Introduction to Basic Manufacturing Processes and ... - always yours

13.12 QUESTIONS
Casting 257
1. Describe in detail the terms ‘solid zone’, ‘mushy zone’ and ‘liquid zone’ used in solidification
of castings. Using figures explain the term directional solidification used in castings.
2. What is “directional solidification”, and what is its influence on casting quality?
3. Is directional solidification is necessary in casting? How does it help in the production of
sound castings?
4. What are the controlling factors of directional solidification in casting? Name different stages
through which the metal contraction takes place during the solidification of the casting?
5. Why do you prefer fabricating of metal parts by casting?
6. Define casting. What four basic steps are generally involved in making a casting?
7. What are the common factors which should be considered before designing a casting?
8. Sketch the cross-section through a permanent mold, incorporating all its principal parts.
Describe its construction in detail.
9. Describe the permanent mold casting process and discuss how it differs from the other
casting processes.
10. What are the common materials used for making the permanent molds?
11. Describe step by step procedure for casting using a permanent mold. What are the advantages,
dis-advantages and applications of permanent mold casting?
12. What different metals and alloys are commonly cast in permanent molds?
13. What is the difference between gravity die casting and pressure die casting?
14. How are die casting machines classified? What are the common constructional features
embodied in most of them?
15. Sketch and explain the construction and operation of a hot chamber die casting machine.
16. How does a cold chamber die casting machine differ from a hot chamber machine? Explain
the working of a cold chamber machine with the help of a diagram.
17. Make a neat sketch to explain the principal parts of an air blown or goose neck type machine.
How does it differ from a hot chamber die casting machine. Discuss their relative advantages,
disadvantages and applications.
18. What is a vacuum die-casting machine? How is the vacuum applied to hot and cold chamber
machines to evacuate the entrapped air completely. What is the main advantage of this type
of machine?
19. Specify features required to be embodied in a successful design of a die-casting die.
20. Describe the various alloys commonly cast through pressure die-casting.
21. What are the general advantages, disadvantages applications of die casting?
22. How does a cold chamber die casting machine differ from a hot chamber die casting machine?
23. Make neat sketch and explain the construction and operation of a hot chamber die casting
machine.
24. Make neat sketch and explain the construction and operation of a cold chamber die casting
machine.
25. Explain the various steps involved in the investment casting of metals.
26. What is investment casting? What are the main materials used for making the investment
pattern?
27. Describe the complete step by step procedure of investment casting. What are the main
advantages and disadvantages of investment casting?