Ans 1:

Engineering materials: Materials which are used by engineers to design and develop
manmade structures, devices, and components to perform intended functions
Classifications:
Primary Classes of Engg . Materials
1. Metals (e.g. aluminium, iron, and titanium)
2. Ceramics (e.g. Al2O3, Fe3C, and SiC)
3. Polymers (e.g. acrylic, polyethylene, and nylon)

Other “class of materials”

• Composites
• Semiconductors (e.g. silicon, germanium, and SiC)
• Biomaterials

Primary Classes of Engg . Materials:

1. Metals: Metals are composed of one or more metallic elements (such as iron,
aluminium, copper, titanium, gold, and nickel). Metals have valence electrons, which
are free to drift through the entire material, forming a “sea of electrons” surrounding
net positive ionic cores. Metals form non-directional metallic bonds. Examples: Al,
Cu, Fe, Ni etc.

Fig.1. Schematic showing positive kernels and sea of electrons in metals

2. Ceramics: Ceramics are composed of metallic and/or non-metallic elements. They are
most frequently oxides, nitrides, and carbides. Examples: Aluminium oxide (or
alumina, Al2O3), silicon dioxide (or silica, SiO2), silicon carbide (SiC), silicon nitride
(Si3N4), clay minerals (i.e., porcelain), cement, and glass. Metallic elements give up
valence electrons to non-metallic elements. All atoms have a filled “inert gas”
configuration. Ceramics form non-directional bonds.

Fig.2. Schematic showing ionic bonding in ceramics

 3. Polymers (plastics or rubber): Polymers are large molecular structures and often
chain-like in nature. Many polymers are organic compounds that are chemically based
on carbon, hydrogen, and other non-metallic elements. Polymers are formed of covalent
bonds in which electrons are mutually shared between adjacent atoms and form
directional bonds.

Fig. 3. Mutual sharing of electrons in a single unit of polymer

Ans 2(a):
1. SHRINKAGE ALLOWANCE
 Provided to compensate for shrinkage of material.
 Pattern is made slightly bigger.
 The amount of allowance depends upon type of material, its
composition, etc.

2. MACHINING ALLOWANCE
 Provided to compensate for machining on casting.
 Pattern is made slightly bigger is size.
 Amount of allowance depends upon size and shape of casting,
type of material, machining process to be used, degree of accuracy
and surface finish required etc.

3. DRAFT OR TAPER ALLOWANCE

 Provided to facilitate easy withdrawal of the pattern.
 Typically taper ranges from 1 degree to 3 degree for
wooden patterns.

4. DISTORTION ALLOWANCE
 This allowance is provided in opposite to the direction of general warping of a casting
 Provided on patterns whose castings tend to distort on cooling

(a)(a) (b) (b) (c) (c)

(a)Required
Requiredshape of of Casting
shape
produced
Casting(b) when no
produced when no Pattern with distortion
Pattern with(c)
distortion
distortion allowance is provided allowance
Required shapecasting
of
casting Casting produced
distortion when
allowance no
is provided Pattern with distortion
allowance
casting distortion allowance is provided allowance
5. RAPPING OR SHAKE ALLOWANCE
 Provided to permit easy withdrawal of the pattern.
 It is a negative allowance.

Ans 2(b):
Gating system refers to the passage through which molten metal passes to enter the mould cavity

Figure. Components of gating system

1. Pouring cup: Acts as a reservoir from which it flows smoothly in the sprue. It reduces the
momentum of the molten metal flowing into the mould by settling first into it. It avoids vertix
formation and turbulence It helps in maintaining the required rate of liquid metal flow. It also helps
in separating dross, slag and foreign element etc. from molten metal before it enters the sprue.
2. Sprue: Sprue is a vertical passage made generally in the cope using a tapered sprue pin. It is
connected at the bottom of the pouring basin. It is tapered with its bigger end to receive the molten
metal. The smaller end is connected to the sprue base. It helps to feed molten metal without turbulence
to the runner, which in turn reaches the mold cavity through the gate.
3. Sprue base: Sprue base is a reservoir for the metal at the bottom of the sprue to reduce the
momentum of the falling molten metal. It prevents mould erosion and collects impurities from molten
metal, and it does not allow them to reach the mould cavity through the runner and gate.
4. Gate (or Ingate): It is a small passage or channel being cut by a gate cutter which connects the
runner with the mould cavity and through which molten metal flows to fill the mould cavity. It feeds
the liquid metal to the casting at a rate consistent with the rate of solidification.
5. Runner: It is a channel which connects the sprue to the gate to avoid turbulence and gas entrapment.
6. Riser: It is a passage in moulding sand made in the cope portion of the mould. Molten metal rises
in it after filling the mould cavity completely. The molten metal in the riser compensates the shrinkage
during solidification of the casting thus avoiding the shrinkage defect in the casting. It also permits
the escape of air and mould gases. It promotes directional solidification, too, and helps in bringing
soundness to the casting. Workers can see through the rises that cavity is full.

Ans 3.
 Ans 4(a).
For steel the shrinkage allowance is 21.0 mm/m.
For dimension 200, allowance is 200 × 21.0/1000 = 4.20 mm
For dimension 150, allowance is 150 × 21.0/1000 = 3.15 mm
For dimension 100, allowance is 100 × 21.0/1000 = 2.10 mm
For dimension 80, allowance is 80 × 21.0/1000 = 1.68

Final dimensions:
Final dimension of the pattern = Req. Casting dimension + shrinkage allowance
For length 200 mm on casting, the pattern length = 204.20 mm
For breadth 150 mm on casting, the pattern breadth = 153.15 mm
For heigth 100 mm on casting, the pattern height = 102.10 mm
For bore dimension 80 mm, the size on the pattern = 81.68 mm

Fig.4a) final dimensions of the pattern (mm)

Ans 4b)
The bore dimension 80, 80 - 2 × 3 = 74 mm
The dimension 100, 100 + 3 + 3 = 106 mm
The dimension 150, 150 + 3 + 3 = 156 mm
The dimension 200, 200 + 3 + 3 = 206 mm
Fig. 4b) Dimensions of the pattern (in mm)