VIVA - VOCE

Q.l. What is pattern and mould?

Ans. A pattern may be defined as a replica or facsimile model the desired casting which
when packed or embedded in a suitable moulding material, produces a cavity called mould.
Q.2. In what way pattern differs from an actual component?
Ans. Pattern differs from an actual component by the following iy-
(a) Pattern carries an additional allowances to compensate for metal shrinkage.
(b) It provides with additional allowances over those portions which are to be machined.
(c) It provides with additional projections such as coreprint, so that it produce seats for
cores.
Q.3. On which factors the selection of pattern material depends?
Ans. Selection of material for pattern is done by taking into consideration the following
factors.
(a) Number of castings
(b) Procedure of moulding i.e. by hand or by machine
(c) Casting method types
(d) Quality of surface finish and degree of accuracy.
Q.4. What is draft allowance?
Ans. Patterns are provided with slight taper on all vertical faces, i.e. the surfaces parallel to
the direction of their withdrawal m the mould, this taper is known as draft or draft
allowances.
Q.5. Which type of pattern will you prefer for the casting of handles, cylinder steam
valve bodies?
Ans. Split pattern.
Q.6. What is the use of follow board?
Ans. A follow board is a wooden board used to support the fragile pattern. It acts as a seat
for the pattern.
Q.7. For what purpose the colours such as Red, Black, Yellow etc. are coated on the
pattern?
Ans. For the identification of some important parts, colours are coated on the pattern, such
as
Red - for machining.
Black - for unmachined surface.
Yellow - for core prints.
 Yellow base and red stripes on it - seats for loose pieces.
Yellow base and black stripes on it - slop off.
No colour - for parting surface.
Q.8. Which pattern will you prefer for the small casting with mass production?
Ans. Gated patterns are used in mass production of small castings.
Q.9. What is the function of shellac or pattern varnish?
Ans. The main function of shellac on pattern is to protect it against atmospheric moisture
and wet moulding sand.
Q.10. What is fillet and state its function?
Ans. A fillet is a concave connecting surface for the rounding out of a corner at two
intersecting planes.
Q.ll. What is core?
Ans. Cores are seperated shapes of sand that are generally required to form the hollow
interior of the casting or a hole through the casting.
Q.12. What is coreprint?
Ans. The core has to be properly seated in the mould on formed impressions in the sand. To
form these impressions, extra projections are added on the pattern surface at proper places.
These projections are known as core prints.
Q.13. If core sand contains more than 5% clay, what happens?
Ans. As excessive clay reduces not only permeability but also collapsibility but also
collapsibility and thus sand containing more than 5% clay cannot be used as core sand.
Q.14. State some commercial core binders.
Ans. Commercially used core binders are thermoplasting binders such as resin and pitch,
thermosetting resin binders such as phenol, urea and furan. They are mainly consisting of oils,
cereals, dextrin, resins, sulphate liquor, molasses and protein.
Q.15. What is the function of parting sand?
Ans. Parting sand avoids the sticking of drag with cope which is rammed above the drag
and over the pattern it avoids sticking with the green sand and makes the withdrawal of
patterns from mould easier.
Q.16. What do you mean by kiss core?
Ans. When core print is absent and consequently no seat is available for the core, the core
is held in position between the cope and the drag simply by the pressure of the cope. This core
is referred to as a kiss core.
 Q.17. What do you mean by ram up core?
Ans. Sometimes it is necessary to set a core with the pattern before the mould is rammed
up, such a core is called ram up core.
Q.18. Why a core is baked before setting it in a mould?
Ans. After baking, cores can withstand the high pressures and temperatures of molten
metal. The main reasons for baking of core is as follows:
(a) Moisture evaporates.
(b) Oxidation of the organic substances which surrounds the grains of core sand.
(c) Improves strength of core.
Q.19. What do you mean by refractoriness?
Ans. Refractoriness is the property of moulding sand which enables it to withstand high
temperature of the molten metal without fusing and thus getting a clean casting.
Q.20. What are the main constituents of moulding sand?
Ans. The main constituents of good moulding sand are (a) Silica ( Si02) (b) Alumina (A1203)
(c) Iron oxide (Fe203) and some alkaline compounds.
Q.21. What is the function of binders in moulding sand?
Ans. The function of binder is to impart sufficient strength and cohesiveness so as to
enable it to retain its shape after the mould has been rammed and the pattern withdrawn.
Q.22. Define Permeability number.
Ans. Permeability number may be defined as the volume of air in cubic centimeter that
will pass through a sand sample of 1 sq.cm cross section and 1 cm high in size in 1 minute at a
pressure of 1 gm per cm 2 .
Q.23. What is sprue pin?
Ans. The passage for pouring molten metal is made by using a tapered pin called sprue
pin.
Q.24. Which sand mould is stronger: Dry sand mould or green sand mould?
Ans. In case of dry sand mould, special binding materials such as resin, clay or molasses
are added to given strong bond to the sand and moulds are baked on oven and hence dry sand
mould is stronger.
Q.25. What is gate and riser?
Ans. Gate is the small passage connecting the runner to the mould cavity.
Riser is the passage through which the molten metal rises up after filling the mould
cavity, thus it ensured that the mould has been completely filled.
Q.26. What is the function of strike off bar?
 Ans. The strike off bar is a piece of metal or wood with a straight edge. It is used to strike
off excess sand from the mould after ramming to provide a level surface.
Q.27. What do you mean by Gating system?
Ans. The Gating system means all the passages through which the molten metal enters
the mould cavity i.e. it includes the pouring basin, runner, gate and riser etc.
Q.28. What is padding?
Ans. Padding means adding of extra metal to the original section of the casting in varying
thickness to achieve the desired directional solidification.
Q.29. What do you mean by gating ratio?
Ans. The term gating ratio is used to describe the relative cross-sectional areas of the
components of a gating system.
Q.30. What are chaplets and what is its function?
Ans. Chaplets are metal spacers and they are used for supporting large and odd shaped
cores which cannot be adequately supported by their own core prints.
Q.31. State some advantages of part line gating over top gating system.
Ans. Advantages: (a) They require less time for it to construct and less skill.
(b) Parting line gates can be improved to reduce turbulence in the molten metal.
(c) Directional solidification can be achieved.
(d) Parting line gates produces very satisfactory results when drag is not very deep.
Q.32. What is Arbors and state its function?
Ans. Arbors is a skeleton structure of iron or steel which is placed in the core box and
sand rammed around it to form the complete core. It is used for extremely large cores in which
the reinforcement provided through rods or wires is also likely to fail.
Q.33. On which factors the furnace type decided?
Ans. The choice of a particular type of the furnace depends upon following factors:
(a) Quantity of metal required to be melted i.e. rate of melting desired.
(b) Required temperature range.
(c) Type of metal to be melted.
(d) Capability of melting medium for absorbing foreign particles such as dust, impurities.
Q.34. What do you mean by bed charge?
Ans. Usually soft and dry pieces of wood is first placed over the sand bed followed by
small amount of coke charge, known as bed charge.
Q.35. Define thermal efficiency of cupola.
Ans. Thermal efficiency of cupola is defined as the ratio of heat actually utilised in
melting and superheating the metal to the heat evolved in it through various means.
 Q.36. What do you mean by capacity of a furnace?
Ans. Capacity of a furnace means the output of a furnace, as the tonnes of molten metal
obtained per hour of heat.
Q.37. Generally which type of furnace is used for non- ferrous metals.
Ans. Generally, for non ferrous metals, crucible furnaces (pit type and tilting type) and
metal pot furnances are mainly used.
Q.38. What do you mean by jamming of cupola?
Ans. The molten metal should be tapped out well before its level rises too high in the
well. If this is not done, the slag, which floats on the surface of the molten metal will start
flowing into the well belt through the tuyeres and thus the air passage will be choked, this
phenomenon leads to the jamming of cupola.
Q.39. What is stack?
Ans. Above the preheating zone, there is a empty portion, which provides the passage to
hot gases to the atmosphere, is known as stack.
Q.40. What is cupolettes?
Ans. Small cupolas (500 kg to 1000 kg capacity) are known as cupolettes.
Q.41. How cupola is specified?
Ans. Cupola specification:
Approx. Specifications
melting Shell Shell Plate Total Numb H.P.
capacity dia. dia. thick- height er of
(in without with ' ness blow
metric lining lining (cm) (cm) of
tons) (cm) (cm) tuyeres er

Q.42. What is blow holes?

Ans. These are entrapped bubbles of gases with smooth walls in the form of cluster of a
large number of small holes below the surface of a casting.
Q.43. What is the possible causes of blow holes? Ans. Possible causes of
blow holes:
(a) Cores are not properly baked.
(b) Excessive moisture in moulding sand.
(c) Inadequately vented.
(d) Excessive use of organic binders.
(e)
Q.44. What is inclusion?
 Ans. If any non-metallic foreign material is present in the cast metal, then it is called an
inclusion.
Q.45. What are the remedies over hot tears or hot cracks? Ans. Remedies: (a) Core
collapsibility and mould collapsibility should be improved,
(b) Provide softer ramming and
(c) Design should be modified.
Q.46. What do you mean by warpage?
Ans. Warpage is unintentional and undesirable deformation in a casting that occurs
during or after solidification.
Q.47. What is the necessity of heat treatment of casting?
Ans. To relieve the internal stresses set up in castings during solidification and to refine
the structure, heat treatment is necessary.
Q.48. State the types of inspection of casting generally used.
Ans. Types of Inspection:
(a) Destructive testing methods.
(b) Non-destructive testing methods.

Q.49. What is the causes of misrun and cold shuts?

Ans. Causes of misrun and cold shuts:
(a) Faulty design
(b) Improper gating
(c) Lack of fluidity in molten metal.
Q.50. What are the remedies over shot metal? Ans. Remedies over shot metal:
1. Higher pouring temperature should be used.
2. Sulphur content should be reduced.
3. Gating system should be modified.
4. Moisture content should be reduced.
5.
Q.51. Which type of inspection method will you prefer for detecting defects such as
blow holes and cracks in a material?
Ans. X-ray radiography inspection method is used to detect blowholes and cracks.
Q.52. Why sprue is always made in tapered form?
Ans. In order to avoid aspiration of air and metal damage, the sprues are generally
tapered downwards.
Q.53. What do you mean by Foundary mechanization?
Ans. Foundary mechanization is defined as utilization of machinery for performing the
work previously done by hand.
 Q.54. Why gravity die casting is so named?
Ans. As the pouring of molten metal in permanent mould (die) is done simply due to
gravity, without any external pressure, it is called gravity die casting.
Q.55. What are the limitations of Investment casting process?
Ans Limitations: (a) It is limited by the size and mass of the casting, as upper limit on the
mass of casting is upto 5 kg.
(d) Expensive process as large manual labours are required for the preparation of the
pattern and the mould.
Q.56. What are chaplets and state its function?
• Ans. Chaplet is 'a metal location piece inserted in a mould either to prevent a core in shifting
its position or give extra support to a core.
Q.57. What is the purpose of rolling?
Ans. The purpose of rolling is to convert larger sections, such as ingots, into smaller
sections which can be used either directly in "as rolled" state or as stock for working through
other processes.
Q.58. What do you mean by plastic deformation?
Ans. When the metal is stretched or compressed beyond the elastic limit and the metal
will not regain its original shape when unloaded, the phenomenon is known as plastic
deformation.
Q.59. Define elongation coefficiency.
Ans. Elongation coefficiency is the ratio of the final length of the rolled strip to its initial
length.
Q.60. What do you mean by extrusion?
Ans. Extrusion consists of compressing a metal inside a chamber to force it out through a
small opening called die.
Q.61. What is strain hardening?
Ans. In case of cold working, recrystallisation does not take place, thus the grains are
permanently distorted. As a result of the greater resistance offered by the metal to
deformation, its strength and hardness are increased. This type of hardening of metal is known
as strain hardening.
Q.62. What is forging?
Ans. Forging is the squeezing of material between the two dies to alter its shape and size.
Q.63, What do you mean by drawing a metal?
 -\

Ans. Drawing involves pulling a metal through a die by means of tensile force applied to
the exit side of the die.
Q.64, What do you mean by draft in case of rolling?
Ans. Draft is the total reduction obtained of the workpiece during the rolling process.
OR It is the difference between the thickness of the workpiece before rolling and after
rolling.
Q.65. What is backward slip?
Ans. Backward slip is the relative difference between the initial velocity of work piece
entering the roll and the horizontal component of roll surface velocity.
Q.66. Define forward slip.
Ans. Forward slip is the relative difference between the final velocity of workpiece
leaving the roll and the roll surface velocity.
Q.67. What do you mean by jumping or upsetting in forging?
Ans. Jumping is the process through which the cross-section of a metal piece is increased
with a corresponding reduction in its length.
Q.68. What is drifting in forging?
Ans. Drifting is a process in which a tool known as drift is made to pass through the
punched hole to produce a finished hole of the desired size.

Q.69. Define blanking and piercing.

Ans. Blanking is the operation of cutting a flat sheet to the desired shape.
Piercing is the operation of production of hole in sheet metal.
Q.70. What is nibbling?
Ans. Nibbling is the operation in-which the complicated shapes are cut out from a sheet of
metal by producing overlapping notches.
Q.71. What do you mean by coining?
Ans, Coining is the operation used for production of coins, medals or other ornamental
parts by sequeezing operation.
Q.72. What are pressure pads?
Ans. The pressure pads are used in drawing operation which serves the cushioning
operation while cup is being found.
 Q.73, What is shunt height of a press?
Ans. It is the total opening between the ram and the bed when the former is in its extreme
position.
Q.74. Why the forged parts are generally heat treated?
Ans. For the following reasons the forged parts are heat treated:
(a) To relieve internal stresses.
(b) To improve machinability.
(c) To improve strength, hardness and other mechanical properties.
Q.75. Which material is used for forging dies?
Ans. Forging dies are constructed from high grade carbon or' alloy steel and must resist
heat, abrasion and pressure.
Q.76. What are the various defects in forging?
Ans. (a) Defects such a* dirt or slag, blow holes etc.
(b) Ingot defects such as pipings, scales, cracks, seams and segregation.
(c) Defects due to improper heating and cooling of the forging such as burnt metal,
decarburization and flakes.
(d) Faulty forging design.
Q.92. What is weld pressure and letter forge pressure, in resistance welding?
Ans. In case of resistance welding, the mechanical pressure is required to be applied at
two stages-first for holding the pieces tightly between the electrode called weld pressure and
secondly when the metal has been heated to plastic state, to forge the metal pieces together to
form the weld is known as forge pressure.
Q.93. What is off time?
Ans. After cooling of weld the electrode pressure is released, thus the time period
between this release of electrodes and start of next welding cycle is called off-time.

Q.94. Which materials are generally used as electrode materials?

Ans. The common refractory-metal alloys used as electrode materials are copper-tungsten
mixture, pure tungsten, pure molybdenum, etc.
Q.95. What is flux and what is its function?
Ans. Flux is a material required to prevent the formation of oxide, nitrides and other
undesirable materials in weld zone.
Q.96. Define "Duty cycle".
Ans. "Duty cycle" is defined as the "arcing time" expressed as percentage of the "total
time".
 Q.97. For welding of tubular and solid structural assemblies in automobile industry,
which type of welding will you prefer and why?
Ans. Resistance flash welding will be preferred for the welding in automobile industries.
Reasons: (a) A flash welding joint is stronger than butt welding.
(b) Lengths and alignment of work pieces is maintained to a high degree of accuracy.
(c) Current consumption is less.
Q.98. What do you mean by oxidizing flame?
Ans. An oxidizing flame is one in which there is an excess of oxygen.
Q.99. What do you mean by neutral flame?
Ans. When equal quantities of oxygen and acetylene are mixed then the flame which is
obtained is the neutral flame.
QC100. What is arc crater?
Ans. Arc crater is the depression caused by the penetration of electric arc into the parent
metal.
Q.101. For arc welding which will you prefer: ac or dc current supply?
Ans. AC supply received from the power mains at 400-440 volts, but the voltage required
for welding is much less and thus a step-down transformer is used. Also there is no fixed
polarity at the terminals when using ac and they interchange in every cycle and thus ac is not
preferred.
Q.102. What is straight polarity?
Ans. Straight polarity means electrode forms the negative terminal and the workpiece
positive.
Q.103. What is reverse polarity?
Ans. Reverse polarity means electrode form the positive terminal and the workpiece
negative.
Q.104. If a thin metal foil upto 0.125 mm thick is to be welded, which welding
process will you prefer?
Ans. Inert gas tungsten arc welding can be used.
Q.105.- To weld the structure of turbine shafts, or boiler parts with 25 mm
thickness, which welding process will you prefer?
Ans. Electro slag welding.
Q.106. For welding of railway rails / broken pieces of valves / pipes etc, which
welding process will you prefer?
Ans. Thermit welding.
Q.109. For metal cutting which will be more advantageous: LPG or acetylene?
 Ans. As the cost of LPG is very less as compared to acetylene, it is mostly used in the gas
cutting / gas welding in the industries.
Q.110. State the limitations of MIG.
Ans. Limitations:
(a) Net suitable for welding low melting point metals.
(b) Weld cleaning is required.
(c) Not suitable for this sheets.
Q.lll. State the application of friction welding.
Ans. It is used in aerospace industries and also in automobile industry.
Q.112. Define thermosetting plastics.
Ans. These are the plastics which are hardened by heat, effecting a non-reversible
chemical change.
Q.113. Define thermoplastics.
Ans. These are the plastics which can be softened again and again by heating.
Q.114. What is elastomers?
Ans. These are the polymers which can be considerably elongated by loading at
atmospheric temperature and spring back to its original shape and size after the removal of
load.
Q.115. What do you mean by plasticisers?
Ans. These are the chemicals added for either softening the resins at forming temperature
or to improve the toughness at the finished stage.
Q.116. What do you mean by calendering?
Ans. Calendering is the process used for making plastic films and sheets.
Q.117. For manufacturing of plastic bottles which type of moulding will you prefer?
Ans. Blow moulding is used for narrow neck containers such as bottles.
Q.118. For thermoplastics which type for moulding is used?
Ans. Generally injection moulding is commonly used for thermoplastics.
Q.119. What is fillers?
Ans. Fillers are the materials added to synthetic resins to dilute them in order to reduce
their consumption.
Q.120. What do you mean by lamination?
Ans. Lamination means variety of material bonded together by heat and pressure to form
a single piece.
 Q.121. State the applications of phenol form aldehyde (Bakelite).
Ans. Its uses includes handles, radio cabinets, plugs, knobs, dials bottle caps, pulley,
wheels, tooling and forming dies, telephone handsets etc.

Q.122. State some uses of polyesters.

Ans. Polyesters are used in carbodies, aircraft parts, sky lights and architectural sheets.
Q.123. State the uses of elastomers.
Ans. Elastomers are widely used for belts, steam hoses and inner tubes.
Q.124. Write the applications of cellulose acetate.
Ans. Cellulose acetate is used for coatings, photographic films, packaging, buttons, toilet
articles, toys and extruded sheets, tubes and rods etc.
Q.125. What is modifiers?
Ans. These are the chemicals added to plastics for changing the properties of base resin.
Q.126. What is the function of stabilisers?
Ans. They are used to prevent deterioration due to the action of heat and light.
Q.127. State the uses of vinyl resins.
Ans. Vinyl resins are used for rain coats, gaskets, electrical plugs, laminated safety glass,
bullet proof safety glass, abrasive resistant linings, fuel tanks and similar other items.
Q.128. Write down the applications of Nylon.
Ans. They are widely used as fibre for making yarn for cloth, bearings and couplings,
gears, wire insulation and combs.
Q.129. Which synthetic resin is used contact lenses?
Ans. Methyl methacrylate.
Q.130. For jigs and fixtures forming dies which thermoplastic is used.
Ans. Ethyl cellulose.