BHARAT UNIVERSITY

DEPERTMENT OF MECHANICAL ENGG.

BME206 - MANUFACTURING TECHNOLOGY – I
Important 2 Mark, 6 Marks and 10 Marks Question

UNIT I

Important 2 Mark Question

1. What are the pattern materials ?

The commonly used pattern making materials are given below

a. Wood – Teak wood, Mahogany, White pine, etc.
b. Metal - Cast iron, Brass, Aluminium, White metal, etc.
c. Plaster – Plaster of paris, Gypsum cement,
d. Plastics - polymers, synthetic resins.
e. Wax.

2. What are the different types of patterns used in foundries ? (or) Name any four types
of commonly used patterns.

The following types of patterns are normally used in foundary.

a. Solid or single piece pattern
b. Split pattern
c. Loose piece pattern
d. Match plate pattern
e. Sweep pattern
f. Skeleton pattern
g. Segmental pattern
h. Shell pattern

3. List any four allowances considered while designing a pattern for a casting

The various types of allowances are normally provided on the pattern are
a. Shrinkage allowance
b. Machining or finish allowance
c. Draft or taper allowance
d. Distortion or camber allowance
e. Rapping or shake allowance.

4. When do you make core (or) what is function of core in moulding sand ?

A core is a body made of sand which is used to make a cavity or a hole in the casting. The shape
of the core is similar to the required cavity in the casting to be made. It is also used to make
recesses, projections, undercuts and internal cavities.
5. Differentiate between mould and core.

Mould Core
Mould is a cavity made with moulding Core is a body of sand used to make a
sand used to make solid castings. cavity of hollow surfaces required in a
casting.
It is used to make casting of the required It is used to make recess, projections,
shape. undercuts and internal cavities in the
casting.

6. What is the merit of CO2 process?

CO2 process is very rapid and takes about 1 minute, which is very much less than the several
hours needed to produce a dry sand mould. Such mould can be used for producing very smooth
intricate castings.

7. What are the properties of good moulding sand ?

a. Porosity or Permeability
b. Plasticity or Flowability
c. Strength or Cohesiveness
d. Adhesiveness
e. Refractoriness
f. Collapsibility

8. Write the composition of good moulding sand.

Green Sand: It contains 5% to 8% water and 15 to 20% clay along with green sand
Loam Sand: Loam sand is a mixture of fine sands, fine refractories, clay, graphite powder
and water. It contains more clay (15%).

9. Mention any two merits and demerits of die casting.

Merits:
a. Castings with very good surface finish can be made.
b. Rate of production (700 castings per hour) is high.
c. Castings with varying thickness wall can be made.
d. There is no possibility of sand inclusions.
Demerits:
a. Only small parts can be made.
b. Only non-ferrous metals can be made.
c. Equipment cost is high.
d. It is more suitable for mass production only.

10. Name four different casting defects

a. Shifts – Two halves mismatching of casting.

b. Hot fear – Internal or external cracks
c. Fins – Thin projection on parting line.
d. Inclusions – Foreign material present in casting.
Important 6 Marks Question

1. Explain the types of pattern in details.

Types Of Patterns :- A pattern is an element used for making cavities in the mould, into which
molten metal is poured to produce a casting.
The type of pattern to be used for a particular casting depends upon many factors like
design of casting, complexity of shape, number of casting required [bulk of casting], mould
process, surface finish and accuracy.

The following patterns are commonly used.

1. Solid or single piece pattern
2. Split or two piece patterns
3. Gated pattern
4. Match plate pattern
5. Skeleton pattern
6. Sweep pattern
7. Loose piece pattern
8. Cope and drag pattern
9. Follow board pattern
10.Segmental pattern

2. What is core? Describe the different types of cores used.

Core:
A core is a body made of sand which is used to make a cavity or a hole in the casting. The shape
of the core is similar to the required cavity in the casting to be made. It is also used to make
recesses, Projections, undercuts and internal cavities.
Types of Cores: The cores can be classified as follows:
(a) According to the state of core:
(i) Green sand core
(ii) Dry sand core
(b) According to the position of the core in the mould:
(i) Horizontal core
(ii) Vertical core
(iii) Balanced core
(iv) Hanging core
(v) Drop core

3. Discuss the properties of moulding sand

MOULDING SAND The special type of sand is used for making mould. Mould sand essentially
contains the following three constituents. They are (i) Sand (ii) Binder (iii) Additive
Sand: Silica sand is widely used as moulding sand. Silica has 80 – 90% silicon dioxide. Silica
gives refractoriness to the sand. There are three main types of moulding sands available.

(a) Natural Sand

(b) Synthetic Sand
(c) Special Sands: (i) Zircon sand (Zr Si O4) (ii) Chromite sand

Binder: Binders are used to bring the property of cohesiveness to the sand. They bind the sand
grains together and give the strength to the moulding sand. There are basically two types of
binders used: (i) Organic binders (ii) Inorganic binders.
Additives: Additives are added to the moulding sand to improve the properties such as strength,
refractoriness and permeability. These additives ay be necessary to give a good surface finish o
the casting or to eliminate the casting defects that arise from either the expansion of the
moulding sand or contraction of the casting. Some common additives are used to improve the
properties of moulding sand given below.
(i) Sea coal
(ii) Saw dust
(iii) Pitch
(iv) Cereals
(v) Silica flour
(vi) Special additives (Fuel oil, Molasses and iron oxide)

4. Briefly explain the carbon dioxide moulding process

CO2 Moulds:
The CO2 moulding process is a sand moulding process in which sodium silicate
(Na2 2Si O3 + n H2O + CO2 → Na2 CO3 + 2SiO2 + n(H2O)
This reaction is very rapid and takes about 1 minute, which is very much less than the several
hours needed to produce a dry sand mould. Such mould can be used for producing very smooth
intricate castings.

5. Write shot note on moulding machine.

Moulding machine is used for mass production. Since the hand moulding is a slow process, it can
be only used for making few castings. For producing more castings, moulding is done by using
moulding machines. It reduces the labours but it increases the quality of the mould.
Moulding machines will do the following operations:

1. Ramming the moulding sand

2. Rapping the pattern for easy removal.
3. Removing the pattern from the sand.
The following types of moulding machines are generally used
a. Jolting machine.
b. Squeezing machine.
c. Sand slinger.
 Important 10 Marks Question

1. Write a note on casting defects, cause and remedies.

Sl.
Defects Causes Remedies
No.

Shrinkage: It is a 1. Improper solidification

1. Proper solidification
2. Incorrect pouring temperature
depression on the casting 2. Pour at correct temperature
1. 3. Faulty gating, runner and riser
surface 3. Modify gating, runner
system.
and riser system.

1. Excess moisture in sand. 1. Control moister content.

2. Blow holes: When the 2. Hard ramming 2. Ram properly
molten metal is poured, 3. Improper venting 3. Provide sufficient vent hole
gases and stream are 4. Excess binder 4. Control binder content.
formed. If these gases
could not be come out,
blow holes are formed on
the interior of the casting.

1. 1. Uneven ramming 1. Provide uniform ramming.

3. Scab: It is the erosion or 2. High velocity of pouring 2. Pour with correct velocity
breaking down a portion
of mould and recess filled
with metal.

4. Swell: It is the 1. Soft ramming 1. Ram properly.

enlargement of casting. 2. Quick pouring 2. Pour with correct velocity
3. Mould not properly 3. Prove adequate support to the
supported. mould.

5. 1. Rapid cooling. 1. Provide uniform cooling

Hard spot: Some spots 2. Pouring at low temperature 2. Pour at correct temperature.
on the surface become
hard.

1. Faulty moulding 1. Modify moulding system.

6. Runout: It is the leakage 2. Improper parting line 2. Provide proper parting line
of metal out of the mould 3. Improper gating system 3. Provide proper gating system.
wile pouring

7. Honey combing: 1. Soft ramming 1. Provide correct ramming

Number of small cavities 2. Faulty gating 2. Provide correct gating system.
3. Faulty pouring 3. Pour at correct temperature.
present on the casting
surface.
 Cracks: Small cracks
8. appear on the corner of
the casting. Due to sharp corners Provide taper or round corners

9. Shift: Mismatching of 1. Worn-out or bent clamping 1. Repair or replace the pins or

casting sections. pins dowel pins in the pattern.
in the moulding box. 2. Assemble the moulding boxes
2. Loose dowels in pattern. properly
3. Misalignment of moulding 3. Provide proper box locating of
boxes. core.
4. Improper box locating of
core.
Cold shut: It is the
10. incomplete filling of the 1. Low pouring temperature 1. Pour at correct temperature.
mould cavity at one 2. Too small gate 2. Provide correct gating system
3. In sufficient molten metal in 3. Pour sufficient molten metal in
pouring.
the ladle for one pouring the ladle for one pouring.
Inclusions: Foreign
material present in 1. Low grade moulding sand. 1. Use of correct grade of
11. casting. 2. Improper skimming. moulding sand.
2. Use proper skimming for
removing impurities.

Fins: This projection on 1. Incorrect assembly of core or
12. parting line. moulds.
2. Inadequate weights.
3. Improper pouring temperature
4. Improper gating system,
1. Assemble the moulds and cores
correctly
2. Provide enough weight in a
correct place.
3. Pour at correct temperature
4. Modify gating system.

13. Dress: Lighter impurities Improper using of strainer and Use strainer and skim bob
appearing on the top skim bob properly
surface of a casting.
Rat tail: It is a long, Improper compressed layer fails Provide proper expansion instead
14. shallow, angular by one layer instead of of forming compressed layer.
depression normally expanding
found in a thin casting.

Blister: The scar covered 1. Improper pouring temperature 1. Pour at correct temperature
15. by the thin layer of a 2. Insufficient molten metal 2. Use sufficient molten metal
metal’

2. Describe shell moulding process with neat sketches. Give the advantages of this process.

The shell mould casting is a semi precise method for producing small castings in large
numbers. The process involves the use of a match plate pattern similar to cope and drag patterns
which are used in green sand mould casting.
Initially, the patterns are machined from copper alloys, aluminium or cast iron depending
upon the lift of the pattern. They are made with usual allowances and polished surfaces. Then it
is attached to the metal match plate.
 The mould material contains 5 to 10% of phenolic resin mixed with fine dry silica. There
are mixed with either dry oil or alcohol. It should be noted that there is no water used.
The pattern is heated to about 230 – 600°C. Then, the sand-resin mixture is either dumped or
blown over its surface. Sometimes, to prevent the sticking of sand with pattern, a release agent
silicone is sprayed over the hot pattern. The heated pattern melts and hardens the resin. This
results in bonding the sand grains closely together and forms a shell around the pattern. After a
specified time of 20 – 30 sec, the pattern and sand are inverted.
The thickness of the shell can be accurately controlled by the time of contact of the
mixture with the heated pattern. In about 20 – 30 sec. a normal shell thickness of 6 mm can be
obtained. The extra sand which is not adhered to the shell is removed off. The thickness of the
shell is depending on the required strength and rigidity to hold the weight of the liquid metal to
be poured into the mould.
Then, the mould is heated in an oven at 300°C for 15 – 60 sec. This curing makes the sell
rigid when it can be stripped off by means of ejector pins mounted on the pattern. Thus the
formed shell constitutes one-half of the mould. Two such halves, placed one over the other make
the complete mould.
While pouring the molten metal, the two halves are clamped down together by clamps or
springs. After cooling and solidification, the shells are broken or shaken away from the castings.

Advantages:

1. A high accuracy castings with tolerances of ± 0.002 to 0.005 mm / mm is possible.

2. Good surface finish cab be obtained.
3. Complex parts can be made by this method.
4. Less sand is used compared to other methods.
5. Moulds can be stored for long time.
6. Permeability of thin shell moulds is high, Therefore, defects are less.
7. Better quality castings can be achieved.

3. What are pattern allowances? Explain briefly each.

The various types of allowances normally provided on the pattern are,

a. Shrinkage allowance
b. Machining or finish allowance
c. Draft or taper allowance
d. Distortion or camber allowance
e. Rapping or shake allowance
Shrinkage allowance: The metals shrink on solidification and contracts further on cooling to
room temperature. To compensate this, the pattern is made larger than the required casting. This
extra size provided on the pattern for metal shrinkage is called shrinkage allowance. If it is not
given, the casting will become smaller.

Machining or finishing Allowance: All the castings are to be machined to get the required
surface finish on the metal. During machining , some of the metals are removed from the casting.
For the purpose, the pattern is made larger than the required size of casting. This extra size given
to the pattern for machining purpose is called machining or finishing allowance.

Draft or taper allowance: If the vertical faces of pattern are perpendicular to parting line, the
edges of mould may be damaged when the pattern is removed from the sand. Hence, the vertical
face are made into taper for easy removal of pattern. This slight taper provided on the vertical
sides of pattern is called draft allowance.

Distortion or Camber allowance: The casting may distort or wrap during cooling if it is an
irregular shape, flat long casting surface, and U or V shape. All surfaces do not shrink uniformly.
The arms having unequal thickness are also the reason for distortion. Due to distortion, the
casting will not get the required shape. It may bend. To avoid this, the shape of the pattern is
slightly bent into the opposite direction. So, the casting neutralizes the initial distortion given on
the pattern and gets the correct shape after cooling.

4. Describe the centrifugal casting process.

Centrifugal Casting is primarily used for making hollow castings, such as pipe without using
core. In this process, a metal mould is made to rotate. The rotating mould is mounted on a
trolley. The trolley moves over rails. /the end of the mould is closed by end cores to prevent the
flow of metal. The metal is poured into the mould or mechanical means as well as moves axially
on the rails. Due to centrifugal force, the molten metal is thrown to the walls of the mould. The
outside of the mould is water-cooled. So, the molten metal immediately solidifies. The
centrifugal casting method is used for producing cylindrical or symmetrical objects.

5. Describe the procedure of making castings by the investment casting process.

The castings obtained by this method have very smooth surfaces and possesses high
dimensional accuracy. Hence, it is called as precision investment casting. Here, the term
“Investment” means the layer of refractory material with which the pattern is covered to make
the mould. Similar to sand casting method, the mould cannot be used again and again.
The method involves the use of expandable (heat disposable) pattern surrounded with a shell
or refractory material to form the casting mould. Castings are formed by pouring the molten
metal in the mould cavities created by melting out pattern. Since the pattern made of wax is
melted out and gets destroyed a]that the reason of using the name called as “Last-wax method”
Initially, the master pattern which is equal to the part to be cast is made by metal that can be
easily machined, such as, brass, aluminium alloy or a fusible alloy (tin, lead and bismuth). The
dimension of the pattern is slightly larger than the actual size of the part to be made to
compensate the adjustments in the die, wax, in the investment material and casting material. The
determination of pattern dimension is very difficult job. It makes the pattern very costly.