ME336-MANUFACTURING PROCESS LAB

SAND MOULD CASTING MULTIPLE CHOICE QUESTIONS WITH ANSWER

1. Which of the following statement is true?

a) Casting is the replica of the object to be cast
b) Pattern is the replica of the casting object
c) Casting and the pattern are same things
d) Molten material is casted into the casting cavity (Ans:b)

2. Which of the following carries the mould cavity where the metal is to be poured during sand mould
preparation?
a) Casting
b) Pattern
c) Sand
d) Core (Ans:b)

3. Which of the following is ‘not’ an allowance given to the pattern for casting?
a) Shrinkage allowance
b) Draft allowance
c) Hole allowance
d) Machining allowance (Ans:c)

4. The following diagram shows the application of which of the allowances given to a pattern?
a) Shrinkage allowance
b) Draft allowance
c) Shake allowance
d) Distortion allowance (Ans: b)

5. The quality of the final product is not dependent on _______________

a) Method of withdrawal of pattern
b) Allowance provided to the pattern
c) The complexity of the casting
d) The metal used in Casting (Ans:d)
6. The life of a pattern is most likely to depend upon which of the following term?
a) Number of castings produced
b) Type of cooling rate of the casting
c) Size of the casting
d) Size of the pattern (Ans:a)

7. What is the function of cores in the casting process?

a) To support the pattern
b) To provide differential cooling rates at specific portions
c) To make holes and cavities
d) For ease of flow of the molten material (Ans: c)

8. A draft allowance is provided to ___________

a) All linear faces
b) Only the interior dimensions
c) Only the exterior dimensions
d) Only the dimensions that are perpendicular to the parting plane (Ans: d)

9. Which of the following is not a part of the pattern at most times?

a) Mould cavity
b) Cope
c) Molten metal
d) Core (Ans: c)

10. Name the missing part of the pattern in the diagram labelled as??
a) Core
b) Riser
c) Sprue
d) Mould cavity (Ans: c)

11. Which of the following factors affect the choice of a pattern at most times?
a) Size and complexity of the casting
b) Characteristics of castings
c) Type of molding and castings method to be used
d) Type of cooling rates to be provided (Ans: d)
12. Which of the following sequence is in the correct order to prepare a cast using the sand casting method?
[1] Mould making [2] Clamping [3] Pouring [4] Cooling [5] Trimming [6] Removal
a) 1,3,2,4,6,5
b) 2,1,3,4,5,6
c) 1,2,3,4,5,6
d) 1,2,3,4,6,5 (Ans: d)

13. What is a function of a riser in a sand casting?

a) Provide good mobility to the molten metal
b) Prevent cavities due to shrinkage
c) To develop holes or hollow cavities in the casting
d) To provide differential cooling rates in specific areas of the casting (Ans: b)

14. Runners, gates and risers are attached to the pattern to __________
a) Provide ease of cooling
b) Provide feed to the molten material
c) Provide design to the casting
d) Enhance the finishing of the casting (Ans: b)

15. Which of the following properties must a material possess to be used in mold making?
a) High refractoriness
b) Chemical and thermal stability
c) High permeability
d) All of the mentioned (Ans: d)

16. Which of the following group of material type is used in mold making?
a) Metallic only
b) Non-Metallic only
c) Both metallic as well as non-metallic
d) Neither metallic nor non-metallic (Ans: c)

17. Which of the following non-metallic material is not used in the synthesis of molds?
a) Magnesite
b) Silimanite
c) Zircon
d) Valcanised rubber (Ans: d)

18. High refractoriness of a material refers to its __________

a) Slipperyness of the material
b) Chemical strength towards other material
c) Strength to withstand at high temperature
d) Ability to get dissolved in molten metal (Ans: c)
19. Which of the following is a perfect composition of clay (Bentonite) used in moulding sand?
a) Al2O3
b) Al2O3.2SiO2
c) Al2O3.2H2O
d) Al2O3.2SiO2.2H2O (Ans: d)
(Note: Bentonite is one type of clay used in moulding sand as a binder. Its chemical formula is represented
as Al2O3.2SiO2.2H2O)

20. Which of the following material is not used for mold making?
a) Iron
b) Zinc
c) Mild steel
d) Alloy steel (Ans: b)
(Explanation: Zinc (Zn) has a very low melting point, making it non-dependable material to be used as the
material for mold making)

21. Phosphorus is added to steel mold for which of the following reason?
a) It increases strength and hardness of steel
b) It increases refractoriness of steel
c) It increases porosity of steel
d) It increases finishing of steel (Ans: a)

22. Which of the following is not a function of a core?

a) It is used to form internal cavities
b) It is used to form a part of green sand mould
c) It is used as a part of gating system
d) It is used as a part of furnace (Ans: d)
(Explanation: All of the above functions are that of a core except that the core is never a part of the furnace.
somehow it may be used to a path to enhance the flow of molten metal.)

23. Which of the following is a function of a core in casting?

a) Interior cavitational passages in a casting
b) To shape an external part of a more intricate casting
c) To strengthen and improve inner and outer surface of the mold
d) All of the mentioned (Ans: a)

24. A permeability of a core should be _________

a) Low
b) Moderate
c) High
d) Has no effect on casting (Ans: c)
(Explanation: The permeability of the material should be high so as to ease the flow of fluids through it
during solidification, may work as gas exchanger or water absorber)
25. Which of the following helps connecting runner and the mold cavity?
a) Sprue
b) Riser
c) Gate
d) Pouring cup (Ans: c)

26. The liquid metal that runs through the channels without friction in the mould obeys which of the
following theorem?
a) Bernoulli’s theorem
b) Clausius theorem
c) Helmholtz’s theorem
d) Carnot’s theorem (Ans: a)
(Explanation: As the metal enters the pouring basin, it has the highest potential energy with no kinetic or
pressure energies. But as the metal moves through the gating system, potential energy converts into kinetic
energy. Thus it obeys the Bernoulli’s theorem)

27. Which of the following flows is responsible for too less pouring time of molten metal in the mould?
a) Laminar flow
b) Viscous flow
c) Turbulent flow
d) Irrotational flow (Ans: c)
(Explanation: Too less pouring time is caused by turbulent flow of nature of the molten metal. The mixing
and collisions of molecules make the change in momentum and molecules get accelerated and hence high
velocity, that cause the less pouring time of molten metal in the mould)

28. Which of the following materials require a longer pouring time?

a) Non-ferrous material
b) Grey cast iron
c) Ferrous alloys
d) Brass (Ans: a)
(Explanation: For nonferrous material, a longer pouring time would be beneficial since they lose heat slowly
and also tend to form dross if a metal is poured too quickly, this dross makes the quality of the material
poor and further defects induced in the material)

29. Which of the following is the purpose of runner extension?

a) To make smooth surface finish
b) To make the casting of specific size and shape
c) To remove slag and dross from the metal
d) To make fast cooling of molten metal (Ans: c)
(Explanation: The metal which moves first into the gating system is likely to contain slag and dross which
should not be allowed to get into the mould cavity. This could be achieved by extending the runner beyond
the in-gate so the clean metal can be expected to go into the mould after completely filling the runner
extension)

30. Which of the following effects can produce porous castings?

a) Aspiration effect
b) Viscous effect
c) Shapiro effect
d) Turbulent effect (Ans: a)
(Explanation: When the mould is made, care should be taken to ensure that the pressure anywhere in the
liquid metal stream does not fall below the atmospheric pressure. Otherwise, the gases originating from
baking of the organic compounds in the mould will enter the molten metal stream, producing porous
castings. This is known as Aspiration effect)

40. Sprue design is made tapered instead of straight ___________

a) To easy flow of molten metal
b) To have smoothness in the metal flow
c) To maintain the pressure balance
d) To avoid the erosion of mould sand (Ans: c)
(Explanation: Pressure balance is maintained, to avoid the negative pressure (to ensure positive pressure
anywhere in the liquid column), the sprue should be tapered. The ideal shape of the sprue is parabola but
to reduce the manufacturing difficulty shape of the sprue is considered as tapered cylinder)

41. The primary purpose of sprue in casting mould is to _____

a) act as a reservoir for molten metal
b) feed the casting at rate consistent with the rate of solidification
c) feed molten metal from the pouring basin to the gate
d) help feed the casting until all solidification takes place (Ans: c)
(Explanation: Sprue is a connecting passage between pouring basin and runner for molten metal in the
tapered form to avoid the aspiration effect so that pressure equally maintained in the column of liquid metal
streaming to the mould)

42. What is the purpose of strainer in the gating system?

a) To make uniform flow
b) To make smooth surface finish of the casting
c) To remove dross from the molten metal
d) To create positive pressure throughout to avoid aspiration effect (Ans: c)
(Explanation: Ceramic strainer in the sprue removes dross and prevent slag from entering to the castings.
Strainer additionally useful to laminize the flow. A typical strainer might be a cylinder of 30-50 mm
diameter, 10-20 mm long, containing ten or more holes, of diameter approximately 3-5 mm)

43. Which of the following is not a hand molding process?

a) Air cooling
b) Ramming
c) Placing
d) Turning over (Ans: a)
View Answer
(Explanation: Among the following processes, air cooling is not a type of hand molding process, while the
remaining other processes are hand molding processes).
44. The following figure represents which hand molding equipment?
a) Bellow
b) Sprue pin
c) Spirit level
d) Swab
Answer: b
(Explanation: The hand molding equipment here is a sprue pin. A tapering is provided to the pin, that is,
the diameter of the pin keeps increasing from one end to another)

45. The following figure represents which hand molding equipment?

a) Gagger
b) Draw spike
c) Peen rammer
d) Swab
Answer: b
(Explanation: The hand molding equipment which is shown in the figure is a draw spike. It is a sharp
tapered rod, that is, the diameter of the rod goes on increasing from the tip till the end)

46. The following figure represents which hand molding equipment?

a) Gate cutter
b) Draw spike
c) Swab
d) Hand riddle
Answer: a
(Explanation: In the given figure of the hand molding equipment which is shown is a gate cutter. A gate
cutter is basically a sheet metal which is given a definite shape, so as to be able to perform proper cutting
operations)

47. The following figure represents which hand molding equipment?

a) Trowel
b) Vent wire
c) Spirit level
d) Swab (Ans: a)
(Explanation: The hand molding equipment which is shown in the figure is a trowel. It is used for flat finish
of the mold surface. These are basically used for cutting in-gates)

48. Which of the following processes is the first step involved in the sand casting?
a) Clamping
b) Cooling
c) Mould making
d) Pouring (Ans: c)

49. It is possible to provide any kind of internal features to the casting by the help of pattern.
a) True
b) False
Answer: b
Explanation: It is not always possible to use pattern for generating internal features to the casting. Any kind
of internal features of the casting which cannot be produced by the application of pattern are produced by
using the separate cores which are mostly formed by the sand that can be green sand or dry sand, depending
on the purpose.

50. In mould making process, moulding time is greatly affected by the shape and size of the casting
components.
a) True
b) False
View Answer

Answer: a
Explanation: In mould making process, the moulding time generally involves positioning of pattern, sand
ramming and pattern extraction from the moulding box. The mould making time is greatly affected by the
size and shape of the casting components, number of cores, and the type of sand mould used in the process.

51. In mould making process, clamping is basically done to prevent any loss of material from the moulding
box.
a) True
b) False
View Answer

Answer: a
Explanation: In mould making process, after placing of cores in the mould, the mould parts are closed and
clamped together by a clamping operation. It is very essential that the mould parts remain closely clamped
together to prevent any loss of molten metal. Clamping is a very important operation and must be performed
with great care.

52. During the pouring process, filling time of molten metal should be short to avoid early solidification of
the casting.
a) True
b) False
View Answer

Answer: a
Explanation: During pouring operation, the molten metal is poured into the mould by the application of
ladle. The filling time of molten metal should be kept short in order to avoid early solidification of any part
of the casting component. The filling of melt through the ladle can be performed manually or by an
automated machine.

53. The process shakeout is generally referred to escaping of gases from the molten casting during the
solidification.
a) True
b) False
View Answer

Answer: b
Explanation: After the solidification of the casting component, the sand mould is broken and the casting
part is extracted from the broken mould. This process is also known as shakeout and it is commonly
performed by a vibrating machine or tool that shakes the sand particles and then the casting comes out from
the flask.

59. Quick solidification of the casting can cause defects like shrinkages, cracks or blow holes.
a) True
b) False
View Answer

Answer: a
Explanation: The molten metal is poured into the mould cavity that begins to cool and solidify. During
solidification, most of the defects which may occur are a result of the solidification process. If the molten
metal solidifies too quickly, then the casting parts may exhibit defects like shrinkage, cracks or blow holes.

60. Shot blasting operation is mainly done to identify the type of defects in the casting part.
a) True
b) False
View Answer

Answer: b
Explanation: After removing of casting part from the mould, the casting part is likely to have some sand
particles and oxide layers which adhered to the surface. Shot blasting is an operation which is mainly
performed to remove any remaining sand particles, especially from internal surfaces. This process also
reduces the surface roughness of the casting part.

61. A trimming press is a machine tool which is widely used for removing the excess material from the
casting part.
a) True
b) False
View Answer

Answer: a
Explanation: During solidification, the material from the channels in the mould solidifies and joined to the
casting part. This excess material should be trimmed from the casting part, for which a trimming press is
used that removes excess material very finely. The time needed for trimming the excess material can be
estimated from the size of the casting’s envelope