GANADIPATHY TULSIS JAIN ENGINEERING COLLEGE

IMPORTANT QUESTIONS AND ANSWERS

Department of Mechanical Engineering

SUBJECT CODE : ME 8351

SUBJECT NAME : MANUFACTURING TECHNOLOGY - I

Regulation: 2017 Year and Semester: II and III

Prepared by

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UNIT I- METAL CASTING PROCESS
PART-A
1. Define pattern. (May/June-2014)
The model of the required casting made in wood, metal or plastics.
2. Define Casting (May/June-2014)
Casting is process of producing metal parts by pouring molten metal
into the mould cavity of the required shape and allowing the metal to solidify.
3. What is the function of core in moulding sand? (April/May -2015
&NOV/DEC- 2016)
To provide a hollow surface or recess on the casting, the core is made of sand.
4. State any four types of patterns. (Nov/Dec-2010) & (April/May -2015)
, (May/June-2012) & (May/June-2016)
i. Solid pattern or single-piece pattern.
ii. Split pattern.
iii. Loose piece pattern.
iv. Match plate pattern.
5. Name four different casting defects. (Nov/Dec-2013)
i. Design of casting and pattern
ii. Moulding and design of mould and core
iii. Metal composition
iv. Melting and pouring
v. Gating and risering
6. List any four products manufactured by using centrifugal casting
process. (Nov/Dec-2014)
i. Water pipes iii. Brake drums
ii. Bush bearings iv. Gun Barrels
7. What is the function of runner and riser. (Nov/Dec-2015)
Runner: i) It is used to make a sprue a hole in the cope.
ii) It receives the molten metal from the pouring basin and passes
to the cavity.
Riser: i) It supplies excess molten metal to the solidifying casting.
ii) It allows the escape of air.

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8. What is core print? Mention its purpose. (Nov/Dec-2012) &

(Nov/Dec-2012)
A core print is an extra projection on the pattern. It supports the core.
9. Write the composition of good moulding sand
Green Sand: It contains 5 to 8% of water and 15 to 20% clay.
Loam Sand: Loam sand is a mixture of fine sands, fine refractories, clay,
graphite powder and water. It contains more than 50% clay.
10. List the factors to be considered in the choice of metal melting
furnaces. (Nov/Dec-2012)
1. Cupola Furnace: For cast iron.
2. Open hearth furnace - For steel.
3. Crucible furnace - For non-ferrous metal.
4. Electrical furnace - For steel, alloy steel, brasses.
11. What is meant by grain fineness number? (Nov/Dec-2014)
Grain Fineness Number (GFN) is a measure of the average size of the
Grains in sand AFS Grain Fineness Number (AFS-GFN), introduced by
American Foundry Society,

12. Write a note on chilled casting. (Nov/Dec-2010)

A chill is an object used to promote solidification in a specific portion of a
metal casting mold. Normally the metal in the mold cools at a certain rate
relative to thickness of the casting.
13. Compare the advantage of metal moulds over sand moulds.
(May/June-2013)
 The main difference between sand casting and die casting is , in die
casting the tool used to make the shape of product is a permanent tool
and the can be used again and again for making the same component.
But in sand casting, the tool i.e sand pattern is destroyed after making on
component.

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 Die casting is economically benefiting for high productive

environment than sand casting.
 Dimensional repeatability of the component can be assured in die
casting compared to sand casting
14. What are Chaplets? (May/June-2016)
Sometimes it is not possible to provide sufficient support for a core in
the moulding being poured, if the cores are bigger in size. In such case
the core is supported with rigid metal pieces called chaplets
15. What are causes for the formation of blow holes in the sand casting?
(May/June-2012) & (May/June-2016)

 Not adequately vented mould

 Excess moisture in the molding sand

 Low permeability and excessive fine grain sand

 Rusted damp chills, chaplets and inserts

 Presence of gas producing ingredients in the mold or core

sands

 Extra hard ramming sands

PART-B

1. Explain the properties of moulding sands. (Dec-2009, 2010, 2012

May2010, 2013& Dec-2016)
1. Strength:
 The sand should have adequate strength in its green, dry and hot states
Green strength is the strength of sand in the wet state and is required for
making possible to Prepare and handle the mould.
 If the metal is poured into a green mould the sand adjacent to the metal
dries and in the dry state it should have strength to resist erosion and the
pressure of metal.

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 The strength of the sand that has been dried or basked is called dry
strength at the time of Pouring the molten metal the mould must be able
to withstand flow and pressure of the Metal at high temperature
otherwise the mould may enlarge, crack, get washed or break
Strength of the moulding sand depends on:
1. Grain size and shape
2. Moisture content
3. Density of sand after ramming
The strength of the mould increases with a decrease of grain size and an
increase of clay content and density after ramming. The strength also goes
down if moisture content is higher than an optimum value.
2. Permeability:
The moulding sand must be sufficiently porous to allow the dissolved
gases, which are evolved when the metal freezes or moisture present or
generated within the moulds to be removed freely when the moulds are poured.
This property of sand is called porosity or permeability.
3. Grain size and shape:
The size and shape of the grains in the sand determine the application in
various types of foundry. These are three different sizes of sand grains.
1. Fine
2. Medium
3. Coarse
 Fine sand is used for small and intricate castings. Medium sand is used
for benchmark and light floor works. If the size of casting is larger
coarse sand is used
 Sand having fine, rounded grains can be closely packed and forms a
smooth surface. Although fine-grained sand enhances mould strength.

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4. Thermal stability:
The sand adjacent to the metal is suddenly heated and undergoes
expansion. If the mould wall is not dimensionally stable under rapid heating,
cracks, buckling and flacking off sand may occur.
5. Refractoriness:
 Refractoriness is the property of withstanding the high temperature
condition moulding sand with low refractoriness may burn on to the
casting
 It is the ability of the moulding material to resist the temperature of the
liquid metal to be poured so that it does not get fused with the metal.
The refractoriness of the Silica sand is highest.
6. Collapsibility:
The moulding sand should collapse during the contraction of the
solidified casting it does not provide any resistance, which may result in cracks
in the castings. Besides these specific properties the moulding material should
be cheap, reusable and should have good thermal conductivity
7. Adhesiveness:
It is the important property of the moulding sand and it is defined as the
sand particles must be capable of adhering to another body, then only the sand
should be easily attach itself with the sides of the moulding box and give easy
of lifting and turning the box when filled with the stand.
8. Reusability:
Since large quantities of sand are used in a foundry it is very important
that the sand be reusable otherwise apart from cost it will create disposal
problems
11. Easy of preparation and control:
Sand should lend itself to easy preparation and control by mechanical
equipment.

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12. Conductivity:
Sand should have enough conductivity to permit removal of heat from
the castings.
2. What are the allowances given while making pattern Explain.
(Dec-2009, 2010, 2012 May-2010, 2013)
A Pattern is always made larger than final casting because it carries
certain allowances due to metallurgical and mechanical reasons.
 Shrinkage allowance
 Draft allowance
 Finish allowance
 Shake allowance
 Distortion allowance
SHRINKAGE ALLOWANCE:
 Almost all the metals used in the casting work shrink or contract during
cooling from pouring temperature to room temperature.
 This contraction takes places in three forms i.e
 Liquid contraction
 Solidifying contraction
 Solid contraction
 To compensate liquid and solidifying contraction, gates and riser are
provided in the mould , whereas for solid contraction adequate
allowances are provided on the pattern
 the different metals shrink at different rates because shrinkage is the
metal property, hence corresponding allowances are also different
 For Aluminium permissible shrinkage allowance is 17 mm/metre

DRAFT ALLOWANCE:
 Withdrawing the pattern from the sand mould, the vertical faces of the
pattern are in continual contact with the sand, which may damage the
mould cavity.
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 To reduce the chances of this happening the vertical faces of the pattern
are always tapered from the parting line.
 Suggested draft values for wood pattern are outer 0.25 to 3.0 degree. and
10 mm to 25 mm per metre on external surfaces and 40mm to 65 mm on
internal surface.

FINISH ALLOWANCE:

 Extra material is to be provided which is to be subsequently removed by

machining or cleaning process.
 Suggested machining allowance or pattern for non ferrous metal up to 3
mm
 But 2mm allowance was provided on pattern.

SHAKE ALLOWANCE:

 Before withdrawal from the sand mould

 To enlarge the mould cavity slightly
 Since it enlarges the final casting made
 It is desirable that the original pattern dimensions should be reduced to
account for this increase.
DISTORTION ALLOWANCE:
 Distortion allowance applies only to those castings of irregular shape or
U & V shape
 Which are distorted in the process of cooling because of metal shrinkage
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 the amount of distortion allowances varies from 2mm to 20 mm as per

size shape and casting material
3. With suitable sketches, explain the various steps of investment casting
Process. What are its advantages? (May-2010 to 2015 & Dec-2010 to 2017)
The investment casting process begins with the production of wax
replicas of the desired castings. These replicas, called patterns, are injection
molded in metal dies. A pattern must be manufactured for each casting to be
produced. A number of patterns (depending on size and complexity) are
attached to a central wax stick, or sprue, to form a casting cluster, or assembly.
After some initial pre-dips, which thoroughly clean the wax, the assemblies are
immersed, or “invested,” into a liquid ceramic slurry, and then into a bed of
extremely fine sand to form a shell. The first critical layers are often applied by
hand. Between each layer the ceramic is allowed to dry. The later, heavier
layers are often applied by automated equipment or special shell building
robots. Enough layers must be applied to build a shell strong enough to
withstand subsequent operations. After the shell is completely dry, the wax is
melted out in a high pressure steam autoclave, leaving a hollow void within the
mold, which exactly matches the shape of the assembly.
Prior to casting, the shells are fired in an oven where intense heat burns out any
remaining wax residue and prepares the mold for the molten metal. In the
conventional gravity pouring method, metal is poured into the shell through a
funnel shaped pour cup and flows by gravity down the sprue channel, through
the gates and into the part cavities. As the metal cools, the parts, gates, sprue
and pouring cup become one solid casting.

After the casting has cooled, the ceramic shell is broken off and the parts
are cut from the sprue using a high speed friction saw. After minor finishing
operations, the castings, which are identical in configuration to the wax
patterns which shaped them, are ready for certification and shipment to the
customer.

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Advantages
 Parts of great complexity and intricacy can be cast
 Close dimensional control and good surface finish
 Wax can usually be recovered for reuse

Disadvantages
 Many processing steps are required
 Relatively expensive process

4. Explain in detail the working principle of centrifugal casting (May-2011,

2012, 2013& 2015 Dec-2013& Nov/Dec- 2016)
Casting, or reforming materials by heating, melting and molding, can be
traced back in history six thousand years. As civilization progressed and the
use of metals became more advanced, the technology of casting metals
advanced as well. As foundry industries began to demand higher yields and
better physical properties from cast metal products, casting processes became
more specialized.
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The centrifugal casting method was developed after the turn of the
20th century to meet the need for higher standards.
Spinning molds generate centrifugal force on molten metal to position the
metal within a mold. As the molten metal solidifies from the outside in, a
casting with dense, close grain structure is created. As a result of close grain
structure the centrifugal process offers products with better physical properties
than castings made using the static casting method. Other advantages of
products made by the centrifugal process are:
 Smoother Surface
 Lighter Weight
 Thinner Walls

Combining proper mold design, mold coatings, mold spinning speeds,

pouring speeds, cooling rates and metal chemistry results in castings with
higher yields, fewer impurities and greater strength.

Advantages

 Formation of hollow interiors in cylinders without cores

 Less material required for gate
 Fine grained structure at the outer surface of the casting free of gas and
shrinkage cavities and porosity

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Disadvantages

 More segregation of alloy component during pouring under the forces of

rotation
 Contamination of internal surface of castings with non-metallic
inclusions
 Inaccurate internal diameter

5. Explain in detail the working principle Shell moulding process, product

and applications. (Dec-2013 &Dec-2015)

Steps in shell-moulding:
Shell-mould casting yields better surface quality and tolerances. The
process is described as follows the 2-piece pattern is made of metal (e.g.
aluminum or steel), it is heated to between 175°C - 370°C, and coated with a
lubricant, e.g. silicone spray. Each heated half-pattern is covered with a
mixture of sand and a thermoset resin/epoxy binder. The binder glues a layer of
sand to the pattern, forming a shell. The process may be repeated to get a
thicker shell. The assembly is baked to cure it. The patterns are removed, and
the two half- shells joined together to form the mould; metal is poured into the
mould. When the metal solidifies, the shell is broken to get the part. Smoother
cavity surface permits easier flow of molten metal and better surface finish on
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Advantages
 Better surface finish
 Better dimensional tolerances.
 Reduced Machining.
 Less foundry space required.
 Semi skilled operators can handle the process.
 The process can be mechanized.
Disadvantages
 The raw materials are relatively expensive.
 The process generates noxious fumes which must be removed.
 The size and weight range of castings is limited.
Applications
 Crankshaft fabrication
 Steel casting parts, fittings
 Moulded tubing fabrication
 Hydraulic control housing fabrication
 Automotive castings (cylinder head and ribbed cylinder
fabrication
Part - C
1. Describe the operation of cupola furnace for melting cast iron? (Dec-
2009, May-2011 & Dec-2014 &2015)

 For many years, the cupola was the primary method of melting used in
iron foundries. The cupola furnace has several unique characteristics
which are responsible for its widespread use as a melting unit for cast
iron.
 Cupola furnace is employed for melting scrap metal or pig iron for
production of various cast irons. It is also used for production of
nodular and malleable cast iron. It is available in good varying sizes.

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The main considerations in selection of cupolas are melting capacity,

diameter of shell without lining or with lining, spark arrester.
Shape
A typical cupola melting furnace consists of a water-cooled vertical
cylinder which is lined with refractory material.

Construction
 The construction of a conventional cupola consists of a vertical steel
shell which is lined with a refractory brick.
 The charge is introduced into the furnace body by means of an opening
approximately half way up the vertical shaft.

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 The charge consists of alternate layers of the metal to be melted, coke

fuel and limestone flux.

 The fuel is burnt in air which is introduced through tubers positioned

above the hearth. The hot gases generated in the lower part of the shaft
ascend and preheat the descending charge.

Working of Cupola Furnace

 The charge, consisting of metal, alloying ingredients, limestone, and
coal coke for fuel and carbonization (8-16% of the metal charge), is fed
in alternating layers through an opening in the cylinder.
 Air enters the bottom through tubers extending a short distance into the
interior of the cylinder. The air inflow often contains enhanced oxygen
levels.
 Coke is consumed. The hot exhaust gases rise up through the charge,
preheating it. This increases the energy efficiency of the furnace. The
charge drops and is melted.
 Although air is fed into the furnace, the environment is a reducing one.
Burning of coke under reducing conditions raises the carbon content of
the metal charge to the casting specifications.
 As the material is consumed, additional charges can be added to the
furnace.
 A continuous flow of iron emerges from the bottom of the furnace.
Advantages
 It is simple and economical to operate.
 High melt rates
 Ease of operation
 Adequate temperature control
 Chemical composition control
 Efficiency of cupola varies from 30 to 50%.

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 Less floor space requirements comparing with those furnaces with same
capacity.

Limitations
 Since molten iron and coke are in contact with each other, certain
elements like si, Mn are lost and others like sulphur are picked up. This
changes the final analysis of molten metal.
 Close temperature control is difficult to maintain
Application
 Cast-iron
2. Write down note on classification of Casting defects causes and remedy.
(Nov/Dec-2010), (May-2011), (Dec-2012, 2013,&2015) (June-2014&2015&
Nov/Dec- 2016 )
Si
Defects Possible causes Effective remedies
no

1  Excess moisture in the  control moisture

moulding sand content
 Rust and moisture n chills  use clean and rust
chaplets used. free chills, chaplet
Blow holes  Cores are not sufficiently  bake the cores
baked properly
 Moulds are not adequately  Provide adequate
vented venting in moulds
and cores
2  High temperature of pouring.  Regulating pouring
 Gas discoed in metal charge temperature
 less amount of flux  Control metal
Porosity  slow solidification composition.
 Increase flux
proportion
 Modify gating and
risering
3  faulty gating and risering and  ensure proper
improper chilling directional
Shrinkage solidification by
modifying gating
risering and chilling

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4  faulty gating system  Modify gating system

 Faulty pouring  Improve pouring to
Inclusions  soft ramming of mould minimize turbulence
 Rough handling of core and  Provide harder
mould ramming
 take care in handling
5  Lack of core collapsibility  Improve core
 Lack of mould collapsibility collapsibility
Hot tears
 Faulty design  Improve mould
or hot  Hard ramming of mould collapsibility
cracks  Modify the design
 Provide softer
ramming
6  Lack of fluidity in molten  adjust proper pouring
Misrun and
metal temperature
cold shuts  Faulty design and gating  Modify the design
and gating system
7  Low strength of mould and  Improve mould and
core core strength
Cuts and  faulty gating  Modify the gating
washes  Lack of binders in facing and system
core sand  Add more binds
(Scabs)

8  Worn out or bent clamping  repair or replace the

 pins pins
 Misalignments of two halves of  Replace dowel
pattern causing misalignment
Mismatch  Improper location and support  Provide adequate
of core core support and
 faulty core boxes locate it properly
 Replace the core
boxes

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