KARPAGAM COLLEGE OF ENGINEERING, COIMBATORE – 641 032

B.E / B.Tech Degree Semester: IV

07 ME 405 PRODUCTION PROCESSES
(Applicable to the students admitted from the Academic year 2007-2008 and onwards)

UNIT - I

1. Silica grains are sometimes coated with a non-thermosetting hydrocarbon resin, which
acts as a

(a) Binder
(b) Additives
(c) Water resistant
(d) Silica Sand Ans: a

2. The Moulding sand has the proper amount of water added to it to give a high strength
with sufficient plasticity, the sand is said to be a

(a) Temporary Sand

(b) Tempered Sand
(c) Loose sand
(d) Moulding sand Ans: b

3. Organic binders mainly used for

(a) Moulding sand making

(b) Mould cavity making
(c) Core making
(d) Both a &b Ans: c

4. Melting Point of a Kaolinite is

(a) 1650° C to 1687° C

(b) 1750° C to 1787° C
(c) 1570° C to 1877° C
(d) 1670° C to 1877° C Ans: b

5. Melting point of a Bentonite is

(a) 1350° C to 1400° C

(b) 1150° C to 1300° C
(c) 1250° C to 1300° C
(d) 1050° C to 1150° C Ans: c
6. Illite is formed from the

(a) Volcanic Rocks

(b) Metamorphic Rocks
(c) Sedimentary Rocks
(d) Mica Rocks Ans: d

7.
S1: The shape & size of the sand grains affected by the strength
S2: The shape & size of the sand grains affected by the Adhesiveness

Ans:
a) S1 is right
b) S2 is right
c) Both S1&S2 is right
d) Both S1&S2 is wrong Ans: d

8. Most commonly used clay is

(a) Fire clay

(b) Illite
(c) Bentonite
(d) Kaolinite Ans: c

9.
S1: The Shrinkage Allowance is the amount the pattern must be made larger than
casting
S2: Green sand is a mixture of silica sand ,clay &moisture.

Ans:
a) S1 is right
b) S2 is right
c) Both S1&S2 is right
d) Both S1&S2 is wrong Ans: c

10. Saw Dust increases

(a) Cohesiveness of the moulding sand

(b) Permeability of the moulding sand
(c) Refractoriness of the moulding sand
(d) Flow ability of the moulding sand Ans: b

11. Cereals are used to

(a) Increase the green and dry strength of moulding sand

(b) Decrease the dry strength of moulding sand
(c) Increase the Permeability of moulding sand
(d) Decrease the Permeability of moulding sand Ans: a
12. The layer of the facing sand ranges from

(a) 5 to 50 mm
(b) 15 to 50 mm
(c) 25 to 50 mm
(d) 35 to 50 mm Ans: c

13. Permeability refers to

(a) Avoid the air to flow through sand

(b) Permit the air to flow through sand
(c) Restrict the air flow through sand
(d) Minimum of air flow through sand Ans: b

14. In the Moisture content test the moist sand should be heated to

(a) 105° C to 130° C

(b) 105°C to 120° C
(c) 105° C to 110° C
(d) 105° C to 140° C Ans: c

15. In the Moisture teller the screen has

(a) 200 mesh

(b) 300 mesh
(c) 400 mesh
(d) 500 mesh Ans: d

16. The green strength of moulding sand ranges from

(a) 20 to 160 k Pa
(b) 30 to 160 k Pa
(c) 40 to 160 k Pa
(d) 50 to 160 k Pa Ans: b

17.
S1: A Pattern which is made with out any loose pieces is called as solid pattern
S2: A Pattern which is made with out any loose pieces is called as Gated pattern

Ans:
a) S1 is right
b) S2 is right
c) Both S1&S2 is right
d) Both S1&S2 is wrong Ans: b
18. Green shear strength of moulding sand ranges from

(a) 10 to 50 k Pa
(b) 10 to 60 k Pa
(c) 10 to 70 k Pa
(d) 10 to 80 k Pa Ans: a

19. In the Strength test the test Specimen

(a) ∅5.08cm x 5.00cm long

(b) ∅5.08cm x 5.04cm long
(c) ∅5.00cm x 5.08cm long
(d) ∅5.08cm x 5.08cm long Ans: d

20. Permeability number is given by

(a) P= V*A / h*ρ*t

(b) P= V*t / h* ρ *A
(c) P= V*h / ρ *A*t
(d) P= V*h* ρ / A*t Ans: c

21. GFN refers to

(a) Grain fitness Number

(b) Grain filter Number
(c) Grain fineness Number
(d) Grain finish Number Ans: c

22. Silica content in a moulding sand ranges from

(a) 60 to 70%
(b) 68 to 86%
(c) 45 to 65 %
(d) 70 to 80% Ans: b

23. In the Hardness test, dial indicator has a spring loaded steel ball of size

(a) 5 mm
(b) 15mm
(b) 25mm
(c) 35mm Ans: a

24. In moisture content test, specimen sand is heated for

(a) 3 hours
(b) 1 hour
(c) 2 hours
(d) 4 hours Ans: c
25. Clay content in Loam sand mould is

(a) 10%
(b) 50%
(c) 20%
(d) 60% Ans: b

26. Dry sand mould are heated to

(a) 110 to 260 ° C

(b) 210 to 260 ° C
(c) 110 to 360 ° C
(d) 220 to 260 ° C Ans: a

27.
S1: The moulding sand mixture is made of sand, binders& additives
S2: Base sand in their natural form does not have bonding strength

Ans:

a) S1 is right
b) S2 is right
c) Both S1&S2 is right
d) Both S1&S2 is wrong Ans: c

28.
S1: CO2 Gas is used together with sodium silicate as a binder.
S2: Mixing of excess amount of water to sand mixture causes to increase the
strength

a) S1 is right
b) S2 is right
c) Both S1&S2 is right
d) Both S1&S2 is wrong Ans: a

29. What is the frequency used in Di-electric core making

(a) 5 MHz
(b) 15 MHz
(c) 25 MHz
(d) 35 MHz Ans: b

30. Low melting point metal is

(a) Aluminium
(b) Sodium
(c) Polyvinyl chloride
(d) Polyethylene Ans: a
31. Water glass is known as

(a) Sodium Styrate

(b) Sodium Chloride
(c) Sodium Silicate
(d) Sodium Nitrate Ans: c

32. In resin bonded sand moulds, sand is mixed with

(a) Linseed Oil

(b) Kerosene
(c) Sodium Silicate
(d) Bentonite Ans: a

33. Dry and core moulds are baked at

(a) 200 to 250° C

(b) 175 to 230° C
(c) 250 to 300 ° C
(d) 300 to 350 ° C Ans: b

34. Core prints are used to

(a) Locate core seats in the mould

(b) Manufacture a core
(c) Locate the core in mould
(d) Finish the core Ans: a

35. Sprue is used to connect

(a) Gate with runners

(b) Mould and pouring basin
(c) Pouring basin with runners and gates
(d) Cope and drag boxes Ans: c

36. Risers are used

(a) To connect pouring basin with gates

(b) Reservoirs of molten metal
(c) To prevent shrinkage cavities
(d) Both (b) and (c) Ans: d

37. The flasks between the cope and drag flasks are referred to as

(a) Soldiers
(b) Cheeks
(c) Bars
(d) Gaggers Ans: b
38. In squeeze moulding machines, pressure of the compressed air ranges from

(a) 5 to 7 atm
(b) 6 to 7 atm
(c) 8 to 9 atm
(d) 9 to 10 atm Ans: a

39. Jolt machines operates at about

(a) 400 strokes / min.

(b) 300 strokes / min.
(c) 200 strokes / min.
(d) 600 strokes / min. Ans: c

40. For short run production, the pattern used is

(a) Brass
(b) White metal
(c) Aluminium
(d) Wood Ans: d

41. For batch production, the pattern used is

(a) Brass
(b) Plastics
(c) Aluminium
(d) Wood Ans: b

42. For mass production, the pattern used is

(a) Wood
(b) Epoxy resins
(c) Aluminium
(d) Gypsum Ans: c

43. Most commonly used wood for pattern making is

(a) White pine

(b) Mahogany
(c) Maple
(d) Deodar Ans: a

44. In the Loose piece pattern, one piece pattern has Projections or Back drafts which lie
above or below the parting plane

a) Because it is impossible to with draw it from facing sand

b) Because it is impossible to with draw it from casting
 c) Because it is impossible to with draw it from green sand
d) Because it is impossible to with draw it from mould Ans: d

45. Most commonly used metal for making pattern is

(a) Brass
(b) Aluminium
(c) White metal
(d) Cast iron Ans: a

46. Most commonly used Plastic material for pattern making is

(a) Polyethylene
(b) Polyvinylchloride
(c) Polyacrylates
(d) Epoxy resins Ans: d

47. The Cores are subjected to much more severe thermal and mechanical effects than
the mould ___________

a) Because they are surrounded on all sides by sand

b) Because they are surrounded on all sides by molten metal
c) Because they are surrounded on all sides by loam sand
d) Because they are surrounded on all sides by green sand Ans: b

48. Patterns are coated with

(a) Polyethylene
(b) Mineral Oil
(c) Linseed oil
(d) Shellac Ans: d

49. Shrinkage allowance for cast iron pattern is

(a) 10 mm/m
(b) 5 mm/m
(c) 15 mm/m
(d) 20 mm/m Ans: a

50. Match the following

a) Deformation process ------ (i) Injection Moulding

b) Machining Process ------ (ii) Brazing
c) Plastic Materials ------ (iii) Turning
d) Joining Processes ------ (iv) Forging

Ans:
a) a-i , b-ii , c- iii , d- iv
 b) a-ii , b-iii , c- iv , d- i
c) a-iii , b-ii , c- i , d- iv
d) a-iv , b-iii , c- i , d- ii Ans: d

51. Manufacturing Process Minimum Size of pattern

a) Sand Casting - (i) 2.5 mm

b) Shell Mould casting - (ii) 0.75 mm
c) Permanent Casting - (iii) 3 mm
d) Plaster Mould casting - (iv) 1.5 mm
Ans:
a) a-i , b-ii , c- iii , d- iv
b) a-ii , b-iii , c- iv , d- i
c) a-iii , b-iv , c- i , d- ii
d) a-iv , b-i , c- ii , d- iii Ans: c

52. Binders Composition

a) Kaolinite - (i) MgO.Al2o3.SiO2. H2o

b) Bentonite - (ii) Al2o3. 2SiO2.2H2o
c) Illite - (iii) Alumina. Al2o3
d) Clay - (iv).K2O. Al2.O3.SiO2. H2o

Ans:
d) a-iii , b-iv , c- i , d- ii
e) a-iv , b-i, c- iii , d- ii
f) a-i , b-ii , c- iii , d- iv
d) a-ii , b-i , c- iv, d- iii Ans: d

53. Shrinkage allowance for Aluminium pattern is

(a) 10 mm/m
(b) 5 mm/m
(c) 15 mm/m
(d) 20 mm/m Ans: a

54. Moulding Sand Strength Ranges

a) Green Strength - (i) 700 Kpa

b) Dry Strength - (ii) 10 to 50 Kpa
c) Green Shear Strength - (iii) 140 to 1800 Kpa
d) Core Blowing - (iv) 30 to 160 Kpa

Ans:
a) a-iii , b-iv , c- ii , d- i
b) a-ii , b-i, c- iv, d- iii
 c) a-iv , b-iii , c- ii , d- i
d) a-i , b-iii , c- iv, d- ii Ans: c

55. Shrinkage allowance for Lead pattern is

(a) 10 mm/m
(b) 5 mm/m
(c) 20 mm/m
(d) 25 mm/m Ans: d

56. Parting Sand is used on parting surfaces of cope and drag __________

a) Because it increases Adhesiveness

b) Because it Improves Refractoriness
c) Because it Improves Porosity
d) Because it avoids Clinging Ans: d

57. Draft Allowances Provided on a Pattern ___________

a) Because it allows for distortion

b) Because it Compensates for Shrinkage
c) Because it enables easy withdrawal of pattern
d) Because it allows material for subsequent machining operation. Ans: c

58. Sodium Silicate is mixed with silica sand mixture and made to react with CO2

a) Because it increases in Viscosity

b) Because it increases in Adhesiveness
c) Because it increases in Refractoriness
d) Because it increases in Cohesiveness Ans: a

59. The common draft allowance is

(a) 2° to 3°
(b) 3° to 4°
(c) 4° to 7°
(d) 1° to 3° Ans: d

60. Molasses as an additive to moulding sand improves

(a) Dry strength of the sand

(b) Collapsibility
(c) Cohesiveness
(d) Both (a) and (b) Ans: d
(P.Lakshmana Kumar) (Dr.S.Charles)
Staff in-charge Professor & Head