Gas defects
y Shrinkage cavities
y Molding material defects
hC
hm
hm hm y Pouring metal defects
P i li
top gate parting line gate bottom gate y Mold shift.
Gas Defects Shrinkage Cavities
y These are caused by liquid shrinkage occurring during the
y A condition existing in a casting caused by the solidification of the casting.
trapping of gas in the molten metal or by mold gases y To compensate for this, proper feeding of liquid metal is
evolved during the pouring of the casting. required. For this reason risers are placed at the
y The defects in this category
g y can be classified into appropriate places in the mold.
blowholes and pinhole porosity. y Sprues may be too thin, too long or not attached in the
y Blowholes are spherical or elongated cavities present proper location, causing shrinkage cavities.
in the casting on the surface or inside the casting. y It is recommended to use thick sprues to avoid shrinkage
cavities.
y Pinhole porosity occurs due to the dissolution of
hydrogen gas, which gets entrapped during heating of
molten metal.
22
8/28/2011
Molding Material Defects Cut and washes
y These appear as rough spots and areas of excess metal, and
y Cuts and washes, are caused by erosion of molding sand by the flowing
metal.
y Scab y This is caused by the molding sand not having enough
strength and the molten metal flowing at high velocity.
velocity
y Metal penetration, y The former can be taken care of by the proper choice of
molding sand and the latter can be overcome by the
y Fusion, and
proper design of the gating system.
y Swell
Scab Metal penetration
y This defect occurs when a portion of the face of a mould
y When molten metal enters into the gaps between sand
lifts or breaks down and the recess thus made is filled by
grains, the result is a rough casting surface.
metal.
y This occurs because the sand is coarse or no mold wash was
y When the metal is poured into the cavity, gas may be
applied on the surface of the mold. The coarser the sand
disengaged with such violence as to break up the sand,
grains more the metal p
g penetration.
which
hi h is
i then
h washedh d away and
d the
h resulting
l i cavity
i filled
fill d
with metal.
y The reasons can be: ‐ too fine sand, low permeability of
sand, high moisture content of sand and uneven mould
ramming.
Fusion Swell
y This is caused by the fusion of the sand grains with Under the influence of metallostatic forces, the mold
wall may move back causing a swell in the dimension
the molten metal, giving a brittle, glassy appearance of the casting. A proper ramming of the mold will
correct this defect.
on the casting
g surface.
y The main reason for this is that the clay or the sand Inclusions
particles are of lower refractoriness or that the Particles of slag, refractory materials sand or
deoxidation products are trapped in the casting during
pouring temperature is too high. pouring solidification. The provision of choke in the
gating system and the pouring basin at the top of the
mold can prevent this defect
23
8/28/2011
Pouring Metal Defects y The mis‐run and cold shut defects are caused either by
The likely defects in this category are a lower fluidity of the mold or when the section
y Mis‐runs and thickness of the casting is very small. Fluidity can be
y Cold shuts improved by changing the composition of the metal
and by increasing the pouring temperature of the
metal.
metal
y A mis‐run is caused when the metal is unable to fill
the mold cavity completely and thus leaves unfilled
cavities.
y A cold shut is caused when two streams while meeting
in the mold cavity, do not fuse together properly thus
forming a discontinuity in the casting.
Two streams of liquid metal which are not hot
Misrun is a casting defect which occurs due to
enough to fuse properly result into a casting defect
(a) Very high pouring temperature of the metal
known as
(b) Insufficient fluidity of the molten metal
(a) Cold shut
(c) Absorption of gases by the liquid metal
(b) Swell
(d) Improper alignment of the mould flasks
(c) Sand wash
Ans. (b)
(d) Scab [Ans. (a)]
Mold Shift IES‐2001
The mold shift defect occurs when cope and drag
Scab is a
or molding boxes have not been properly aligned.
(a) Sand casting defect
(b) Machining defect
(c) Welding defect
(d) Forging defect
Ans. (a)
24
8/28/2011
IAS‐2004 GATE‐2003
Match List‐I (Casting Defects) with List‐II (Explanation) and select the correct
answer using the codes given below the lists: Hardness of green sand mould increases with
List‐I List‐II
(Casting Defects) (Explanation) (a) Increase in moisture content beyond 6 percent
A. Metallic projections 1. Consist of rounded or rough internal or exposed cavities
including blow holes and pin holes (b) Increase in permeability
B. Cavities 2. Formed during melting, solidification and moulding.
C. Inclusions 3. Includes single folds, laps, scars adhering sand layers and (c) Decrease in permeability
oxide scale
D. Discontinuities 4. Include cracks, cold or hot tearing and cold shuts (d) Increase in both moisture content and
5.Consist of fins, flash or massive projections and rough
surfaces
permeability
Codes: A B C D A B C D
(a) 1 5 3 2 (b) 1 5 2 4
(c) 5 1 2 4 (d) 5 1 3 2 Ans. (c)
Ans. (d)
IES‐1998 IES‐2005
Assertion (A): Stiffening members, such as webs In gating system design, which one of the
and ribs, used on a casting should be liberally following is the correct sequence in which choke
provided. area, pouring time, pouring basin and sprue sizes
Reason (R): They will provide additional strength are calculated?
to a cast member.
to a cast member
(a) Choke area ‐ Pouring time ‐ Pouring basin – Sprue
(a) Both A and R are individually true and R is the
correct explanation of A (b) Pouring basin ‐ Sprue ‐ Choke area ‐ Pouring time
(b) Both A and R are individually true but R is not the (c) Choke area ‐ Sprue ‐ Pouring basin ‐ Pouring time
correct explanation of A (d) Pouring basin ‐ Pouring time ‐ Choke area ‐ Sprue
(d) A is false but R is true [Ans. (a)] Ans. (a)
IES‐1997 IES‐2009
If the melting ratio of a cupola is 10: 1, then the In which one of the following furnaces most of the
coke requirement for one ton melt will be non‐ferrous alloys are melted?
(a) 0.1 ton (a) Reverberatory furnace
(b) 10 tons (b) Induction furnace
(c) 1 ton (c) Crucible furnace
(d) 11 tons (d) Pot furnace
Ans. (a) Ans. (d)
25
8/28/2011
IAS‐2001 IAS‐2004
Which of the following pattern‐materials are used Which one of the following gating systems is best
in Precision Casting? suited to obtain directional solidification?
1. Plaster of Paris (a) Top grating
2. Plastics (b) Part
Part‐line
line grating
3. Anodized Aluminium Alloy (c) Bottom grating
4. Frozen Mercury (d) Stepped grating
Select the correct answer using the codes given below:
(a) 1 and 2 (b) 2 and 4 (c)3 and 4 (d) 1 and 3 Ans. (d)
Ans. (b)
Cast Aluminium Code Cast Aluminium Code Contd..
y Four digit identification system
y Second two digits identify the aluminium alloy or
y First digit indicates alloy group indicate the aluminium purity.
1 – Aluminium, 99% or more y The last digit is separating from the other three by a
2 – copper decimal point and indicates the product form; that is,
3 –
3 Silicon, with copper and/or magnesium
Silicon with copper and/or magnesium castings or ingots
4 – silicon y A modification of the original alloy is indicated by a
5 – magnesium serial letter before the numerical designation.
6 – not used y Alloy A514.0 indicates an aluminium alloy casting with
magnesium as the principal alloy. One modification to
7 – zinc
the original alloy has made, as indicated by the letter A.
8 – tin
9 – other elements
IES 2011
In the designation of Aluminium casting A514.0
indicates :
(a) Aluminium purity
(b) Aluminium content
(c) Percentage of alloy element
(d) Magnesium Content
Ans. (d)
26
10/9/2011
Shell Moulding
y The sand is mixed with a thermosetting resin is
allowed to come in contact with a heated metal pattern
Special Casting (2000C).
y A skin
ki (shell)
( h ll) off about
b 3.5 mm off sand
mixture adhere to the pattern.
d and
d plastic
l i
y Then the shell is removed from the pattern.

y The cope and drag shells are kept in a flask with
necessary backup material and the molten metal is
poured into the mold.
By S K Mondal
y Can produce complex parts.
y A good surface finish and good size tolerance

reduce the need for machining.
g
y Materials can be cast: CI, Al and Cu alloys.
Shell moulding process
Molding Sand in Shell Molding y Hot coating: the mixture is heated to 150oC– 180oC prior
y The molding sand is a mixture of fine grained quartz sand to loading the sand. In the course of sand mixing, the
and powdered bakelite. soluble phenol formaldehyde resin is added. The mixer is
allowed to cool up to 80 – 90o C. Hot coting gives better
y Cold coating and Hot coating methods are used for
properties to the mixtures than cold method.
coating the sand grains with bakelite.
y Cold coating: quartz sand is poured into the mixer and

then the solution of powdered bakelite in acetone and
ethyl aldehyde are added. (mixture is 92% quartz sand,
5% bakelite, 3% ethylaldehyde )
Contd…
1
10/9/2011
Advantages Limitations
y Dimensional accuracy. y Expensive pattern
y Smoother surface finish. (Due to finer size grain used) y Small size casting only.
y Very
y thin sections can be cast. y Highly complicated shapes cannot be obtained.
y Very small amount of sand is needed. y More sophisticated equipment is needed for handling
the shell moldings.
IES 2010
Applications Consider the following advantages of shell
mould casting:
y Cylinders and cylinder heads for air‐ cooled IC
1. Close dimensional tolerance.
engines
2. Good surface finish.
y Automobile transmission parts. 3. Low cost.
y Piston rings 4. Easier.
Which of these are correct?
(a) 1, 2 and 3 only (b) 2, 3 and 4 only
(c) 1, 2 and 4 only (d) 1, 2, 3 and 4
IES‐1996 IES‐2005
Consider the following ingredients used in In shell moulding, how can the shell thickness
moulding: be accurately maintained?
1. Dry silica sand (a) By controlling the time during which the pattern
2.Clay is in contact with mould
3.Phenol formaldehyde (b) By controlling the time during which the pattern
is heated
4.Sodium silicate
(c) By maintaining the temperature of the pattern in
Those used for shell mould casting include
the range of 175oC – 380oC
(a) 1, 2 and 4 (b) 2, 3 and 4
(d) By the type of binder used
(c) 1and 3 (d) 1, 2, 3 and 4
2
10/9/2011
IES‐2006 IES 2007
Shell moulding can be used for:
(a) Producing milling cutters Which of the following are employed in shell
moulding?
(b) Making gold ornaments
1. Resin binder 2. Metal pattern 3. Heating coils
(c) Producing heavy and thick walled casting
Select the correct answer using the code given
(d) Producing thin casting below:
(a) 1 and 2 only (b) 1 and 3 only
(c) 2 and 3 only (d) 1, 2 and 3
IAS‐2007 IAS‐1999
Match List I (Moulding Process) with List II (Binding
The mould in shell moulding process is made up Agent) and select the correct answer using the codes
given below the lists:
of which of the following? List I List II
A. Green sand 1. Silicate
(a) Gypsum + setting agents
B. Core sand 2. Organic
(b) Green sand + clay C. Shell moulding 3. Clay
D. CO2 process 4. Plaster of Paris
(c) Sodium silicate + dried sand 5. Plastic
Codes:A B C D A B C D
(d) Dried silica + phenolic resin (a) 3 2 5 1 (b) 3 2 4 1
(c) 2 3 5 4 (d) 2 3 4 5
Investment Casting
Investment casting process or lost wax process
Basic steps:
1. Produce expendable wax, plastic, or polystyrene patterns.
2. Assemble these patterns onto a gating system
3.
3 Investing or covering the pattern assembly with refractory
slurry
4. Melting the pattern assembly to remove the pattern material
5. Firing the mould to remove the last traces of the pattern
material
6. Pouring molten metal
7. Knockout, cutoff and finishing.
Fig. Investment flask‐casting procedure
3
10/9/2011
Ceramic Shell Investment Casting
y In ceramic shell investment casting a ceramic shell is
built around a tree assembly by repeatedly dipping a
pattern into a slurry (refractory material such as
zircon with binder).
y After each dipping and stuccoing is completed, the

assembly is allowed to thoroughly dry before the next
coating is applied.
IES 2009
y 2 marks
y Tight dimensional tolerances
y Costly patterns and moulds
y Excellent surface finish (1.2 to 3.0 μm )
y Labour costs can be high
y Machining
g can be reduced or completely
p y
eliminated y Limited size
y High melting point alloy can be cast, almost any

metal can be cast
y Almost unlimited intricacy
4
10/9/2011
Applications IES 2011
The proper sequence of investment casting steps is :
y Aerospace and rocket components. (a) Slurry coating – pattern melt out‐Shakeout – Stucco
coating
y Vanes and blades for gas turbines. (b) Stucco coating – Slurry coating – Shakeout – Pattern
melt out
y Surgical instruments
(c) Slurry coating – Stucco coating – Pattern melt out –
Shakeout
(d) Stucco coating – Shakeout – Slurry coating – Pattern
melt out
GATE‐2006 IES‐1992
The most preferred process for casting gas turbine
An expendable pattern is used in blades is:
(a) Slush casting (a) Die moulding
(b) Squeeze casting (b) Shell moulding
(c) Centrifugal casting (c) Investment moulding
(d) Investment casting (d) Sand casting
JWM 2010 IES 2010
Consider the following materials : Assertion (A): These investment casting is used for
1. Wax precision parts such as turbine plates, sewing
2. Wood machines etc.
3. Plastic Reason (R): The investment castings have a good
surface finish and are exact reproductions of the
Which of these materials can be used as pattern in master pattern.
investment casting process ?
(a) 1, 2 and 3 (b) 1 and 2 only correct explanation of A
(c) 2 and 3 only (d) 1 and 3 only (b) Both A and R are individually true but R is NOT the
(d) A is false but R is true
5
10/9/2011
IES 2007 IES‐2006
Consider the following statements in respect of
investment castings: Which of the following materials are used for
1. The pattern or patterns is/are not joined to a stalk or making patterns in investment casting method?
sprue also of wax to form a tree of patterns. 1. Wax 2. Rubber 3. Wood 4. Plastic
2.The prepared moulds are placed in an oven and heated Select the correct answer using the codes given below:
gently to dry off the invest and melt out the bulk of wax.
(a) Only 1 and 3 (b) Only 2 and 3
3.The moulds are usually poured by placing the moulds in
a vacuum chamber. Which of the statements given above (c) Only 1, 2 and 4 (d) Only 2, 3 and 4
are correct?
(a) 1 and 2 only (b) 1 and 3 only
(c)2 and 3 only (d) 1, 2 and 3
IAS‐1996 Permanent Mould Casting
Light and intricate parts with close dimensional
y The process in which we use a die to make the
tolerances of the order of ± 0.005 mm are
castings is called permanent mold casting or gravity
produced by
die casting, since the metal enters the mold under
(a) Investment castingg gravity.
gravity
(b) Die casting y Some time in die‐casting we inject the molten metal
(c) Centrifugal casting with a high pressure. When we apply pressure in
(d) Shell mould casting injecting the metal it is called pressure die casting
process.
y Grey cast iron is used for mould material.
Advantages Disadvantages
y Good surface finish and dimensional accuracy y High initial mold cost
y Metal mold gives rapid cooling and fine‐grain y Shape, size, and complexity are limited
structure y Mold life is very limited with high‐melting‐point
metals such an steel.
steel
y Multiple‐use molds.
y Low melting point metals can be cast
‐ Aluminum
‐ Zinc
‐ Magnesium alloys
‐ Brass
‐ Cast iron
6
10/9/2011
Applications Die Casting
y Molten metal is injected into closed metal dies under
y Pistons/cylinders/rods
pressures ranging from 100 to 150 MPa.
y Gears
y Pressure is maintained during solidification
y Kitchenware
y After which the dies separate and the casting is ejected
along with its attached sprues and runners.
y Cores must be simple and retractable and take the

form of moving metal segments
Die casting machines can be
Video
y Hot chamber
y Cold chamber
Hot chamber machines are
y Good for low temperature (approx. 400°C)
y Faster than cold chamber machines
y Cycle times must be short to minimize metal
contamination
y Metal starts in a heated cylinder
y A piston forces metal into the die
y The piston retracts, and draws metal in
y Metal: Lead, Tin, Zinc
Hot Chamber
7
10/9/2011
Cold chamber machines
y Casts high melting point metals ( > 600°C)
y High pressures used
y Metal is heated in a separate crucible
l h d bl
y Metal is ladled into a cold chamber
y The metal is rapidly forced into the mold before it
cools
y Copper, Brass and Aluminium can cast.
Advantages
y Extremely smooth surfaces (1 µm)
y Excellent dimensional accuracy
y Rapid production rate
y Better mechanical properties compared to sand
casting
y Intricate parts possible
y Minimum finishing operations
y Thin sections possible
Limitations ¾Applications
y Carburettors
y High initial die cost
y Automotive parts
y Limited to high‐fluidity nonferrous metals
y Bathroom fixtures
y Part size is limited y Toys
y Porosity may be a problem
¾Common metals
y Some scrap in sprues, runners, and flash, but this can
y Alloys of aluminum, zinc, magnesium, and lead
be directly recycled y Also possible with alloys of copper and tin
8
10/9/2011
IES 2011 IES‐2009
Consider the following advantages of die casting over
Which of the following are the most suitable
sand casting :
materials for die casting?
1. Rapidity of the process
(a) Zinc and its alloys
2. Smooth surface
3.
3 Strong dense metal structure (b) Copper and its alloys
Which of these advantages are correct ? (c) Aluminium and its alloys
(a) 1, 2 and 3 (d) Lead and its alloys
(b) 1 and 2 only
(c) 2 and 3 only
(d) 1 and 3 only
JWM 2010 IES‐2005
Assertion (A) : In die casting method, small
thickness can be filled with liquid metal. Which one of the following processes produces a
casting when pressure forces the molten metal
Reason (R) : The air in die cavity trapped inside the
into the mould cavity?
casting causes problems.
(a) Shell moulding
g (b) Investment casting
g
correct explanation of A (c) Die casting (d) Continuous casting
IES‐2006 IES‐1995
In which of the following are metal moulds used? Assertion (A): An aluminium alloy with 11 % silicon is
used for making engine pistons by die casting
(a) Greensand mould technique.
(b) Dry sand mould Reason (R): Aluminium has low density and addition
(c) Die casting process of silicon improves
p its fluidity
y and therefore its
castability.
(d) Loam moulding
explanation of A
9
10/9/2011
IES‐1995 IAS‐2007
Match List I with List II and select the correct answer taking the help
of codes given below the lists: Consider the following statements:
List I List II 1. Zinc die castings have low strength.
(Products) (Process of manufacture)
A. Automobile piston in aluminium alloy 1. Pressure die‐casting 2. In the die casting process, very thin sections or
B. Engine crankshaft in spheroidal
graphite iron
hi i 2. Gravity die‐casting
G i di i
complex shapes can be obtained easily.
C. Carburettor housing in aluminium alloy 3. Sand casting Which of the statements given above is/are correct?
D. Cast titanium blades 4. Precision investment
casting (a) 1 only
5. Shell moulding
Code: A B C D A B C D (b) 2 only
(a) 2 3 1 5 (b) 3 2 1 5 (c) Both 1 and 2
(c) 2 1 3 4 (d) 4 1 2 3
(d) Neither 1 nor 2
IAS‐1996 IES 2011
Assertion (A): Die casting yields a product of good Consider the following statements :
accuracy and finish. 1. Hot chamber machine is used for casting zinc, tin and
Reason (R): Low melting alloys used in die other low melting alloys.
casting. 2. Cold chamber machine is used for die casting of
(a)
( ) Both
B h A and d R are individually
i di id ll true and
d R is
i the
h ferrous alloys
3. Rapid cooling rate in die casting produces high
(b) Both A and R are individually true but R is not the strength and quality in many alloys.
Which of these statements are correct?
(d) A is false but R is true (a) 1, 2 and 3 (b) 1 and 2 only
(c) 2 and 3 only (d) 1 and 3 only
GATE‐2007 IES‐1995
Assertion (A): Aluminium alloys are cast in hot
Which of the following engineering materials is chamber die casting machine.
the most suitable candidate for hot chamber die Reason (R): Aluminium alloys require high melting
casting? when compared to zinc alloys.
(a)
( ) Low carbon
b steell
explanation of A
(b) Titanium (b) Both A and R are individually true but R is not the
(c) Copper correct explanation of A
(d) Tin (c) A is true but R is false
10
10/9/2011
Centrifugal Casting
y Process: Molten metal is introduced into a rotating sand,
metal, or graphite mould, and held against the mould
wall by centrifugal force until it is solidified
y A mold is set up and rotated along a vertical (rpm is

reasonable), or horizontal (200‐1000 rpm is reasonable)
axis.
y The mold is coated with a refractory coating.
y During cooling lower density impurities will tend to rise

Fig. True centrifugal casting
towards the center of rotation.
Properties
y The mechanical properties of centrifugally cast jobs are
better compared to other processes, because the inclusions
such as slag and oxides get segregated towards the centre
and can be easily removed by machining. Also, the
pressure acting
p g on the metal throughout
g the solidification
causes the porosity to be eliminated giving rise to dense
metal.
y No cores are required for making concentric holes in the
case of true centrifugal casting.
y Fine grained structure at the outer surface of the y More segregation of alloy component during pouring under
casting free of gas and shrinkage cavities and the forces of rotation
porosity
y Contamination of internal surface of castings with non‐
y Formation of hollow interiors in cylinders without
cores metallic
lli inclusions
i l i
y Can produce a wide range of cylindrical parts, y Inaccurate internal diameter
including ones of large size.
y Good dimensional accuracy, soundness, and y Shape is limited.
cleanliness y Spinning equipment can be expensive
y There is no need for gates and runners, which
y Poor machinability
increases the casting yield, reaching almost 100 %.
11
10/9/2011
Common metals GATE‐2002
y Iron
y steel In centrifugal casting, the impurities are
y stainless steel (a) Uniformly distributed
y alloys of aluminium, copper, and nickel (b) Forced towards the outer surface
(c) Trapped near the mean radius of the casting
(d) Collected at the centre of the casting
GATE‐1993 IES‐2008
Which of the following casting processes does not
Centrifugally cast products have
/do not require central core for producing pipe?
(a) Large grain structure with high porosity 1. Sand casting process
(b) Fine grain structure with high density 2. Die casting process
(c) Fine grain structure with low density 3 Centrifugal casting process
3.
(d) Segregation of slug towards the outer skin of the Select the correct answer using the code given below:
casting (a) 1 and 2
(b) 2 only
(c) 2 and 3
(d) 3 only
IES‐2009 IES 2007
Which one of the following casting processes is Which one of the following is the correct
statement?
best suited to make bigger size hollow In a centrifugal casting method
symmetrical
y p
pipes?
p (a) No core is used
(b) Core may be made of any metal
(a) Die casting
(c) Core is made of sand
(b) Investment casting (d) Core is made of ferrous metal
(c) Shell moulding
(d) Centrifugal casting
12
10/9/2011
IES‐1998 IES‐2009
Poor machinability of centrifugally cast iron pipe Which of the following are the most likely
is due to characteristics in centrifugal casting?
(a) Chilling (a) Fine grain size and high porosity
(b) Segregation (b) Coarse grain size and high porosity
(c) Dense structure (c) Fine grain size and high density
(d) High mould rotation speed (d) Coarse grain size and high density
IES 2007 IES‐2000
Match List I with List II and select the correct answer using the code given
below the Lists:
Match List I (Process) with List II (Products/materials)
List I List II and select the correct answer using the codes given
(Casting Process) (Principle) below the Lists:
A. Die casting 1.The metal solidifies in a rotating mould List I List II
B. Investment casting 2.The pattern cluster is repeatedly dipped
into a ceramic slurry and dusted with A. Die casting 1. Phenol formaldehyde
refractory
f
C. Shell moulding 3. Molten metal is forced by pressure into
B. Shell molding 2. C.I. pipes
a metallic mould C. CO2 molding 3. Non‐ferrous alloys
D. Centrifugal casting 4. After cooling, the invest is removed
from the Casting by pressure jetting or D. Centrifugal casting 4. Sodium silicate
vibratory cleaning
Code: A B C D A B C D
(a) 2 1 3 4 (b) 3 4 2 1 (a) 1 3 4 2 (b) 3 1 4 2
(c) 2 4 3 1 (c) 3 1 2 4 (c) 3 1 2 4 (d) 1 3 2 4
IAS‐2004 Semi‐centrifugal Casting
Match List‐I (Name of the Process) with List‐II (Advantage) and select the correct y Centrifugal force assists the flow of metal from a
answer using the codes given below the lists:
List‐I List‐II
central reservoir to the extremities of a rotating
(Name of the Process) (Advantage)
A. Sand Casting 1. Large cylindrical parts with good quality
B.
B Ceramic mold casting
C i ld i 2.Excellent dimensional accuracy and surface
E ll di i l d f
symmetrical
y mold,, which mayy be either expendable
p or
finish
C. Die casting 3. Intricate shapes and close tolerance parts multiple‐use
D. Centrifugal casting 4. Almost any metal is cast and there if no limit to
size, shape and weight y Rotational speeds are lower than for true centrifugal
5. Good dimensional accuracy, finish and low
Codes:A B C
porosity
D A B C D
casting
(a) 2 3 5 1 (b) 4 1 2 3
y Cores can be used to increase the complexity of the
(c) 2 1 5 3 (d) 4 3 2 1
product.
13
10/9/2011
IAS‐2003
Assertion (A): Semi‐centrifugal casting process is
similar to true centrifugal casting except that the
central core is used in it to form inner surface.
Reason (R): In semi‐centrifugal casting process the
axis of spin
p is always y vertical
explanation of A
Fig. Semi‐centrifugal casting
Centrifuging
y Uses centrifuging action to force the metal from a central
pouring reservoir into separate mold cavities that are
offset from the axis of rotation.
y Low speed
y May used to assist in the pouring of investment casting

trees.
Fig. Method of casting by the centrifuging process
IES‐2000 Dry Sand Molding
Match List I (Type of casting) with List II (Working principles)
and select the correct answer using the codes given below the y To reduce gas forming materials air dried mould used.
Lists:
List I List II Types:
A. Die casting 1. Molten metal is forced into the die
under pressure
B. Centrifugal casting 2. Axis of rotation does not coincide with 1 Skin drying and
1.Skin
axis of mould
C. Centrifuging 3. Metal solidifies when mould is rotating 2.Complete mold drying
D. Continuous casting 4. Continuously pouring molten metal
into mould
Codes: A B C D A B C D
(a) 1 3 2 4 (b) 4 3 2 1
(c) 1 2 3 4 (d) 4 2 3 1
14
10/9/2011
Slush Casting IAS‐2004
y Slush casting is a variation of the permanent mold process Which of the following are produced by slush
in which the metal is permitted to remain in the mold only casting?
until a shell of the desired thickness has formed. (a) Hollow castings with thick walls
y The mold is then inverted and the remaining liquid is (b) Hollow castings with thin walls
poured out.
(c) Thin castings
y When the mold halves are separated, the resulting casting
is a hollow shape with good surface detail but variable wall (d) Thick castings
thickness.
y Frequently used to cast low‐melting‐temperature metals
into ornamental objects such as candlesticks, lamp bases,
and statuary.
IES 2011 Squeeze Casting
The method of casting for producing ornamental pieces Process:
are:
1. Molten metal is poured into an open face die.
(a) Slush and gravity casting
2. A punch is advanced into the die, and to the metal.
(b) Pressed and slush casting
3 Pressure (less than forging) is applied to the punch
3.Pressure
(c) Gravity and semi permanent mould casting and die while the part solidifies.
(d) Semi permanent mould and pressed casting 4.The punch is retracted, and the part is knocked out
with an ejector pin.
y Overcomes problems with feeding the die, and
produces near net, highly detailed parts.
IAS‐2002 Single Crystal Casting
Match List I (Casting Process) with List II The process is effectively:
(Applications) and select the correct answer using the 1. Prepare a mold so that one end is a heated oven, and
codes given below the Lists:
the other end chilled. The part should be oriented so
List I List II
that the cooling happens over the longest distance.
(Casting Process) (Applications)
A. Centrifugal casting 1. Carburetor 2. Cast metal into the mold
C t t l i t th ld
B. Squeeze casting 2. Pipes 3. Solidification will begin at the chill plate. These
C. Die Casting 3. Wheels for dendrites will grow towards the heated end of the
automobiles
part as long dendritic crystals. The part is slowly
4. Gear housings
pulled out of the oven, past the chill plate.
Codes: A B C A B C
(a) 2 3 1 (b) 4 1 3 4. Remove the solidified part.
(c) 2 1 3 (d) 4 3 1
15
10/9/2011
IES 2009
y Creep and thermal shock resistance properties.
2 marks
Plaster Casting Pit Moulding
y Process: A slurry of plaster, water, and various additives is
y This method is used for very large castings and is done on
additives is pouted over a pattern and allowed to set. The
the foundry floor.
pattern is removed and the mould is baked to remove
excess water. After pouring and solidification, the mould is
broken and the castingg is removed.
y Advantage: High dimensional accuracy and smooth
surface finish, thin sections and intricate detail can
produce.
y Limitations: Lower‐temperature nonferrous metals only:
y Common metals: Primarily aluminium and copper
IES‐1996 Loam Moulding
Which of the following pairs are correctly matched?
1. Pit moulding ..................For large jobs. y Moulding loam is generally artificially composed of
2. Investment moulding ... Lost wax process. common brick‐clay, and sharp sand.
3.
3 Plaster moulding ……… Mould prepared in
Mould prepared in
gypsum. y Loam means mud.
(a) 1, 2 and 3 (b) 1 and 2 y Loam Moulding is restricted to forms which cannot be
(c) 1 and 3 (d) 2 and 3
cast conveniently in any other process.
y It is costly.
16
10/9/2011
IES‐1997 GATE‐1998
Which one of the following pairs is not correctly List I List II
matched? (A) Sand casting (1) Symmetrical and
circular shapes only
(a) Aluminium alloy piston …………Pressure die casting (B) Plaster mould casting (2) Parts have hardened
(b) Jewellery……………………….. Lost wax process skins and soft interior
(C) Shell mould casting (3) Minimum post‐
(c) Large pipes ……………………..Centrifugal casting casting processing
(d) Large bells ………………………Loam moulding (D) Investment casting (4) Parts have a tendency
to warp
(5) Parts have soft skin
and hard interior
(6) Suitable only for non‐
ferrous metals
Match the following moulding/casting processes with List I List II
the product:
(A) Rivets for aircraft body 1. Forging
Moulding/Casting processes Product
(A) Slush casting (P) Turbine blade (B) Carburettor body 2. Cold heading
(B) Shell moulding (Q) Machine tool bed (C) Crankshafts 3
3. Aluminium‐based
(C) Dry sand moulding (R) Cylinder block alloy
(D) Centrifugal casting (S) Hollow castings (D) Nails 4. Pressure die casting
like lamp shades 5. Investment casting
(T) Rain water pipe
(U) Cast iron shoe
brake
IES‐2003 IES‐1993
Match List I (Products) with List II (Casting Process) and select Match the items of List I (Equipment) with the items
the correct answer using the codes given below the Lists:
of List II (Process) and select the correct answer using
List I List II
(Products) (Casting Process)
the given codes.
A. Hollow statues 1. Centrifugal Casting List I (Equipment) List II (Process)
B.
B Dentures 2.
2 Investment Casting P ‐ Hot Chamber Machine 1. 1 Cleaning
C. Aluminium alloy pistons 3. Slush Casting
Q ‐ Muller 2. Core making
D. Rocker arms 4. Shell Moulding
5. Gravity Die Casting R ‐ Dielectric Baker 3. Die casting
Codes: A B C D A B C D S ‐ Sand Blaster 4. Annealing
(a) 3 2 4 5 (b) 1 3 4 5 5. Sand mixing
(c) 1 2 3 4 (d) 3 2 5 4
(a) P‐2, Q‐1, R‐4, S‐5 (b) P‐4, Q‐2, R‐3, S‐5
(c) P‐4, Q‐5, R‐1, S‐2 (d) P‐3, Q‐5, R‐2, S‐1
17
10/9/2011
IAS‐2004
Match List‐I (Name of the Casting Process) with List‐II (Process Definition) and select
the correct answer using the codes given below the lists:
List‐I List‐II
(Name of the Casting Process) (Process Definition)
A. Die casting 1.This process involves use of a mould made of
Dried silica sand and phenolic resin mixture
B.
B Electroslag
El l casting
i 2. In this process, molten metal is forced by
I hi l l i f d b
Pressure into a metal mould
C. Centrifugal casting 3. This process employs a consumable electrode
D. Precision casting 4. This process involves rotating a mould while the
metal solidifies
5. This process produces very smooth, highly
Accurate castings from both ferrous and non
ferrous alloys
(a) 5 4 1 2 (b) 2 3 4 5
(c) 5 3 4 2 (d) 2 4 1 5
Conventional Casting Process Ch‐21 Special Casting Process Ch‐22
Q. No Option Q. No Option
1 A 13 C Q. No Option Q. No Option
2 A 14 D 1 D
11 A
3 C 15 D 2 C
12 A
4 A 16 B 3 C 13 D
5 D 17 B 4 B 14 A
6 A 18 B 5 C
15 A
7 D 19 D 6 A
16 B
8 C 20 A 7 D 17 A
9 B 21 A 8 C
10 D 9 B
11 A 10 D
12 B
18

(Freestudy1.blogspot - Com) Metal Casting PPT With Q A PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

(Freestudy1.blogspot - Com) Metal Casting PPT With Q A PDF

Uploaded by

Copyright:

Available Formats

8/28/2011

y The pattern must be removed before pouring, the

y The molten metal is poured into the sprue hole, flows

Sequential steps in making a sand casting y The mold is opened, the pattern board is drawn

y Sand is then packed into the drag half of the mold. y The mold is reassembled with the pattern board

y Moulding sand: The freshly prepared refractory

(b) To provide efficient venting 2. Suitable placement of chaplets

are amplified by an increase in temperature.

Compiled by: S K Mondal Made Easy Contd… Compiled by: S K Mondal Made Easy

y Pattern Allowances IES‐1995

(b) Cast iron

y Inner surfaces of the pattern require higher draft than

y Draft is always provided as an extra metal.

Desired characteristics of a core y Permeability: Gases evolving from the molten metal

y Then, the permeability number, R is obtained by

y Plasticity: It is the measure of the moulding sand to flow Other Sands

y Runner: The channel through which the molten

Bottom gate: No mould erosion, used for very deep moulds,

(a)650.0 (b)350.0 (c)290.7 (d)190.0

(d) Runner area : ingate area : casting area

IES‐1994 Chvorinov’s rule

Where, v = volume of casting [Ans. (a)]

Compare the solidification time of two of the riser exceeds the modulus of the casting by a

y In steel castings, it is generally preferable to choose a

[Use Modulus Method]

Caine’s Method Table: Constants in Caine’s Method

[Ans. (b)] [Ans. (a)]

y Then the shell is removed from the pattern.

y Can produce complex parts.

y A good surface finish and good size tolerance

y Materials can be cast: CI, Al and Cu alloys.

Molding Sand in Shell Molding y Hot coating: the mixture is heated to 150oC– 180oC prior

y Cold coating: quartz sand is poured into the mixer and

y After each dipping and stuccoing is completed, the

y High melting point alloy can be cast, almost any

y Cores must be simple and retractable and take the

(d) A is false but R is true

y A mold is set up and rotated along a vertical (rpm is

y The mold is coated with a refractory coating.

y During cooling lower density impurities will tend to rise

(d) Centrifugal casting

y May used to assist in the pouring of investment casting

You might also like