CASTING PROCESS
Casting types, procedure to make sand mould, types of core making, moulding tools,
machine moulding, special moulding processes CO2 moulding; shell moulding, investment
moulding, permanent mould casting, pressure die casting, centrifugal casting, continuous casting,
casting defects.
Define Casting?
In this process the raw material is melted, heated to the desired temperature and poured
into the mould cavity where it takes the desired shape. After the molten metal solidifies in the
mould cavity the product is taken out to get the casting.
What is the sequence of operations required in sand casting process?
1. Pattern Making
2 Mould making
3 Core making
4 Melting of metal and pouring
5 Cooling and solidification
6 Cleaning of castings and inspection
Define Pattern?
A pattern is defined as a model of a casting, constructed in such a way that it can be used
for forming an impression (mould) in damp sand.
What are the requirements of a good pattern?
Light in weight, Smooth and wear resistance surface, Secure the desired shape and size of
the casting, Ability to withstand rough handling.
Types of Patterns:
Types of patterns depends on the following factors
1. The shape and size of casting.
2 Number of castings required.
3 Method of moulding employed.
4 Anticipated difficulty of the moulding operation.
2. Split pattern
5 Gated pattern
6 Skeleton pattern
7 Sweep pattern
10 Segmental pattern
11 Shell pattern
12 Lagged-up patterns
Pattern Allowances
Shrinkage Allowances
Shrinkage allowance is an allowance added to the pattern to compensate for the metal
shrinkage that takes place while the metal solidifies.
Draft or taper allowance
It is the taper provided on vertical surfaces of a pattern to facilitate its removal from the
mould without excessive rapping or breakage of cavity edges.
Machining allowance
Machining or finishing allowance is the extra material provided on certain details of a
casting so that the casting may be machined to exact dimensions. It depends on the following
factors
(i) Casting process
(ii) Size of the casting
(iii) Degree of finish
(iv) Machining method.
(v) Metallic alloy
Rapping or shaking allowance
This allowance is provided to compensate for enlargement of the mould cavity because of
excessive rapping.
Distortion allowance
This allowance is provided on the pattern to compensate for possible distortion of the
casting because of the unequal cooling rates of different sections of the casting and uneven
internal stresses.
UNIT 1 CASTING
PART B
1. With reference to metal casting, explain the following types of patterns with
suitable sketches of examples:
(i) Solid pattern
(iii) Loose piece pattern
3. Centrifuge Casting
5. Explain the following process in detail
l. Hot Chamfer Die Casting
2. Cold Chamfer Die Casting
UNIT II WELDING
QUESTION BANK
TWO MARKS
1. Define welding process?
2. State the classification of welding process?
Note : Fusion Welding, Pressure Welding
Note : Autogeneous, Homogeneous, Heterogeneous
3. What are the different types of fusion welding?
4. What are the different types of pressure welding?
5. State the flame characterstics of gas welding process?
6. State the difference between TIG & MIG welding process?
7. What do you mean by Arc blow?
8. What is the principal of arc welding?
9. Difference between the A.C & D.C arc welding process?
10. List out the common types of electrodes?
11. What do you mean by distortion?
12. What are the influencing factors for the below welding process?
1. Resistance Arc Welding
2. Oxy-acetylene welding
7. Ultrasonic welding
2. Oxy-acetylene welding
7. Ultrasonic welding
PART B QUESTIONS
1. Explain the oxy-acetylene gas welding process with a neat sketch. State its advantages &
Disadvantages?
2. Explain the flame characterstics of gas welding process?
NOTE : MENTION TEMPERATURE,COLOUR OF THE FLAME IN DRAWING
3. Discuss any four ways to control output of arc welding transformer?
4. With the help of suitable diagrams, explain the following types of welding: State its
applications, advantages & disadvantages?
1. Resistance Arc Welding
2. Oxy-acetylene welding
7. Ultrasonic welding
For the above questions, explain any two/four process as stated in the question paper. Each
process may carry 8 or 16 marks.
5. Distinguish between soldering and brazing?
6. Sketch the different types of weld defects and mention how they occur?
7. Explain different types of soldering methods?
8. Explain different types of brazing methods?
UNIT 3 MACHINING
General principles (with schematic diagrams only) of working and commonly performed
in the following machines: Lathe, Shaper, Planer, Horizontal milling machine, Universal drilling
machine, Cylindrical grinding machine, Capstan and Turret lathe, Basics of CNC machines.
General principles and applications of the following process: abrasive jet machining,
Ultrasonic jet machining, Electric discharge machining, Electro chemical machining, plasma arc
machining, Electron beam machining and laser beam machining
PART A QUESTIONS
MACHINING
1. What is swing diameter?
2. Write the Specifications of a typical lathe?
3. What is the difference between a ram-type turret lathe and saddle type turret lathe?
4. What is the purpose of a mandrel? How many types of mandrels is there in common use?
5. Write down any four operations performed by a shaper?
6. Under what conditions planning operation would be preferred over other machining process
such as milling, broaching, shaping, etc?
7 Mention the operations performed by a planer
8. Write down any four operations that can be performed in a drilling machine?
9. What is point - to- point system?
10. What is the role of computer for NC machine tool?
11.Name various elements of CNC machines?
12. Classify CNC machines?
PART B QUESTIONS
FIRST PORTION
1. Explain the construction and working principle of a lathe with sketch?
2. Explain taper turning operation in a lathe by a taper turning attachment. Discuss its
advantages?
3. Write down any four differences between shaper and planer?
4. With a neat sketch, explain the principal parts and angles of a plain milling cutter, Explain
them.
5. How do you classify cylindrical grinders? What is the difference between Plain and
Universal cylindrical grinder?
6. Write down the differences between a capstan and a turret lathe.
7. Define CNC and DNC. With a help of a diagram explain the working of NC machine tool.
SECOND PORTION
1. With a neat sketch explain the following process. List its applications, advantages and
limitations.
1. Electrical Discharge Machining
(16 or 8 MARK)
(16 or 8 MARK)
3. Ultrasonic Machining
(16 or 8 MARK)
(16 or 8 MARK)
(16 or 8 MARK)
(16 or 8 MARK)
(16 or 8 MARK)
PART A
PART B
1. Discuss in detail about the hot & cold working of metals?
2. Difference between hot and cold working process?
ROLLING
1. Discuss in detail about mechanism of rolling?
2. Classification of different types of rollers with a neat sketch?
Two high rolling mill, Three high rolling mill, Four high rolling mill, Multiple-roll mills.
3. Explain in detail about the Rolling Defects
4. Explain the following shape rolling process with a neat sketch
Ring Rolling, Thread Rolling
FORGING
1. Comparision between press forging and drop forging?
2. Write the difference between open die and closed die forging process?