DEPARTMENT OF MECHANICAL ENGINEERING

PUDUCHERRY TECHNOLOGICAL UNIVERSITY, PUDUCHERRY

ME214 MANUFACTURING PROCESSES
B. TECH III-YEAR V-SEMESTER

UNIT I METAL CASTING PROCESSES

QUESTION BANK - TWO MARKS
1. What is natural moulding sand? Give its Constituents.
2. Name any four types of commonly used patterns.
3. What are the characteristics of Core?
4. What is the ideal profile of a Sprue?
5. What is the merit of CO2 process?
6. Write the requirements of good pattern.
7. State the essential process of mounding sand.
8. What are hot spot and hot tear?
9. State any two merits and demerits of the investment casting process.
10. What are the pattern materials?
11. What is meant by permanent mould casting?
12. Explain the term fettling?
13. Mention any two merits and demerits of the die casting.
14. Name the alloy which are generally die cast. Why are aluminium alloys preferably cast in
cold chamber die casting machines?
15. Make a note on Loam mould.
16. List out any four defects in casting.
17. What is core venting?
18. What is meant by split pattern?
19. Define the term mould.
20. What are the defects caused by low pouring temperature?
21. What is meant by match plate pattern?
22. Define AFS grain fineness numer?
23. How will you calculate the grain fineness number?
24. How patterns differ from casting?
25. What are the functions of riser?
26. What are core prints?
27. What is meant by CO2 moulding?
28. What are the functions of gating and risering?
29. Classify moulding machines.
30. What is the composition of moulding sand?
31. What is the function of core?
32. Which process is called “Lost wax process”? Why?
33. List out the pattern allowance.
34. What is the causes of the casting defects called “Hot tear”?
35. Name the different melting furnaces employed for metal casting?
36. What is a Misrun?

PART B – EIGHT/TWELVE MARKS

1. How the size of the silica sand is identified? Explain with suitable example.
2. Explain the working of sand slinger machine.
3. (i) Explain the properties required for moulding sand.
(ii) Explain the preparation of moulding sand process.
4. What are the pattern allowances? Explain briefly each.
5. What is the importance of allowance considered in pattern? Explain.
6. (i) Explain any one type of centrifugal casting with neat diagram.
(ii) Name any five casting defects and explain the remedies for those defects.
7. Name any five casting defects and explain the remedies of the following categories
(i) Metallic projection (ii) Cavities (iii) Defective surfaces.
8. Name and explain the various patterns that are normally encountered in foundry practice.
9. (i) Explain the working principle of investment casting.
(ii) Define the casting defects and their inspection methods.
10. (i) What are the pattern making allowances and briefly explain them.
(ii) Describe Shell moulding process.
11. Explain the CO2 process of core making stages its advantage and disadvantages.
12. (i) Explain the ceramic moulding process and states its merits and demerits.
13. (ii) What are the factors which govern the selection of a proper material for pattern making?
14. Sketch common Hot chamber die casting machine. Explain with its applications.
15. (i) What are the specific advantages of match plate patterns? Explain how they are used for
making mould.
(ii) Classify the types of patterns and sketch any three of them.
16. Write short note on “Green sand mould and Shell moulding”.
17. Briefly explain about investment casting.
18. Explain with neat schematic true centrifugal casting process.
19. (i) What is core and explain how to make a core?
(ii) Explain and construction of Cupola furnace with diagram.
20. (i) Write a short note on Chills”
(ii) Describe various materials used for making patterns. What are its merits and demerits?
21. With neat sketch explain the sand casting process.
22. Explain the different moulding sand and its properties.
23. (i) What are the basic requirements of core sand? How does it differ from moulding sand?
(ii) What are the different types of furnaces used in foundry? Describe in detail with neat
sketches any one of them.
24. (i) Describe the steps involved in the preparation of green sand mould with cope and drag
pattern.
(ii) Briefly explain cold-chamber die casting process with a neat sketch.
25. What are the defects occurring in products made by casting process? Explain with neat
sketch.
26. Draw the cupola furnace and indicate the various zones in it. Describe its operations and
various zones present.