5.

1 Fundamentals of Metal Casting

IDENTIFICATION
1. A solidification process in which molten metal is poured into a mold and allowed it to cool.
CASTING
2. Portion of the runner through which the molten metal enters the mold cavity. GATE
3. It states that for incompressible liquids and in a system with impermeable walls, the rate of
flow is constant. LAW OF MASS CONTINUITY
4. Capability of the molten metal to fill mold cavities. FLUIDITY
5. Length of the solidified metal in the spiral passage. FLUIDITY INDEX
MULTIPLE CHOICE
1. A vertical channel through which the molten metal flows downward in the mold.
a. Sprue b. Runners c. Gate d. Risers

2. It serves a reservoirs, supplying molten metal to the casting as it shrinks during solidification.
a. Sprue b. Runners c. Gate d. Risers

3. It quantify the aspect of fluid flow, it represents the ratio of the inertia to the viscous forces.
a. Bernoulli's Theorem b. Law of Mass Continuity
c. Reynold's Number d. Sprue Design

4. Which of these is NOT a characteristic of molten metal that influences fluidity.

a. Viscosity b. Surface Tension c. Inclusions d. Heat Transfer

5. It is the function of the volume of a casting and its surface area.

a. Solidification Time b. Bernoulli's Theorem c. Porosity d. Sprue Design

ENUMERATION
Give 5 casting defects
1. Metallic Projection 4. Defective Surface
2. Cavities 5. Incomplete Casting
3. Discontinuities 6. Incorrect dimensions or shape
 5.2 Metal Casting Processes
Identification
1. It is the industry of pouring liquid metal into a mold to achieve a desired shape. METAL
CASTING
2.a workshop or factory for casting metals. FOUNDRY
3. A liquid conforms to the shape of the vessel that holds it: this is the fundamental principle
underlying all metal casting process. CASTING PROCESS
4. It is the first step to prepare a model-pattern. PATTERN MAKING
5. Also called GREEN SAND collected from natural resources. NATURAL SAND

Multiple Choice
1.Principal raw material used in Moulding

a.Moulding Sand c.Natural Sand

b.Metal cast d.Permanent mold
2.Tempered well-prepared foundry sand

a.dry sand c.Natural sand

b.Green sand d.Facing sand
3.Original sand having excess moisture

a. Dry sand c. Facing sand

b. Green sand d. Parting Sand
4.Forms the face of the mold

a. Dry sand c. Facing sand

b. Green sand d. Green sand
5.Uses sand to hold the desired shape to be cast

a. Metal Casting
b. Casting process
c. Sand casting
d. Moulding sand

Enumeration
TYPES OF MOULDS
1.Green Sand Mould
2.Skin dried mould
3. Dry sand Mould
4. Air Dried mould
5.3 Metal Casting Design Materials and Economics

Identification:

1. The line or plane, separating the upper(cope) and lower(drag) halves of molds. Parting
line
2. The lowest density of all commercial casting alloys. They have good corrosion resistance
and moderate strength, depending on the particular heat treatment used. Magnesium-
based alloys
3. A low-melting-point alloy group, have good fluidity and sufficient strength for structural
applications. These alloys are commonly used in die casting. Zinc-based alloys
4. Represent the largest amount of all metals cast, and can easily be cast into intricate
shapes. They generally possess several desirable properties, such as wear resistance,
hardness, and good machinability. Cast irons
5. Provided in sand-mold patterns to enable removal of the pattern without damaging the
mold. Draft
Multiple choice:

1. Pattern dimensions should also provide for shrinkage of the metal during solidification
and cooling. Allowances for shrinkage, also known as
a. patternmaker’s allowances
b. shrinkage allowances
c. patternmaker’s shrinkage allowances
d. Pattern shrinkage
2. These alloys have high electrical conductivity and generally good atmosphere corrosion
resistance, except for some acids.
a. Copper-based alloys
b. Aluminum-based alloys
c. Magnesium-based alloys
d. Zinc-based alloys
3. Generally have long freezing ranges and high melting temperatures. They develop several
structures, depending on their compositions and processing parameters
a. Cast irons
b. Cast stainless steels
c. Cast steels
d. Gray cast iron
4. This should be avoided, because they may warp during cooling because of temperature
gradients or develop poor surface finish.
a. Flat areas
b. Shrinkage
c. Residual stresses
d. Machining allowances
 5. An important part of the production of many alloy groups, especially ferrous castings,
and may be necessary to produce improved mechanical properties.

a. Heat casting
b. Heat treating
c. Cold treating
d. Metal casting

Enumeration:
5 Designs for expendable-mold casting
 Corners, angles, and section thickness
 Flat areas
 Shrinkage
 Parting line
 Draft
 Dimensional tolerances
 Machining allowance
 Residual stresses

5.4 Forging of Metals

Identification

1. A process in which the upper die moves along an orbital path and forms the part
incrementally. (Orbital Forging)

2. Usually performed at the end of a round rod or wire in order to produce a larger gross
section.(Heading)

3. A process in which the workpiece is shaped by compressive force applied through various dies
and tools.(Forging)

4. It is gathered into a localized area.(Edging)

5. Capability of a material to undergo deformation without cracking.(Forgeability)

Multiple choice

1.) Is a process of indenting the surface of a workpiece with a punch in order To produce a
cavity.

a. Heading b. Hubbing c. Forging d. Piercing

2.) It is serve as a parting agent in the workpiece of a forging process.

a. Metal filler b. Die c. Lubricant d. Workpiece

3.) Die materials are composed of the following. EXCEPT

a. Chromium b. Nickel c. Copper d. Molybdenum

4.) Operations in which the part formed is closed to the final dimension of the desired
component.
a. Coining b. Near-net shape c. Close-die forging d. Heading
5.) Test in forging metals where the specimen twisted until it fails .
a. Hot-twist test b. Upsetting test c. Cold-twist test d. Downsetting test

Enumeration
Reasons why die failures occurs
1. Overloading
2. Misuse
3. Improper design
4. Improper handling
5. Defective materials

5.5 Extrusion and Drawing of Metals

Identification:
1.Forcing a billet through a die, can also create solid and hollow cross sections. Extrusion
2.This process if for metals that don`t have sufficient ductility at room temperature it also reduce
the require extrusion force. Hot Extrusion
3.Oil that is used in Hydrostatic Extrusion. Vegetable Oil
4.The cross-section of a round wire/rod is reduced in size or change in shape by pulling it
through a die. Drawing Processes
5.Used to produce copper wire for electrical wiring. Wire Drawing
Multiple Choice:
1.Changing or reduction of cross section of rod, wire, or tube by pulling it through a die.
a. Hydrostatic Extrusion c. Drawing of Metals
b. Wire Drawing d. Impact Extrusion
2.Which of these is NOT a component of Impact Extrusion?
a. Die c. Billet
b. Blank d. Punch
3.Impact Extrusion is also considered as?
a. Hot Extrusion c. Impact Extrusion
b. Cold Extrusion d. Hydrostatic Extrusion
4.Brittle materials can be extruded using this method since the ductility increases with the
hydrostatic pressure.
a. Hot Extrusion c. Impact Extrusion
b. Cold Extrusion d. Hydrostatic Extrusion
5.Which materials is not generally extruded?
a. Aluminum c. Lead
b. Steel d. Gold

Enumeration
Extrusion Processes
1. Extrusion
2. Direct Extrusion
3. Forward Extrusion
 5.6 Sheet Metal Forming Process

Identifications;

1. Metal formed by an industrial process into thin , flat pieces. it is one of fundamental
forms use in metalworking. (sheet metal)
2. an old process with involves the forming of axisymmetric parts over a mandrel, by the
use of various tools and sellers. (spinning)
3. Cutting process in which a piece of sheet metal is removed from a larger piece
of stock by applying a great enough shearing force. (blanking)
4. Process of bending the edge of sheets metals, usually to 90 degree. (flanging)
5. Used for forming continuous lengths of sheet metal and for large production runs. (roll
forming)

Multiple choice;

1. It is an important cutting process that is effective on many metallic materials as well as

nonmetallic ones.

a. Flame Cutting b. Laser-beam Cutting c. Water-jet Cutting d. Band Saw

2. Shearing Dies include all of the following except

a. Tool and die materials b.Transfer die c. Progressive die d.Compound dies
3. In this cutting process the material is removed from a piece of sheet metal by applying a great
enough shearing force.

a. Punching b.Blanking c. Cutting d. Piercing

4. In this process plates are bents using a set of rolls by adjusting the distance between the three
rolls, various curvatures can be obtained.

a. Roll forming b.Beading c. Roll-bending d. Hemming

5. It is a process of forming a flat piece of material into a hallow shaped by means of a punch
which causes the blank to flow into the die-cavity.

a. Stretch forming b. Bulging c. Deep drawing process d. Rubber forming

Enumeration; Method of cutting sheet metal

1. Band sawing
2. Flame cutting
3. Laser – beam cutting
4. Water – jet cutting
5. Flame sawing
 5.7 Processing of Powder Metals

Identification
1. Process was first used five thousand years ago by Egyptians to make iron tools. Powder
Metallurgy Process
2. Produces a liquid-metal stream by injecting molten metal through a small orifice.
Atomization
3. Also known as the removal of oxygen. Reduction of Metal Oxides
4. It is also called the shape index. Shape factor
5. Powder is fed though the roll gap and is used to make coins and sheet metal. Rolling
Multiple Choice
1. In shaping ceramics, the particles must be mixed with additives, which of the following is
included?
a) Lubricants b. Binder c. Deflocculent d. All of the above
2. This is a method wherein molten glass is floated over a “bath” of molten tin before it is
solidified in a separate chamber.
a) Pressing b. Float Method c. Drawing Process d. Rolling Process
3. The following methods are Techniques for Strengthening and Treating Glass except
a) Thermal Tempering b. Chemical Tempering c. Laminated Glass
d.Oxide Powder in Tube
4. The air is blown through the mandrel to prevent the tube from collapsing into itself.
a) Tubing b. Rods c. Blowing d.Pressing
5. It is a type of pressing wherein high pressure is applied to ceramic particles with a
moisture content below 4%, causing compaction.
a) Dry Pressing b.Wet Pressing c. Isostatic Pressing d.Hot Pressing
Enumeration
Production of Metal Powders
1. Powder production
2. Blending
3. Compaction
4. Sintering
5. Finishing operations
5.8 Forming and Shaping Plastics

IDENTIFICATION:

1. This is the section where the heat generated by the shearing of the plastic and by the
heaters causes melting to begin. Ans: melt section

2. This is a term for producing hinge joints and ball – and – socket joints in one operation
and without any post- molding assembly. Ans: overmolding

3. This is a process developed in 1969, a mixture of resin with two or more reactive fluids is
forced into the mold cavity at high speed. Ans: reaction – injection molding

4. This process is used to make plastic products with a solid outer skin and a cellular inner
structure. Ans: structural - foam molding

5. This is a series of processes for forming thermoplastic sheet or film over a mold by
means of the application of heat and pressure Ans: thermoforming
MULTIPLE CHOICE :

1. This is a type of compression mold used for shallow or flat parts.

a. Flash – type
b. Positive type
c. Injection type
d. Semipositive type

2. A variation of casting that is important to the electrical and electronics industry.

a. Centrifugal casting
b. Potting and encapsulation
c. Foam molding
d. Electrical casting

3. This is a process in which the resin and fibers are combined at the time of curing.

a. Casting
b. Blow molding
c. Filament winding
d. Extrusion

4. It is basically consists of casting and liquid matrix and the solid reinforced, using either
conventional casting processes or pressure infiltration casting

a. Solid – phase processes

b. Two – phase processing
c. Pultrusion
d. Liquid – phase processing
 5. It involves sol – gel and the polymer – precursor techniques.

a. Chemical synthesis
b. Pellets
c. Slurry infiltration
d. Pulforming

ENUMERATION:

 5 Types of Molding Processes

Answer:
1. Compression molding
2. Vacuum – bag molding
3. Contact molding
4. Resin transfer molding
5. Injection molding

>>6.1 Fundamentals of Cutting

Identification
1. It is the process of removing unwanted materials in the form of chips from a block of metal
using a cutting tool. Metal Cutting
2. Term used to describe the breaking away of a small piece from the cutting edge of the tool.
Chipping
3. It is a cutting in which the work piece is rotated on a cutting tool that removes a layer of
material as it moves to the left. Turning Operation
4. It occurs on the relief face of the tool and the side relief angle. Flank Wear
5. It consists of segments that maybe firmly or loosely attached to each other. Discontinuous
Chip

Multiple Choice
1. It breaks the produced chips into small pieces.
b) Chip breakers
c) Chip curl
d) Chip formation
e) Chipping
2. Which of the following is one of the main causes of chipping?
b) Fracture
c) Mechanical shock
d) Surface area
e) Shape and size
4. What do you call to the forces acting or being applied in cutting process?
b) Resultant force
c) Thrust force
d) Full force
e) All of the above
5. Which of the following is/are being investigated as possible substitute for lead?
b) Carbon and manganese
c) Aluminum
d) Bismuth and tin
e) Hydrogen
6. Which of the following is not the most common cutting process?
b) Turning operation
c) End-milling operation
d) Slab-milling operation
e) Tool wear

Enumeration
Tool life wear and failure.
1. Flank Wear
2. Crater Wear
3. Chipping
6.2 Cutting Tool Materials

IDENTIFICATION:
__________1. Generally used for cutting steels, cast irons, and abrasive nonferrous materials,
and have largely replaced HSS tools because of their better performance. (Tungsten Carbide)

__________2. Consists of 70% aluminum oxide and 30% titanium carbide; others contain
molybdenum carbide, niobium carbide, and tantalum carbide. (Cermets)

__________3. Another term for cast-cobalt alloys. (Stellite)

__________4. Most commonly used ceramic coating. They have chemical inertness, low thermal
conductivity, resistance to high temperature, resistance to flank and crater wear. (Aluminum
Oxide)

__________5. It is being used widely as a coating, particularly on tungsten-carbide and silicon-

nitride inserts. (Polycrystalline Diamond)

MULTIPLE CHOICE:
1. Commonly known as Stellite tools, these alloys are cast and ground into relatively simple
tool shapes.
a. Cast-Cobalt Alloys
b. High-Speed Steels
c. Carbides
d. Carbon and Medium Alloy Steels

2. It is the hardest substance of all known material.

a. Cubic Boron Nitride
b. Alumina- Based Ceramics
c. Diamond
d. Carbides

3. These are the oldest tool materials and have been used since 1880. Its hardness rapidly
decreases as the temperature increases.
a. High-Speed Steels
b. Whisker-Reinforced Materials
c. Coated tools
d. Carbon Steels

4. What are the typical applications of multiple-coated tools?

a. High-speed, continuous cutting: TiC/Al2O3
b. Heavy-duty, continuous cutting: TiC/Al2O3/TiN
c. Light, interrupted cutting: TiC/TiC + TiN/TiN
d. All of the Above
5. Also known as Cemented or Sintered Carbides. Introduced in the 1930’s and have high
hardness over a wide range of temperatures, so can be used for higher cutting speeds, high elastic
modulus and thermal conductivity, and low thermal expansion.
a. Inserts
b. Coated tools
c. Aluminum Oxide
d. Carbides

ENUMERATION:
Cutting-tool material Characteristics:
1.Hardness
2. Toughness
3. Wear Resistance
4. Thermal Shock Resistance
5. Chemical Stability or Inertness

6.3 Machining Processes

IDENTIFICATION
1. A multi tooth tool that produces a number of chips in one revolution. (Milling Cutter)
2. These cutters are able to produce elaborate contours and are often used in the machining of
dies and molds. (Ball nose end mills)
3. These machines tools are versatile and capable of milling, drilling, boring and tapping with
repetitive accuracy. (Computer Numerical Control Machines)
4. This process is a combination of shaving and skiving. It is an advance in broaching
technology. (Turn Broaching)
5. Includes a number of highly versatile machining operations capable of producing a variety of
configurations with the use of milling cutter. (Milling)

MULTIPLE CHOICE
1. It supports the saddle and gives the table vertical movement so that the depth of cut can be
adjusted.
a) Overarm
b) Head

c) Knee
d) Work table
2. It supports the table and can move in the transverse direction. (A)
a. Saddle
b. Work table
c. Head
d. Overarm
3. Which of the following machines have three axes of movement, which are usually imparted
manually or by power?
a) Profile Milling Machines

b) Plain Milling Machines

c) Bed-Type Machines
d) Rotary Table Machines
4. It is an important production process and can produce parts with very good surface finish and
dimensional accuracy.
a. Planing

b. Broaching
c. Milling
d. Shaping
5. It is a tool used on machines called gear shapers.
a) Rack-shaped straight cutter
b) Hob
c) Cutting Bevel Gears

d) Pinion-shaped Cutter
ENUMERATION
(1-3) Types of Saws
1. Hacksaws
2. Circular Saws
3. Band Saws