Two marks-Manufacturing Technology-I University Questions and Answers Unit I 1 State any four types of patterns.

Ans: The various types of patterns which are commonly used are as follows: Single piece or solid pattern 2) 3) 4) 5) Two piece or split pattern Loose piece pattern Cope and drag pattern Gated pattern

1)

2 Mention any two advantages and disadvantages of die casting. Ans: Advantages: It is a very fast process. Moulds have longer life. Better surface can be obtained. Limitations: Moulds are much costlier. This method is not suitable for small quantity production. Shape and weight of the casting is limited. 3. What function of core ? Ans: Functions of core are: Core provides a means of forming the main internal cavity for hollow casting. Core provides external undercut feature Cores can be inserted to obtain deep recesses in the casting. Cores can be used to increase the strength of the mould.

4 What are the advantages and applications of ceramic moulds? Ans: Advantages: It is less expensive Intricate objects can be casted. Castings of thin sections and which do not require machining can be produced. Applications: It is mainly used for all material using better ingredient in slurry.

5. Ans:

What are the pattern materials? (Dec. 2008) 1) Wood

2) Metal 3) Plastic 4) Plaster 5) Wax 6. Explain the term fettling. Ans: Fettling is the name given to cover all those operations which help the casting to give a good appearance. It includes the removal of cores, sand, gates, risers, runners and other unwanted projections from the casting.

7 What is the purpose of flux? Ans: 1) It acts as shield to weld. 2) To prevent atmospheric reaction of molten metal with atmosphere.

8) How can slag inclusions in welding be avoided? Ans: Avoid multi layer welding Reduce arc length Increase electrode angle Avoid using large electrode

9) Why is flux coated on filler rods? Ans: The coating improves penetration and surface finish. Suitable coating will improve metal deposition rates. 10) What is the application of carburizing flame? Ans: Carburizing flame is generally used for: 1.steel rods 2. Welding of low alloy 3. Non-ferrous metals 4. High carbon steel

11) What are the diameter and length of the electrodes available in the market? (Dec. 2009) Ans: Standard length of electrodes are 250 mm, 300 mm and 450 mm. Standard diameters of electrodes are 1.6,2 ,2.5, 3.2, 4,5,6,7,8, and 9 mm.

12) List the various alloys and metal used in pattern. Ans: The various metals and alloys employed for making patterns ate : (a) Aluminium and its alloys (b) Steel (c) Brass (d) Cast iron (e) White metal 13 List the three forms of contraction. Ans: Contraction takes place in three forms (1) Liquid contraction (2) Solidifying contraction (3) Solid contraction 14 Shrinkage of metal depends on what factors ? Ans: The shrinkage of metal depends on the following factors : (1) The metal to be cast (2) Pouring temperature of the molten metal (3) Dimensions of the casting (4) Method of moulding 15 Define permeability. Ans : The sand must be porous to allow the gases and steam generated within the moulds to be removed freely. This property of sand is known as permeability or porosity. 16 Explain the principle of oxy-actelyene welding. Ans: When acetylene, in correct proportion, is mixed with oxygen in a welding torch and ignited, then the flame resulting at the tip of the torch is sufficiently hot to melt and join the parent metals. 17. 1 Name the steps involved in making a casting. Ans: Steps involved in making a casting are (1) Pattern making (2) Sand mixing and preparation (3) Core making (4) Melting (5) Pouring (6) Finishing (7) Testing

(8) Heat treatment (9) Re-testing 18 Why is a pattern larger than casting ? Ans: A pattern is slightly larger than the casting because a pattern carries allowance compensate for metal shrinkage. 19)What are the factors affecting resistance welding? Ans: Four factors are involved in operation of resistance welding: 1 Amount of current passing through the workpiece. 2The pressure that electrodes transfer to the workpiece. 3. Time during which current flows. 4 Area of electrde tip in contact with the workpiece.
20)Sand casting is which of the following types: (a) expendable mold or (b) permanent mold? Write in short about gas welding Name the types of flames Name the types of flames What do you mean by filler metal Answer. (a).
21). What can you state about temperature and pressure during the sand casting process? Temperature is high (melting temperature) and pressure is low (gravity). 22). What is the advantage of slow cooling over fast cooling? Slow, uniform cooling allows the liquid metal to reach every corner of the mould, therefore preventing the forming of micro porosities.

5 Marks

1)Question (a) What are the cast irons? (b) What is their basic range of composition? (c) What are some of the properties of cast irons that make them important engineering materials? (d) What are some of their application? (e) What are the four basic types of cast irons? Answer (a) Cast irons are a family of ferrous alloys intended to be cast into a desired shape rather than worked in the solid state. (b) These alloys typically contain 2 to 4 percent C and 1 to 3 percent Si. Additional alloying elements may also be present to control or vary specific properties. c) Cast irons are easily melted and highly fluid and do not form undesirable surface films or shrink excessively; consequently, they make excellent casting irons. They also possess a wide range of strength and hardness values and can be alloyed to produce superior wear, abrasion, and wear resistance. In general, they are easy to machine. (d) Their applications include engine cylinder blocks and gear boxes, connecting rods, valve and pump casings, gears, rollers, and pinions. (e) The four basic types of cast irons are white, gray, ductile and malleable.
2) Can a chaplet also act as a chill? Explain. While, in theory, a chaplet can serve as a chill, in practice chaplets rarely do so. Chaplets are intended to support a core or a section of mold. If they are placed in a position to support the core, they may not be in a location that requires a chill. Chaplets have a large footprint, and this helps to transfer heat to the core. However, heat transfer to the core is not an option for

faster cooling of the casting; heat instead must be conducted outside of the mold. Therefore, the chaplet cannot usually be considered a chill.

3). Molten metal can be poured into the pouring cup of a sand mold at a steady rate of 1000 cm3/s. The molten metal overflows the pouring cup and flows into the down sprue. The cross-section of the sprue is round, with a diameter at the top = 3.4 cm. If the sprue is 25 cm long, determine the proper diameter at its base so as to maintain the same volume flow rate. Solution: Velocity at base v = (2gh)
0.5

= (2 x 981 x 25)
0.5

= 221.5 cm/s Assuming volumetric continuity, area at base A = (1000 cm 3 /s)/(221.5 cm/s) = 4.51 cm
2

Area of sprue A = D
2

/4; rearranging, D
2

= 4A/ = 4(4.51)/ = 5.74 cm

2

D = 2.39 cm 4) Explain the advantages and limitations of sharp and rounded fillets, respectively, in casting design. Sharp corners and fillets should be avoided in casting design because of their tendency to cause cracking and tearing of the casting during solidification. Fillet radii should be large enough to avoid stress concentrations and yet small enough to avoid a low rate of cooling and hot spots that can cause shrinkage cavities in the casting. 5) Explosion welding & Braze welding 6) What is weld decay? How is this prevented? Ans : http://www.corrosionclinic.com/types_of_corrosion/weld_decay_weldment_corrosion.htm 7) What is Arc blow? How is this prevented? 8) Advantages and limitations of plasma arc cutting 9) State the Influence of elements on the weldability of carbon steels 10) What are Steps involved in Making Sand Castings

There are six basic steps in making sand castings: 1. Patternmaking 2. Core making 3. Molding 4. Melting and pouring 5. Cleaning Pattern making The pattern is a physical model of the casting used to make the mold. The mold is made by packing some readily formed aggregate material, such as molding sand, around the pattern. When the pattern is withdrawn, its imprint provides the mold cavity, which is ultimately filled

with metal to become the casting. If the casting is to be hollow, as in the case of pipe fittings, additional patterns, referred to as cores, are used to form these cavities. Core making Cores are forms, usually made of sand, which are placed into a mold cavity to form the interior surfaces of castings. Thus the void space between the core and mold-cavity surface is what eventually becomes the casting. Molding Molding consists of all operations necessary to prepare a mold for receiving molten metal. Molding usually involves placing a molding aggregate around a pattern held with a supporting frame, withdrawing the pattern to leave the mold cavity, setting the cores in the mold cavity and finishing and closing the mold. Melting and Pouring The preparation of molten metal for casting is referred to simply as melting. Melting is usually done in a specifically designated area of the foundry, and the molten metal is transferred to the pouring area where the molds are filled. Cleaning Cleaning refers to all operations necessary to the removal of sand, scale, and excess metal from the casting. Burned-on sand and scale are removed to improved the surface appearance of the casting. Excess metal, in the form of fins, wires, parting line fins, and gates, is removed. Inspection of the casting for defects and general quality is performed.
10 Marks: 1. Explain Metal Defects due to Pouring 2. Explain Solidification shrinkage , Directional solidification, Nucleation and growth 3. Explain Welding Joints and Types 4. Describe FIVE welding Defects 5. The total solidification times of three casting shapes are to be compared: (1) a sphere, (2) a cylinder, in which the length-to-diameter ratio = 1.0, and (3) a cube. For all three geometries, the volume = 1000 cm3. The same casting alloy is used in the three cases. (a) Determine the relative solidification times for each geometry. (b) Based on the results of part (a), which geometric element would make the best riser? (c) If the mold constant = 3.5 min/cm2in Chvorinov's Rule, compute the total solidification time for each casting. Solution: For ease of computation, make the substitution 10 cm = 1 decimeter (1 dm). Thus 1000 cm
3

= 1.0 dm
3

. (1) Sphere volume V = D

3

/6 = 1.0 dm
3

.D
3

= 6/ = 1.910 dm
3

. D = (1.910)

0.333

= 1.241 dm Sphere area A = D

2

= (1.241)
2

= 4.836 dm
2

V/A = 1.0/4.836 = 0.2067 dm Chvorinovs Rule TTS = (0.2067)

2

Cm = 0.0428Cm (2) Cylinder volume V = D

2

H/4 = D
3

/4 = 1.0 dm
3

.D
3

= 4/ = 1.273 dm
3

Therefore, D = H = (1.273)
0.333

= 1.084 dm Cylinder area A = 2D

2

/4 + DL = 2(1.084)
2

/4 + (1.084)(1.084) = 5.536 dm
2

V/A = 1.0/5.536 = 0.1806 dm Chvorinovs Rule TTS = (0.1806)

2

Cm = 0.0326Cm (3) Cube: V = L

3

=1.0 dm
3

. L = 1.0 dm Cube area = 6L

2

= 6(1)
2

= 6.0 dm
2

V/A = 1.0/6.0 = 0.1667 dm Chvorinovs Rule TTS = (0.1667)

2

Cm = 0.02778Cm (b) Sphere would be the best riser, since V/A ratio is greatest. (c) Given that Cm = 3.5 min/cm
2

= 350 min/dm
3

Sphere: TTS = 0.0428(350) = 14.98 min Cylinder: TTS = 0.0326(350) = 11.41 min Cube: TTS = 0.02778(350) = 9.72 min 6 A cylindrical riser is to be designed for a sand casting mold. The length of the cylinder is to be 1.25

times its diameter. The casting is a square plate, each side = 10 in and thickness = 0.75 inch. If the metal is cast iron, and the mold constant = 16.0 min/in2in Chvorinov's Rule, determine the dimensions of the riser so that it will take 30% longer for the riser to solidify. Solution: Casting volume V = tL
2

= 0.75(10.0)
2

= 75 in
3

Casting area A = 2L
2

+ 4Lt = 2(10.0)
2

+ 4(10.0)(0.75) = 230.0 in
2

V/A = 75/230 = 0.3261 Casting TTS = 16(0.3261)

2

= 1.70 min Riser TTS = 1.30(1.70) = 2.21 min Riser volume V = D

2

H/4 = 0.25D
2

(1.25D) = 0.3125D
3

Riser area A = 2D
2

/4 + DH = 0.5D
2

+ 1.25D
2

= 1.75D
2

V/A = 0.3125D
3

/1.75D
2

= 0.1786D Riser TTS = 16.0(0.1786D)

2

= 16.0(0.03189)D
2

= 0.5102D
2

= 2.21 min D
2

= 2.21/0.5102 = 4.3316 D = (4.3316)

0.5

= 2.081 in H = 1.25(2.081) = 2.602 in