Moulding and Pattern Notes

Which of the following pattern is used to produce a number of castings?
a. loose piece pattern b. split pattern c. gatted

pattern d. match plate pattern
(Ans:c)
The pattern used for mass production is
a. match plate pattern b. split pattern c. skeleton

pattern d. single plate pattern
(Ans:a)
The typical shrinkage allowances for casting materials in mm/metre is as follows.
1. Grey cast iron 1. 10.5 to 21

2. Aluminium 2. 7 to 10.5
3. Bronze 3. 14
4. Brass 4. 18
The correct match is
a. 1-2, 2-4, 3-1, 1-3 b. 1-3, 2-4, 3-1, 4-2
c. 1-4, 2-2, 3-1, 4-3 d. 1-1, 2-4, 3-2, 4-3
(Ans:a)
In casting, the amount of draft (in mm per metre) on exterior surfaces is about
a. 10-20 b. 20-30 c. 30-40 d. 40-50
(Ans:a)
The amount of draft required does not depends upon
a. shape and size of casting b. moulding method c. material of

pattern d. method of production
(Ans:c)
Distortion allowance is not provided in the following shape of casting.
a. U b. T c. C d. O
(Ans:d)
The distortion in casting can not be prevented by
a. modification of casting design
b. providing distortion allowance

c. providing sufficient machining allowance to cover the distortion effect
d. providing proper shrinkage allowance
(Ans:d)
The machining allowance provided to ferrous castings for making small and
average sized casting is
a. 1.5mm b. 3mm c. 4.5mm d. 6mm
(Ans:b)
During sand conditioning, the items added and their qualities are given
1. Silica 1. Helps in cooling the mould

2. Coal dust 2. Increase adhesiveness
3. Clay 3. Withstand high temperature
4. Water 4. Impart necessary bond to the moulding sand
The correct matching is
a. 1-2, 2-3, 3-1, 4-4 b. 1-3, 2-1, 3-2, 4-4 c. 1-3, 2-1, 3-4, 4-
2 d. 1-2, 2-1, 3-3, 4-4
(Ans:c)
The low permeability in sand can cause which of the following defects in casting
a. Rough surface b. Blow holes c. hot tears d. Drop
(Ans:b)
Pages: 1 2 3 4 5 6
Which of the following is not a type of core according to their position?
a. Horizontal b. Vertical c. Inclined d. Balanced
(Ans:c)
Which of the following is not true about core chaplet used in casting?
a. It is a metal location piece b. It prevents core in shifting its

position
c. It gives extra support to core d. It is removed after casting
(Ans:d)
Crucible furnace is used for melting of
a. Cast iron b. Copper base alloys c. Cast

iron d. Non ferrous metal
(Ans:d)
In casting, gating ratio is defined as the ratio of
a. sprue area : total area : total gate area b. total gate area :
sprue area : total area
c. total area : sprue area : total gate area d. total area : total gate
area : sprue area
(Ans:a)
Which of the following is true in case of directional solidification?
i. all parts of a casting do not cool at the same time due to varying cross sections
ii. The rate of heat loss varies to adjoining mould walls
iii. The thinnest section solidify first and the riser solidify last
a. i, ii & iii b. i & ii c. i &

iii d. only iii
(Ans:a)
Which of the following helps in entrapping impurities and debris flowing towards
the casting?
a. sprue well b. sprue c.
choke d. skimbob
(Ans:d)
What is the minimum thickness for casting of simple design for cast iron and
Aluminium?
a. 3mm and 6mm b. 4mm and 3mm c. 3mm and

3mm d. 6mm and 3mm
(Ans:c)
Which of the following is true about riser?
i. It permits the molten metal to rise above the highest point in the casting.
ii. Filling up of mould cavity can be visually checked from it.
iii. The casting solidifies directionally towards the riser
a. i & ii b. i & iii c. only ii d. i, ii & iii
(Ans:d)
In casting, scrabs or buckles occurs due to

a. Sand casting from the cope surface
b. Misalignment of pattern parts
c. Very large casting
d. Excessive mould hardness by ramming
(Ans:a)
Which of the following is not a casting defect?
a. Swell b. Shrinkage c. Hot

tears d. Hot cracks
(Ans:d)
Which of the following is true for sand castings?
i. They can not be used for pressure tight vessels
ii. They are stronger than wrought products
iii. They have lower density and poor strength
iv. They have poor ductility
a. i, ii, & iii b. ii, iii & iv c. i, iii & iv d. i, ii

& iv
(Ans:c)
In three boxes moulding the middle box is known as
a. cope b. drag c. cheek d. flange
(Ans:c)
The tapper provided to the pattern for its removal is known as
a. shaking allowance b. distortion allowance c. machining

allowance d. draft allowance
(Ans:d)
The property of sand due to which gas and steam escapes from sand is
a. cohesiveness b. adhesiveness c. permeability d.

Flowabilty
(Ans:c)
According to their use, which of the following is not a type of moulding sand?
a. green sand b. dry sand c. loam

sand d. wet sand
(Ans:d)
The function of cores in casting is to
a. form extended parts b. form internal cavities
c.used for directional solidification d. none of the above
(Ans:b)
Which of the following sand is applied directly next to the surface of the pattern?
a. parting sand b. facing sand c. loam

sand d. core sand
(Ans:b)
Green sand consists of
a. 70% sand and 30% clay
b. 40% sand and 60% clay
c. 30% sand and 70% clay
d. 60% sand and 40% clay

(Ans:a)
Machine moulding is used for
1. small castings
2. large castings
3. complex shapes
4. none of the above
(Ans:a)
In permanent mould casting, the molten metal is poured
1. under external pressure

2. under gravity
3. partially under gravity and partially under external pressure
(Ans:b)
In permanent mould casting, the moulds are usually coated with a refractory
wash and then lamp black to
1. Reduce chilling effect

2. To prevent shrinkage
3. Facilitates the removal of casting
Which of the above are true?
a. only i b. i & ii c. i & iii d. ii & iii

(Ans:c)
In permanent moulds, castings are capable of maintaining clearance of the order

of
1. 0.02 to 0.1mm
2. b. 0.06 to 0.3mm
3. c. 0.1 to 0.8mm
4. d. 1 to 3mm
(Ans:b)
Which of the following is not true for permanent mould casting?
1. They are superior in hardness

2. can be used for pressure tight vessel (upto 15 Kgf/cm2)
3. can be used for large size castings
4. not suitable for alloys of high temperature
(Ans:c)
In semi permanent mould casting
1. metallic core is used

2. sand core is used
3. wooden core is used
4. no core is used
(Ans:b)
In slush casting
1. metallic core is used

2. sand core is used
3. wooden core is used
4. no core is used
(Ans:d)
In which of the following types of castings, the molten metal is allowed to solidify
upto the required thickness?
1. Permanent mould casting

2. Semi permanent mould casting
3. Slush casting
4. Die casting
(Ans:c)
Ornaments, toys and statue of low melting alloys are made by which of the
following method?

2. b. Semi permanent mould casting
3. Slush casting
4. Die casting
(Ans:c)
In which of the following methods, close fitting cores are pushed in the cavities?

2. b. Semi permanent mould casting
3. Slush casting
4. Pressed casting
(Ans:d)
In hot chamber die casting machine
1. melting unit is an integral part of machine

2. It is used for high melting (above 500°C) alloys
3. No pressure is used for forcing the metal inside the die
4. None of the above
(Ans:a)
In cold chamber die casting machine
1. melting unit is an integral part of machine

2. melting chamber is an external part of machine
3. melting chamber can be placed anywhere
4. low pressure is required to force the molten metal into the die casting
(Ans:b)
In die casting machines, the problem of rapid oxidation of the steel dies at high
temperature is overcome by
1. using better die material

2. By circulating water through plates adjacent to the dies
3. Using metal in semi liquid or plastic state
Which of the above are true?
a. only ii b. i & ii c. ii & iii d. i, ii & iii
(Ans:d)
To overcome the problems like blow holes in casting we use
1. Direct air pressure type die casting machine

2. Submerged plunger type casting machine
3. Hot chamber die casting machine
4. Vacuum die casting machine
(Ans:d)
Which of the following is true for die used in die casting machine?
1. One part of die is stationery and other is moveable

2. Both part of die are stationery
3. Both part of die are moveable
(Ans:a)
In die casting, which of the following keeps the two halves of die in proper
alignment?
a. Dowel pins b. Ejector pins c.

Chaplets d. Fillets
(Ans:a)
To produce non ferrous castings having mechanical properties comparable with

forgings, the following method is used
1. slush casting
2. squeeze casting
3. semi permanent mould casting
4. permanent mould casting
(Ans:b)
No core is needed to form hole in
1. semi permanent mould casting

2. permanent mould casting
3. die casting
4. centrifugal casting
(Ans:d)
Cast iron pipes and cylindrical barrels are produced in
1. true centrifugal casting

2. semi centrifugal casting
3. centrifuged casting
4. die casting
(Ans:a)
Core is used in the following casting method
1. slush casting
(Ans:b)
Which method is used for non symmetrical castings?

(Ans:c)
Fly wheels, track wheels and gears can be produced by

(Ans:b)
Use of runner, risers and cores are eliminated in
1. Centrifuged casting
2. Die casting
4. Semi permanent mould casting
(Ans:a)
In precision casting, for final casting, we use
1. metal pattern
2. non metal pattern
3. wax pattern
4. no pattern
(Ans:c)
The tolerances in case of lost wax or precision casting is
a. ± 0.001mm b. ± 0.005mm c.
±0.05mm d. ±0.01mm
(Ans:b)
Dental castings and turbine blades are produced by
1. Centrifugal casting
2. Investment casting
3. Die casting
4. Sand casting
(Ans:b)
The slurry in Plaster mould casting consists of
1. 100 parts of plaster and 160 parts of water

(Ans:a)
In plaster mould castings, talc is added to the plaster while mixing to

1. strengthen the mould
2. fast drying of mould
3. to prevent cracking of mould
4. to reduce initial setting time
(Ans:c)
The thickness of shells in shell moulding is
a. 0.3 to 0.6mm b. 0.6 to 0.9mm c. 0.9 to

1.2mm d. 1.2 to 1.5mm
(Ans:a)
A mould made up of dried silica sand and phenolic resin is used in
1. Investment moulding
2. Shell moulding
(Ans:b)
Petrol engine cylinder are made by
1. Shell moulding
2. Plaster mould casting
(Ans:a)
In which of the following process, the metal is rapidly chilled to the point of
solidification
3. Continuous casting
4. Die casting
(Ans:c)
Billets and slabs are made by
2. Continuous casting
3. Die casting
4. Slush casting
(Ans:b)
METAL FORMING AND CASTING PROCESSPick out the most appropriate option:1.
Advantage of cold working is(
) better dimensional accuracy (
) better surface finish(
) higher strength (
) all of these.
2.
Typical hot working temperature range for steel is(
) 650–1050°C (
) 650–723°C(
) 500–910°C (
) none of these.
3.
The forging operation of “upsetting” is(
) reverse of drawing down process (
) it is a bending operation(
c
) it is a drifting operation (
) none of these.
4.
“Alligatoring” is a defect associated with(
) forging process (
) casting process(
) extrusion process (
) rolling process.
5.
A “die” is used in(
) casting process (
) extrusion process(
) forging process (
) all of these.
6.
Out of the following, which is the defect which is not associated with casting process:(
a
) Blow holes (
) Scale(
) Centre burst (
) Hot tear.
7.
Which “term” is not associated with casting process?(
) Gate (
) Runner (
) Riser (
) Swage.
8.
Fuel used in a cupola consists of (
) steam coal (
) furnace oil (
) electricity (
d
) hard coke.
9.
Which allowance is not provided on the “pattern” made for a casting ?(
) Machining allowance (
) Solidification allowance(
) Draft allowance (
) Shrinkage allowance.
10.
“Blanking” is an expression used in(
) sheet metal work (
) casting process(
) drawing (
) rolling.
Indicate, if following statements are True or False:
1.
Mechanical working processes result information of grain-flow lines which reduces thestrength of
parts.2.
“Blow hole” and shrinkage cavities occur in castings.The factors which cause these defectsare
similar in nature.3.
Sand mould is an example of permanent mould.4.
Mismatch is shift of the individual parts of a casting with respect to each other.5.
Hooker extrusion is a cold extrusion process.6.
The permeability of fine grained moulding sand will be more.
Manufacturing Process
MAIT
BY- RAMAKANT RANA
ANSWERS1.
(
2.
3.
4.
5.
6.
7.
d
)
8.
9.
10.
1.
2.
3.
4.
5.
T
6.
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Moulding and Pattern Notes

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Moulding and Pattern Notes

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Which of the following pattern is used to produce a number of castings?

a. loose piece pattern b. split pattern c. gatted

The pattern used for mass production is

a. match plate pattern b. split pattern c. skeleton

The typical shrinkage allowances for casting materials in mm/metre is as follows.

1. Grey cast iron 1. 10.5 to 21

The correct match is

a. 1-2, 2-4, 3-1, 1-3 b. 1-3, 2-4, 3-1, 4-2

c. 1-4, 2-2, 3-1, 4-3 d. 1-1, 2-4, 3-2, 4-3

a. 10-20 b. 20-30 c. 30-40 d. 40-50

The amount of draft required does not depends upon

a. shape and size of casting b. moulding method c. material of

Distortion allowance is not provided in the following shape of casting.

The distortion in casting can not be prevented by

a. modification of casting design

b. providing distortion allowance

d. providing proper shrinkage allowance

a. 1.5mm b. 3mm c. 4.5mm d. 6mm

1. Silica 1. Helps in cooling the mould

The correct matching is

a. Rough surface b. Blow holes c. hot tears d. Drop

Which of the following is not a type of core according to their position?

a. Horizontal b. Vertical c. Inclined d. Balanced

a. It is a metal location piece b. It prevents core in shifting its

c. It gives extra support to core d. It is removed after casting

Crucible furnace is used for melting of

a. Cast iron b. Copper base alloys c. Cast

In casting, gating ratio is defined as the ratio of

Which of the following is true in case of directional solidification?

ii. The rate of heat loss varies to adjoining mould walls

a. i, ii & iii b. i & ii c. i &

a. 3mm and 6mm b. 4mm and 3mm c. 3mm and

Which of the following is true about riser?

ii. Filling up of mould cavity can be visually checked from it.

iii. The casting solidifies directionally towards the riser

a. i & ii b. i & iii c. only ii d. i, ii & iii

In casting, scrabs or buckles occurs due to

b. Misalignment of pattern parts

c. Very large casting

d. Excessive mould hardness by ramming

Which of the following is not a casting defect?

a. Swell b. Shrinkage c. Hot

Which of the following is true for sand castings?

i. They can not be used for pressure tight vessels

ii. They are stronger than wrought products

iii. They have lower density and poor strength

iv. They have poor ductility

a. i, ii, & iii b. ii, iii & iv c. i, iii & iv d. i, ii

a. cope b. drag c. cheek d. flange

The tapper provided to the pattern for its removal is known as

a. shaking allowance b. distortion allowance c. machining

a. cohesiveness b. adhesiveness c. permeability d.

a. green sand b. dry sand c. loam

The function of cores in casting is to

a. form extended parts b. form internal cavities

c.used for directional solidification d. none of the above

a. parting sand b. facing sand c. loam

Green sand consists of

a. 70% sand and 30% clay

b. 40% sand and 60% clay

c. 30% sand and 70% clay

d. 60% sand and 40% clay

Machine moulding is used for

In permanent mould casting, the molten metal is poured