Manufacturing and Production Systems

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Available Questions: 26

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Topic: Fundamentals of Casting
Questions: 25

Q1. Select the pattern feature that permits easy withdrawal of a wooden pattern from a sand mould having vertical surfaces. State its purpose.

Q2. A cast component requires a cylindrical hole completely through its body. Select the mould element required to produce this internal passage.

Q3. During sand casting, gases generated inside the mould must escape through the moulding material. Select the mould property that supports this requirement.

Q4. Molten metal enters a sand mould at a high temperature. Identify the mould property that enables the mould to withstand contact with molten metal without excessive deterioration.

Q5. A pattern is compacted with moulding sand and then removed before pouring. State the feature that remains in the sand after pattern removal.

Q6. A rectangular casting has a uniform cross-section and no internal cavity. Select a suitable basic arrangement for separating the mould so that the pattern can be removed conveniently.

Q7. A casting has a volume of 250 cm3 and the molten metal density is 7.8 g/cm3. Calculate the mass of the casting.

Q8. A casting requires 3.6 kg of metal. The metal density is 7.2 g/cm3. Determine the required casting volume.

Q9. A mould cavity has a volume of 1800 cm3 and molten metal enters it at an average volumetric flow rate of 300 cm3/s. Calculate the ideal filling time.

Q10. Arrange the following operations in their logical sand-casting sequence: 1. Pour molten metal, 2. Prepare mould, 3. Remove casting, 4. Solidification, 5. Prepare or select pattern.

Q11. A pattern contains a vertical wall that is perpendicular to the moulding-board surface. Apply the principle of draft to this feature and explain the consequence of providing insufficient draft.

Q12. A cast housing requires an internal cavity that cannot be formed by the external surface of the pattern alone. Illustrate the roles of the pattern, mould cavity and core in producing this component.

Q13. A foundry observes that gases remain trapped in a sand mould during pouring. Select the relevant mould property and recommend a suitable improvement in mould preparation.

Q14. A simple stepped component is to be produced using sand casting. Determine the principle for selecting the pattern orientation and parting plane so that pattern removal is facilitated.

Q15. A mould cavity volume is 2400 cm3. The available pouring system supplies metal at an average rate of 400 cm3/s. Determine the theoretical filling time and state one practical consideration that may make actual filling different.

Q16. A casting requires a metal volume of 750 cm3. The metal density is 7.6 g/cm3. Calculate the casting mass and express the result in kilograms.

Q17. A sand mould is required for a component having both external surfaces and an internal passage. Develop a basic mould arrangement identifying the functions of the mould cavity and core.

Q18. A small cast component has a simple external shape and does not require an internal cavity. Recommend the basic mould arrangement and justify the selection.

Q19. A mould cavity requires 4.5 kg of molten metal for the casting. The metal density is 7.5 g/cm3. Determine the corresponding casting volume.

Q20. A steel component consists of an external rectangular body and a circular internal passage. Develop the sequence for producing the component by basic sand casting, beginning with pattern preparation and ending with casting removal. Explain the role of the pattern, mould and core at the appropriate stages.

Q21. A cast bracket contains two external steps and one internal cylindrical hole. Design a basic pattern-and-core arrangement for producing this geometry by sand casting. Explain the function of each major element.

Q22. A sand mould produces a rectangular casting of dimensions 300 mm x 150 mm x 40 mm. The metal density is 7.8 g/cm3. The mould is filled at an average rate of 600 cm3/s. Calculate the casting volume, casting mass and theoretical filling time.

Q23. A casting has a vertical external wall, a deep internal cavity and a geometry that could be damaged during pattern withdrawal. Develop a basic moulding strategy using pattern features, mould arrangement and a core. Explain the engineering purpose of each selected feature.

Q24. A sand-cast component has a volume of 1250 cm3. The molten metal density is 7.8 g/cm3. The available pouring rate is 500 cm3/s. Calculate the casting mass and theoretical mould-filling time, then recommend two mould-preparation considerations before pouring.

Q25. Define permeability of moulding sand and state its significance in sand casting.