Introduction to Foundry Processes

Introduction to Foundry Processes 1.2

Types of Foundries

1.3

Advantages of Metal Casting

1.4

Applications of Metal Casting

1.5

Comparison of Casting with metal Joining, Metal Removing Processes

1.6

Different Sections of a Foundry

Exp.2

To Study about Pattern, Pattern Making, Pattern Allowances & Types of Patterns

2.1

Types of Material used for making Pattern with description

2.2

Difference between Pattern and Casting

2.3

Types of Pattern

2.4

Design consideration of the Pattern

2.5

Types of Allowances for the Pattern with description

2.6

Colour Code of the Pattern

Exp. 3

To Study about Molding sand, its properties & Sand Testing

3.1

Types of Molding Sand with Properties of each sand.

3.2

Testing of Molding Sand

3.3

Testing of Core Sand

Exp. 4

To Study about Mold & Mold Making

4.1

Molding Tools & Equipments with Figure

4.2

Molding Machines

4.3

Hand Molding Tools

4.4

Types of Molding

4.4.1

Bench Molding

4.4.2

Floor Molding

4.4.3

Pit Molding

4.4.4

Green Sand Molding

4.4.5

Dry Sand Molding

4.4.6

Loam Sand Molding

4.4.7

Machine Molding

Exp. 5

To Study about Core & Core Making

5.1

Introduction & Defination

5.2

Types of Core

5.3

Core making Machines

5.4

Core Prints

5.5

Core Venting & Baking

5.6

Core Shifting & Chaplets

5.7

Finishing of Core

Exp. 6 To Study about Getting Systems Processes

6.1

Introduction

6.2

Types of Gates & Risers

6.3

Gating Ratio

6.4

Design of Risers

6.5

Directional Solidification in Casting

6.6

Physical Behaviours of Metal during Solidification

Exp.7

To study about Melting Practices

7.1 Types of Foundry Furnace 7.1.1

Crucible Furnace

7.1.2

Cupola Furnace

7.1.3

Electric Arc Furnace

7.1.4

Induction Furnace Exp. 8 To study about Advance Casting Processes

8.1

Investment Casting

8.2

Continues Casting

8.3

Centrifugal Casting

8.4

Shell Molding

8.5

Gravity/ Permanent Die Casting

8.6

Pressure Die Casting

8.7

Vacuum Casting

8.8

Full Mold Casting

8.9

Slush Casting

Exp.9

To inspect & perform Testing of Casting

9.1

Casting Defects their Causes & Remedies

9.2

Non- Destructive testing of the Casting Exp. 10 To study about Modernizing & Mechanization of Foundry

10.1

Typical Layout

10.2

Sand Reclamation Tech.

10.3

Material Handling

10.4

Application of Computer in Casting Processes

PRODUCTION ENGINEERING DEPARTMENT CASTING TECHNOLOGY OBJECTIVE TYPE PRESENTATION ================================================================ NOTE:Give short presentation for answer and for all other wrong answer with detail description Each student having only one unique question Roll No. as per the Sequence i.e. 1) For roll No. 5001 and so on. Some questions having Bold Font gives right answer. 1) Cope in Foundry Practice refers to a. Bottom half of moulding box b. Top half of moulding box c. Middle Portion of half of moulding box d. Coating of the Mould face 2) In Sand Mouling, The middle Part of Flask is called a. Cope b. Cheek c. Drag d. Flask- Middle 3) Riddle is a. A round sleve

b. A long, flat metal Plate fitted with an offset handle c. Used to make or repair corners in a mould d. Used to scoop sand deep in the mould 4) In order to ram the sand softer on the pattern face and harder at the back of the mould, following type of moulding machine is used a. Jolt b. Sand slingers c. Squeezing d. Stripper plate 5) Uniform sand hardness is obtain through the mould by following machine a. Jolt b. Sand slingers c. Squeezing d. Stripper Plate e. Diaphragm Moulding Page2 6) The Purpose of Chaplets is a. Just like chills to ensure directional solidification b. To provide efficient venting c. To support the core d. To join lower & upper parts of the moulding box e. Compress moulding sand 7) Which of the following is not a casting defect a. Hot tear b. Blow Hole c. Scab d. Decarburization e. Shift 8) Chills are metal insert of steel that are placed at appropriate locations in the mould walls to a. Decrease the freezing rate b. Increase the freezing rate c. Help directional solidification d. Prevent directional solidification e. Help progressive solidification 9) Fluidity is greatly influenced by a. Carbon Content of molten metal b. Melting temperature of molten metal c. Inoculants addition d. Pouring temperature of molten metal e. Finishing of the mould 10) The chief advantage of Die casting is a. Possibility of incorporating thick sections in small castings

b. Casting of inserts is possible c. Wide tolerances are possible d. High production rates are possible e. Any material can be die cast easily 11) The main Advantage of shell moulding is that a. A metallic pattern is used b. The moulds are stronger c. Thin sections can be easily obtained d. Highly complex section can be easily obtained e. High production rate is possible 12) For mounting several pattern at a time following type of pattern is used a. Combined pattern b. Loose piece pattern c. Sweep pattern d. Match Plate Pattern e. Metallic Pattern Page3 13) Draft on pattern for casting is a. Shrinkage allowances b. Identification number marked on it c. Taper to facilitate its removal from mould d. Increase in size of cavity due to shaking pattern e. For machining allowances 14) Strength and permeability of served sand are related to a. Grain size b. Clay content c. Hardness d. Moisture content e. Type of sand 15) Casting Process is preferred for parts having a. A few detail b. Many detail c. No details d. Non symmetrical shape e. None of the above 16) In order to facilitate the withdrawal of pattern a. Pattern is made smooth b. Water is applied on pattern surface c. Allowances are made on the pattern d. Draft is provided on Pattern e. Withdrawing facilities are provided 17) Least shrinkage allowance is provided in the case of following

a. Brass b. Aluminium c. Cast Iron d. Steel e. White cast iron 18) The draft allowance on the patterns is provided in order to a. Provide good draft of air in the sand moulding b. Provide for distortion that might take place c. Remove the pattern easily from the moulding d. Increase the strength of the mould wall e. Push the pattern easily into the moulding 19) The taper provided on pattern for its easy and clan withdrawal from the mould is called a. Taper allowance b. Draft allowance c. Distortion allowance d. Pattern allowances e. Casting allowance Page4 20) The draft allowance on the metallic pattern in comparison to wooden ones is a. Same b. More c. Less d. More/less depending on size e. None of the above 21) A big advantage of using synthetic sand in foundry shop is that a. It is less costly b. Its properties can be controlled easily c. It possesses high moisture d. It possesses high % of Clay e. It is highly refractory 22) Which of the following materials has more shrinkage allowance a. Cast Iron b. Brass c. Lead d. Aluminium alloys e. Steel 23) Which of the following provides an added projection on a pattern and forms a seat to support and locate the core in the mould a. Mould print b. Core print c. Drag d. Cope

e. Chaplet 24) The mould is housed in a a. Flask b. Cope c. Drag d. Cheek e. Moulding box 25) Loose piece patterns are a. A sort of split pattern b. Used when the pattern can’t be drawn from the mould c. Similar to core prints d. Never used in foundry work e. None of the above 26) Cores are used to a. Make desired recess in the casting b. Strengthen moulding sand c. Support loose pieces d. Remove pattern easily e. None of the above 27) Trovel is Page5 a. A round sleve b. A long, flat metal plate fitted with an offset handle c. Used to make or repair corners in a mould d. Used to scoop sand deep in the mould e. None of the above 28) Shrinkage allowance is made by a. Adding to external and internal dimensions b. Subtracting from external and internal dimensions c. Subtracting from external dimensions and adding to internal dimensions d. Adding to external dimensions and subtracting from internal dimensions e. None of the above 29) Which of the following is not a casting process a. Extrusion Process b. Semi Centrifugal Method c. Slush Process d. None of the above 30) Shell Moulding Wood for pattern is considered dry when moisture content is a. zero % b. 5% c. Less than 15% d. Less than 25%

e. None of the above 31) The purpose of the gate is to a. Feed the casting at a rate consistent with the rate of solidification b. Act as reservoir for molten metal c. Help feed the casting until all solidification takes place d. Feed molten metal from pouring basin to gate e. None of the above 32) Pick up correct statement a. Loose piece patterns are used when the pattern can be drawn from the mould b. Sweep pattern eliminate the need for 3D pattern c. Match Plate patterns are made by fastening each half of a split pattern on the same side of one plate d. Cope and drag patterns are solid one piece patterns 33) Lifter is a. A round sleve b. A long, flat metal plate fitted with an offset handle c. Used to make or repair corners in a mould d. Used to scoop sand deep in the mould e. None of the above 34) The impurities in true centrifugal casting a. Get collected at outer surface b. Mix up thoroughly throughout c. Get collected at the inner surface Page6 d. Ger collected at the middle portion in between inner & outer surface e. Are thrown out 35) Which of the following type of sand is used ot keep the green sand from sticking to the pattern a. Burnt sand b. Synthetic sand c. Core sand d. Parting sand e. Loam sand 36) Facing sand used in foundry work comprises of a. Alumina, silica and clay b. Silica & clay c. Clay and alumina d. Silica and alumina 37) Loam sand comprises of a. 50% sand and 10% of moisture b. 40% clay and 10% moisture c. 50% clay and 18% moisture

d. 80% clay and 20% moisture e. None of the above 38) Dilatometer is used to find out following property of moulding sand a. Permeability b. Moisture content c. Hot strength d. Compactness e. Fineness 39) The purpose of sprue is to a. Feed the casting at a rate consistent with the rate of solidification b. Act as a reservoir for molten metal c. Help feed the casting until all solidification takes place d. Feed molten metal from pouring basin to gate e. None of the above 40) Accuracy of shell moulding is of the order of a. 0.001 mm/mm b. 0.003 to 0.005 mm/mm c. 0.01 mm/mm d. 0.1 mm e. None of the above 41) The mould for casting ferrous materials in continuous casting process is made of a. Low carbon steel b. Medium carbon steel c. High carbon steel d. Copper e. None of the above Page7 42) Sand slingers gives a. Better packing of sand near pattern b. Better packing of sand near the flask c. Uniform sand density in the mould d. All of the above e. None of the above 43) The trowel in a foundry shop is used to a. Ram the moulding sand b. Swab the edges and the mould cavity c. Blow excess sand d. Repair corners in a mould e. Flatten and smoothen the sand during moulding operation 44) When using disposable pattern the metal should be poured a. Very slowly b. Rather rapidly

c. At same rate as for other casting processes d. Any rate e. None of the above 45) The purpose of pouring basin is to a. Feed the casting at a rate consistent with the rate of solidification b. Act as a reservoir for molten metal c. Help feed the casting until all solidification takes place d. None of the above 46) Match plate pattern is used in a. Green sand moulding b. Bench moulding c. Pit moulding d. Machine moulding e. None of the above 47) For steel casting, the following types of sand is batter a. Fine grain b. Coarser grain c. Medium grain d. All are eqaually good e. None of the above 48) All the size of casting increases, it is often better to use increasingly a. Fine grain b. Medium grain c. Coarse grain d. Any one of the above e. None of the above Page8 49) The purpose of riser to a. Feed the casting at a rate consistent with the rate of solidification b. Act as a reservoir for molten metal c. Help feed the casting until all solidification takes places d. Feed molten metal from pouring basin to gate 50) Slick is a. A round sleve b. A long, flat metal Plate fitted with an offset handle c. Used to make or repair corners in a mould d. Used to scoop sand deep in the mould 51) Hot Tears refers to a. Casting defects b. Processes of fabrication c. Process of heat treatment d. Weathering of non ferrous materials

e. Strengthening of alloys 52) Slick in a foundry shop is used to a. Make and repair corners in a mould b. Thoroughly mix up moulding sand c. Make venting holes in the mould d. Prepate gates e. Swab the edges of the mould cavity 53) True centrifugal casting a. Is used to ensure purity and density at extremities of a casting b. Is used to cast symmetrical objects c. Is used to obtain high density and pure casting d. Uses a heavy cast iron mould to act as chill e. None of the above 54) Investment casting is used for a. Shapes which are made by difficulty using complex pattern in sand casting b. Mass production c. Shapes which are very complex and intricate and can’t be cast by any other method d. There is nothing like investment casting e. Stainless steel parts 55) The material of pattern in the case of investment casting a. Thermosetting resin b. Special plastic c. Synthetic sand d. Wax e. Mercury 56) Pipes subjected to very heavy pressure of the order of 100 kg/cm2 are made by Page9 a. Electric resistant welding b. Centrifugal casting c. Die casting d. Extrusion process, as seamless pipes e. Gravity continues casting 57) Water pipes of large length and diameter are made by a. Semi-centrifugal casting b. Continuous casting c. Sand casting d. Forging 58) Which of the following processes would produce strongest components a. Die casting b. Hot rolling c. Extrusion

d. Cold rolling e. Forging 59) The runners and ingates, respectively are located as follows in casting of ferrous metals a. In cope and in drag b. In drag and in cope c. Both in cope d. Both in drag e. In any of the above arrangements 60) In centrifugal casting cores are made of a. Steel b. Cast iron c. Hard sand d. Plastic e. None of the above 61) Semi- centrifugal casting a. Is used to ensure purity and density at extremities of a casting b. Is used to cast symmetrical objects c. Is used to obtain high density and pure casting d. Uses heavy cast iron mould to act as chill e. Is not used for any purpose 62) For gravity Cast iron the pattern shrinkage allowance is of the order of a. 2 to 5 mm/m b. 5 to 7 mm/m c. 7 to 10.5 mm/m d. 10.5 to 13.5 mm/m e. 13.5 to 18 mm/m 63) Surface to be machined are marked on the pattern by the following colour a. Black Page10 b. Yellow c. Red d. Blue e. Green 64) Colour scheme is employed on the pattern in order to identify the a. Pattern allowances b. Cope and drag c. Location of core print d. Material of pattern e. None of the above 65) Blue colour on the pattern is marked for a. Machineed surface b. Unfinished surface

c. Loose piece pattern d. Surfaces to be chilled e. Never used in pattern making operation 66) For gray cast iron, the volumetric shrinkage is of the order of a. 6-5 % b. 5-3.5% c. 3.5-2.5% d. 1.9 to negative value 67) The pouring Temperature for grey cast iron a. 1000C b. 1250C c. 1400C d. 1550C e. 1650C 68) Chilled surfaces are mark on the pattern by a. Oblique red strips b. Yellow cross strips c. Black cross strips on yellow d. Oblique red strips on yellow e. None of the above 69) A large intricate heavy casting weighing in tons is to be cast. The most appropriate moulding process would be a. Machine moulding b. Pit moulding c. Cement moulding d. Green sand moulding e. Ceramic moulding 70) The patterns in the case of machine moulding are mounted on a. Match plats Page11 b. Moulding boards c. Follow boards d. Steel table e. Plastic boards 71) In the die casting process a. Molten metal is fed into the cavity in metallic mould by gravity b. Metal is poured into die cavity and after a predetermined time the mould is inverted to permit a part of metal still in molten state to flow out of cavity c. Cavity is filled with a pre calculated quality of metal and core or plunger is inserted to force the metal into cavity d. Metal is forces into mould under high pressure e. None of the above

72) The hot chamber die casting method is used in cast a. Brass b. Magnesium c. Aluminium d. Alloys of lead, tin and zinc e. All of the above 73) In hot chamber method of die casting a. Only low melting point metals can be cast b. High melting point metal can be cast c. Die is kept hot by electrical heating d. Die is kept cold by circulating water e. None of the above 74) In general the draft on the casting is of the order of a. 1-5 mm/m b. 5-10 mm/m c. 10-15mm/m d. 15-20 mm/m e. 20-30 mm/m 75) Blind risers a. Assist in feeding the metal into casting proper b. Help to trap slag or other lighter partials c. Supply the hottest metal when pouring is completed d. Do not exist e. None of the above 76) The allowances to be provided in disposable pattern are a. Shrinkage and finish b. Distortion c. Draft d. Shake e. (a) and (b) above Page12 77) Honey combing/ Sponginess refers to a. Presence of impurities in molten metal b. Molten metal at low temperature c. Formation of a no. Of cavities in close proximity in a casting d. Defects due to poor heat treatment e. Surface defects produced during hot working 78) The sand is packed on pit mould with a. Manually b. Sqaueezers c. Jolt machine d. Sand slingers

e. Portable blowers 79) Sprue in casting refers to a. Gate b. Runner c. Riser d. Horizontal passage e. Vertical passage 80) Which of the following casting process utilises wax pattern a. Shell moulding b. Plaster moulding c. Slush moulding d. Investment casting e. Semi- centrifugal casting 81) In slush casting processes a. Molten metal is fed in to the cavity in metallic mould by gravity b. Metal is poured in to die cavity and after a predetermined time the mould is inverted to permit a part of metal still in molten state to flow out of cavity c. Cavity is filled with a precalulated quantity of metal and a core or plunger in inserted to force the metal in to cavity d. Metal is forces into mould under high pressure e. None of the above 82) In slush casting a. Consumable pattern are used b. Plunger is used to force molten metal to fill up cavities c. Vacuum is applied to facilitate complete filling of casting d. When a solid shell of sufficient thickness has formed remaining liquid is poured out e. Mercury is used for filling the master mould at normal temperature 83) Ornaments are cast by a. Die casting b. Continuous casting c. Pressed casting d. Centrifugal casting Page13 e. Gravity casting 84) Statues, toys, etc are cast by a. Die casting b. Pressed casting c. Centrifugal casting d. Slush casting e. None of the above 85) Steel and cast iron pipes are cast by a. Die casting

b. Continous casting c. True centrifugal casting d. Centrifuging e. Investment casting 86) In centrifugal casting, the impurities are a. Uniformly distributed b. Collected in the centre of casting c. Forced outside the surface d. Present in the middle section of casting e. None of the above 87) The core in the centrifugal casting is made of a. Carbon steel b. Properly treated sand c. Plastic d. Abrasive material e. No core is used 88) Large and heavy casting are made by a. Green sand moulding b. Pit moulding c. Dry sand moulding d. Pressure moulding e. Machine moulding 89) The tolerance produced by the investment casting process are of the order of a. A few microns b. +/- 0.05 mm c. +/- 1 mm d. +/- 5 mm e. None of the above 90) Sweep pattern is used for moulding parts having a. Rectangular section b. Elliptical shape c. Uniform symmetrical shape d. Complicated shape having intricate details Page14 e. None of the above 91) Flogging in foundry practices refers to a. A type of moulding method b. Removal of sprues and risers c. A non destructive testing method d. Removal of slag during pouring e. A casting defects 92) The internal cracks in casting can be easily found out by the following method of testing

a. Magnetic particle inspection b. Fluorescent penetranent c. Ultrasonic Testing d. Dye penetrant e. None of the above 93) The surface and subsurface cracks in non magnetic alloys can be easily located and detected by the following inspection method a. X- ray testing b. Ultrasonic testing c. Magnetic particle inspection testing d. Dye penetrant testing e. Any one of the above 94) Internal hot tear defects in casting can be inspected by the following method a. Radiography b. Visual inspection c. Damping test d. Fluorescent penetrant test e. Hardness test 95) Fettling is an operation performed a. Before casting b. During casting c. After casting d. After heat treatment e. Before heat treatment 96) Shell moulding process requires a. Wooden pattern b. Sand pattern c. Plastic pattern d. Metal pattern e. None of the above 97) Slag inclusion in casting is a a. Surface defect b. Internal defect c. Crack Page15 d. Notch e. No defect 98) Core Prints are used to a. Strengthen core b. Form seat to support and hold the core in place c. Fabrication core d. All of the above

e. None of the above 99) Jolt machine produce a. Uniform ramming about the pattern b. Uniform ramming about the flask c. Uniform distribution throughout d. Pack sand loosely all around e. None of the above 100) Blow holes are casting defects a. Which occur due to some sand shearing from the cope surface b. Which take the form of internal voids or surface depression due to excessive gaseous material not able to escape c. Which occur due to discontinuity in metal casting resulting from hindered contraction d. Caused by two streams of metals that are too cold to fuse properly e. None of the above 101) Which is the most widely used metal for casting a. Aluminium b. Brass c. Magnesium alloys d. Cast iron 102) For small and intricate casting the sand grains should be a.Fine b.Medium c. Coarse d.Rounded 103) Permeability is poor for a.Fine grains b.Medium grains c. Coarse grains d.Rounded grains 104) Match the appropriate combination between foundry tools Foundry tool The purpose served by them Swab Repairing and finishing the mould Slick Reinforcement of sand in the top part of the moulding box Page16 Lifter Moistening the sand around the edges before removing the pattern Riddle Smoothing and cleaning out depressions in the mould 105) Which of the following in not foundry tool? a. Trowel

b. Arbour c. Riddle d. Slick 106) Chaplets in the foundry practice are used to a. Provide efficient venting b. Ensure directional solidification c. Support the core d. Reinforce the sand in the top part of the moulding box 107) The wood pattern used for the production of a metal is called a. Master b. Skelton c. Duplicate d. Investment 108) Metal patterns are used for a. Small casting b. Large casting c. Precise and intricate casting d. Large scale production casting 109) The surface to be left un-machined is marked on the pattern by a. Green colour b. Black colour c. Yellow colour d. Blue colour 110) Wax pattern is used in a. Shell moulding b. Die casting c. Investment casting d. Centrifugal casting 111) Carburettors are manufactured by a. Fine sand casting b. Die casting c. Slush casting d. Shell moulding 112) Hollow casting of desired thickness are producted by a permanent mould without used of cores in Page17 a. Machine moulding b. Slush casting c. Pressed casting d. Investment casting 113) The most preferred process for casting gas turbine blades is (IES- 97) a. Die moulding

b. Shell moulding c. Investment casting d. Sand casting 114) The plastic articles are usually produced by a. Shell moulding b. Green sand moulding c. Plaster moulding d. Injection casting 115) Which one of the following pairs is not correctly matched? Aluminium Pressure die casting Jewellery Lost wax process Large Pipes Centrifugal Casting Large Bells Loam Moulding 116) Two streams of metal that are not hot enough to fuse properly result into a casting defect known as a. Cold shots b. Swell c. Shrinkage d. Sand wash 117) Match 4 correct pairs between list-1 and 2 Processes Products Investment Casting Turbine Rotor Die Casting Turbine Blades Centrifugal Casting Connecting Rods Drop Forging Cast Iron Pipes Caruretter Body Find the answer... 118) Wax Pattern is used a. Shell moulding b. Die casting c. Investment casting d. Centrifugal casting 119) The vertical surfaces of a pattern are provided a taper known as ________ allowance a. Distortion b. Machining c. Draft d. Shrinkage Page18 120) Which is the negative allowance in the pattern making of sand casting a. Distortion b. Machining

c. Draft d. Shrinkage e. Rapping 121) They Binder in case of synthetic sand is a. Clay b. Water c. Molasses d. Bentonite and water 122) In the sand moulding top flask is known as a. Cope b. Drag c. Fillet d. Cheek 123) In the sand moulding the bottom flask is known as a. Cope b. Drag c. Fillet d. Cheek 124) Match plate pattern is used in a. Green sand moulding b. Bench moulding c. Pit moulding d. Machine moulding e. None of the above 125) In order to facilitate the withdrawal of pattern a. Pattern is made smooth b. Water is applied on pattern surface c. Allowances are made on the pattern d. Draft is provided on Pattern e. Withdrawing facilities are provided 126) Slick in a foundry shop is used to a. Make and repair corners in a mould b. Thoroughly mix up moulding sand c. Make venting holes in the mould d. Prepare gates e. Swab the edges of the mould cavity ==================================================================================