Design of springs

01 CASTING

1. [MCQ]  3. [MCQ] 
Directional solidification in castings can be
Assertion (A): Aluminium alloys are cast in hot
improved by using
chamber die casting machine.
(a) Chills and chaplets
Reason (R): Aluminium alloys require high melting
(b) Chills and padding
when compared to zinc alloys.
(c) Chaplets and padding
(a) Both A and R are true and R is the correct
(d) Chills, chaplets and padding
explanation of A
4. [MCQ] 
(b) Both A and R are true but R is not a correct
explanation of A Consider the following ingredients used in moulding
1. Dry silica sand 2. Clay
(c) A is true but R is false
3. Phenol formaldehyde 4. Solidum silicate
(d) A is false but R is true
Those used for shell mould casting include
2. [MCQ]  (a) 1, 2 and 4 (b) 2, 3 and 4
Match List-I (Product) with List-II (Process of (c) 1 and 3 (d) 1, 2, 3 and 4
manufacture) and select the correct answer using the 5. [MCQ] 
codes given below the lists. Which of the following methods are used for
List-I obtaining directional solidification for riser design?
A. Automobile piston in aluminium alloy 1. Suitable placement of chills.
B. Engine crankshaft in spheroidal graphite iron 2. Suitable placement of chaplets.
C. Carburettor housing in aluminium alloy 3. Employing padding.
D. Cast titanium blades Which of these statements are correct?
List-II (a) 1 and 2 (b) 1 and 3
1. Pressure die-casting (c) 2 and 3 (d) 1, 2 and 3
2. Gravity die-casting 6. [MCQ] 
3. Sand casting Misrun is a casting defect which occurs due to
4. Precision investment casting (a) Very high pouring temperature of the metal
5. Shell moulding (b) Insufficient fluidity of the molten metal
Codes: (c) Absorption of gases by the liquid metal
A B C D (d) Improper alignment of the mould flasks
(a) 2 3 1 5 7. [MCQ] 
(b) 3 2 1 5 Which of the following pairs are correctly matched?
(c) 2 1 3 4 1. Pit moulding . . . for large jobs
(d) 4 1 2 3 2. Investment moulding . . . Lost wax process
3. Plaster moulding . . . Mould prepared in gypsum
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(a) 1, 2, and 3 (b) 1 and 2 1. The molten metal should enter the mould cavity
(c) 1 and 3 (d) 2 and 3 with as high a velocity as possible.
8. [MCQ]  2. it should facilitate complete filing of the mould
cavity.
Which one of the following pairs is not correctly
3. It should be able to prevent the absorption of air
matched?
of gases from the surroundings on the molten
(a) Aluminium alloy . . . Pressure die casting piston
metal while flowing through it.
(b) Jewellery . . . Lost wax process
Select the correct answer using the codes given
(c) Large pipes . . . Centrifugal casting
below:
(d) Large bells . . . Loam moulding
(a) 1, 2 and 3 (b) 1 and 2
9. [MCQ] 
(c) 2 and 3 (d) 1 and 3
If the melting ratio of a cupola is 10 : 1, then the coke
13. [MCQ] 
requirement for one ton melt will be
(a) 0.1 ton (b) 10 tons A spherical drop of molten metal of radius 2 mm was
(c) 1 ton (d) 11 tons found to solidify in 10 seconds. A similar drop of
10. [MCQ]  radius 4 mm would solidify in
(a) 14.14 second (b) 20 seconds
Assertion (A): Steel can be melted in hot blast
(c) 18.30 second (d) 40 seconds
cupola.
Reason (R): In hot blast cupola, the flue gases are 14. [MCQ] 
used to preheat the air blast to the cupola so that the In solidification of metal during casting,
temperature in the furnace is considerably higher compensation for solid contraction is
than that in a conventional cupola. (a) Provided by the oversize pattern
(a) Both A and R are true and R is the correct (b) Achieved by properly placed risers
explanation of A (c) Obtained by promoting direction solidification
(b) Both A and R are true but R is not a correct (d) Made by providing chills
explanation of A
15. [MCQ] 
(c) A is true but R is false
(d) A is false but R is true Match List-I (Type of casting) with List-II
(Working principles) and select the correct answer
11. [MCQ] 
using the codes given below the lists.
A sand-casting mould assembly is shown in the
List-I
given figure. The elements marked A and B are
A. Die casting B. Centrifugal casting
respectively
C. Centrifuging D. Continuous casting
List-II
1. Molten metal is forced into the die under
pressure
2. Axis of rotation does not coincide with axis of
mould
3. Metal solidifies when mould is rotating
4. Continuously pouring molten metal into mould
(a) Sprue and riser (b) Ingate and riser Codes:
(c) Drag and runner (d) Riser and runner A B C D
12. [MCQ]  (a) 1 3 2 4
Which of the following are the requirements of an (b) 4 3 2 1
ideal gating system? (c) 1 2 3 4
(d) 4 2 3 1

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16. [MCQ]  20. [MCQ] 

Match List-I (Process) with List-II A gating ratio of 1 : 2 : 4 is used to design the gating
(Products/Materials) and select the correct answer system for magnesium alloy casting. This gating
using the codes given below the lists. ratio refers to the cross-section areas of the various
List-I gating elements as given below:
A. Die casting B. Shell molding 1. Down sprue 2. Runner bar
C. CO2 molding D. Centrifugal casting 3. Ingates
List-II The correct sequence of the above elements in the
1. Phenol formaldehyde ratio 1 : 2 : 4 is
2. C.I. pipes
(a) 1, 2 and 3 (b) 1, 3 and 2
3. Non-ferrous alloys
(c) 2, 3 and 1 (d) 3, 1 and 2
4. Sodium silicate
Codes: 21. [MCQ] 
A B C D Match List-I (Products) with List-II (Casting
(a) 1 3 4 2 Process) and select the correct answer using the
(b) 3 1 4 2 codes given below the lists.
(c) 3 1 2 4 List-I
(d) 1 3 2 4 A. Hollow statutes
B. Dentures
17. [MCQ] 
C. Aluminium alloy pistons
Scab is a D. Rocker arms
(a) Sand casting defect List-II
(b) Machining defect 1. Centrifugal casting 2. Investment casting
(c) Welding defect 3. Slush casting 4. Shell moulding
(d) Forging defect 5. Gravity die casting
18. [MCQ]  Codes:
A B C D
The main purpose of chaplets is (a) 3 2 4 5
(a) To ensure directional solidification (b) 1 3 4 5
(b) To provide efficient venting (c) 1 2 3 4
(c) For aligning the mould boxes (d) 3 2 5 4
(d) To support the cores
22. [MCQ] 
19. [MCQ] 
In gating system design, which one of the following
Assertion (A): In CO2 casting process, the mould or is the correct sequence in which choke area, pouring
core attains maximum strength. time, pouring basin and sprue sizes are calculated?
Reason (R): The optimum gassing time of CO2 (a) Choke area – Pouring time – Pouring basin –
through the mould or core forms Silica Gel which Sprue
imparts sufficient strength to the mould or core. (b) Pouring basin – Sprue – Choke area – Pouring
(a) Both A and R are true and R is the correct time
explanation of A (c) Choke area – Sprue – Pouring basin – Pouring
(b) Both A and R are true but R is not a correct time
explanation of A (d) Pouring basin – Pouring time – Choke area –
(c) A is true but R is false Sprue
(d) A is false but R is true

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23. [MCQ]  28. [NAT]
In shell moulding, how can the shell thickness be
accurately maintained?
(a) By controlling the time during which the pattern
is in contact with mould
(b) By controlling the time during which the pattern
is heated
(c) By maintaining the temperature of the pattern in
the range of 175°C – 380°C
(d) By the type of binder used
24. [MCQ]  mm and length = 50 mm.
The centrifugal casting method is used for casting
29. [MSQ]
articles of
(a) Symmetrical shape about vertical axis
(b) Symmetrical shape about horizontal axis
(c) Irregular shape
(d) Non-ferrous metal only
25. [MSQ] 
A riser in casting is described by which of the
following:
(a) An insert in the casting that inhibits buoyancy
of the core
(b) Gating system in which the sprue feeds directly
into the cavity
30. [MSQ]
(c) Metal that is not part of the casting
(d) Source of molten metal to feed the casting and
compensate for shrinkage during solidification
(e) Waste metal that is usually recycled
26. [NAT] 
A vertical true centrifugal casting process is used to
produce bushings that are 200 mm long and 200 mm
in outside diameter. If the rotational speed during
solidification is 500 rev/min, determine the inside
diameter (mm) at the top of the bushing if the inside
diameter at the bottom is 150 mm.
31. [MSQ]
27. [NAT] 
A riser in the shape of a sphere is to be designed for
a sand casting mold. The casting is a rectangular
plate, with length = 200 mm, width = 100 mm, and
thickness = 18 mm. If the total solidification time of
the casting itself is known to be 3.5 min, determine
the diameter (mm) of the riser so that it will take 25%
longer for the riser to solidify.
GATE WALLAH MECHANICAL WORKBOOK

In casting experiments performed using a certain
alloy and type of sand mold, it took 155 sec for a
cube-shaped casting to solidify. The cube was 50 mm
on a side.
(a) Determine the value of the mold constant in
Chvorinov's rule (s/mm)2.
(b) If the same alloy and mold type were used, find
the total solidification time (min) for a
cylindrical casting in which the diameter = 30

Turbulence during pouring of the molten metal is
undesirable for which of the following reasons (two
best answers):
(a) it causes discoloration of the mold surfaces
(b) it dissolves the binder used to hold together the
sand mold
(c) it increases erosion of the mold surfaces
(d) it increases the formation of metallic oxides that
can become entrapped during solidification
(e) it increases the mold filling time
(f) it increases total solidification time

A riser in casting is described by which of the
following (three correct answers):
(a) an insert in the casting that inhibits buoyancy of
the core
(b) gating system in which the sprue feeds directly
into the cavity
(c) metal that is not part of the casting
(d) source of molten metal to feed the casting and
compensate for shrinkage during solidification
(e) waste metal that is usually recycled

Which of the following riser types are completely
enclosed within the sand mold and connected to the
main cavity by a channel to feed the molten metal
(two correct answers):
(a) blind riser
(b) open riser
(c) side riser
(d) top riser
4
 CASTING

32. [NAT]  37. [NAT] 

The downsprue leading into the runner of a certain
mold has a length = 175 mm. The cross-sectional
area at the base of the sprue is 400 mm2. The mold
cavity has a volume = 0.001 m3. Determine
(a) the velocity of the molten metal flowing through
the base of the downsprue (mm/s)
(b) the volume rate of flow (mm3/s)
(c) the time required to fill the mold cavity (s).
33. [NAT]  diameter = 12.5 cm. If the rotational speed of the pipe
The flow rate of liquid metal into the downsprue of a
mold = 1 liter/sec. The cross-sectional area at the top
of the sprue = 800 mm2, and its length = 175 mm.
What area should be used at the base of the sprue to
avoid aspiration of the molten metal (mm2)?
34. [NAT]  been poured out after a thin shell has been
Molten metal can be poured into the pouring cup of
a sand mold at a steady rate of 1000 cm3/s. The
molten metal overflows the pouring cup and flows
into the downsprue. The cross section of the sprue is
round, with a diameter at the top = 3.4 cm. If the
sprue is 25 cm long, determine the proper diameter
at its base so as to maintain the same volume flow
rate (cm).
35. [NAT]  True centrifugal casting is performed horizontally to
In the casting of steel under certain mold conditions,
the mold constant in Chvorinov's rule is known to be
4.0 min/cm2, based on previous experience. The
casting is a flat plate whose length = 30 cm, width
= 10 cm, and thickness = 20 mm. Determine how
long it will take for the casting to solidify (min).
36. [NAT]  (c) What volume of molten metal must be poured
A disk-shaped part is to be cast out of aluminum. The
diameter of the disk = 500 mm and its thickness = 20
mm. If the mold constant = 2.0 sec/mm2 in
Chvorinov's rule, how long will it take the casting to
solidify (min)?
A cylindrical riser is to be used for a sand-casting
mold. For a given cylinder volume, determine the
diameter-to-length ratio that will maximize the time
to solidify.
38. [NAT] 
A horizontal true centrifugal casting operation will
be used to make copper tubing. The lengths will be
1.5 m with outside diameter = 15.0 cm, and inside
= 1000 rev/min, determine the G-factor.
39. [MCQ] 
Shell molding is best described by which one of the
following:
(a) casting operation in which the molten metal has
solidified in the mold
(b) casting process in which the mold is a thin shell
of sand bonded by a thermosetting resin
(c) sand-casting operation in which the pattern is a
shell rather than a solid form
(d) casting operation used to make artificial sea
shells?
40. [NAT] 
make large diameter copper tube sections. The tubes
have a length = 1.0 m, diameter = 0.25 m, and wall
thickness = 15 mm.
(a) If the rotational speed of the pipe = 700 rev/min,
determine the G-factor on the molten metal.
(b) Is the rotational speed sufficient to avoid “rain?”
into the mold to make the casting if
solidification shrinkage and contraction after
solidification are considered (m3)?
Solidification shrinkage for copper = 4.5%, and solid
thermal contraction = 7.5%.

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