Metal Casting: Fundamentals and Applications
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Questions and Answers

What is the primary function of a mold in the metal casting process?

  • To resist the high temperature of the molten metal (correct)
  • To shape the metal into its desired form
  • To cool the molten metal
  • To machine the metal object
  • What is the result of pouring molten metal into a mold and allowing it to solidify?

  • A welded product
  • A forged product
  • A machined product
  • A casting (correct)
  • Which of the following is an advantage of the metal casting process?

  • Allows for the creation of intricate shapes (correct)
  • Is limited to small-sized products
  • Requires expensive tools and machinery
  • Can only be used for ferrous materials
  • What is the primary reason why metal casting is used in manufacturing?

    <p>It can create intricate shapes and minimize other operations</p> Signup and view all the answers

    What is the benefit of using metal casting in manufacturing?

    <p>It allows for large savings in weight</p> Signup and view all the answers

    What is a limitation of the metal casting process?

    <p>The size and weight of the product are limitations</p> Signup and view all the answers

    What is the purpose of using sand as a mold material in metal casting?

    <p>It resists the high temperature of the molten metal</p> Signup and view all the answers

    What is a characteristic of metal casting that allows for the creation of intricate parts?

    <p>Molten material can flow into very small sections</p> Signup and view all the answers

    Which of the following woods is available in the Himalayas and is known for its strong and durable wood?

    <p>Deodar</p> Signup and view all the answers

    Which of the following characteristics is NOT associated with Mahogany wood?

    <p>It is soft and cheap</p> Signup and view all the answers

    What is the main advantage of using wooden patterns in casting?

    <p>They are very cheap and easily available</p> Signup and view all the answers

    Which of the following metals is known for its good resistance to sand abrasion and corrosion?

    <p>Cast Iron</p> Signup and view all the answers

    What is the main disadvantage of using metallic patterns in casting?

    <p>They are heavy and expensive</p> Signup and view all the answers

    Which of the following woods is known for its fragrance and is available in the Himalayas at a height of 1500 to 3000 meters?

    <p>Deodar</p> Signup and view all the answers

    What is the main advantage of using Brass and Bronze patterns in casting?

    <p>They have better surface finish than cast iron</p> Signup and view all the answers

    Which of the following is a disadvantage of using Cast Iron patterns in casting?

    <p>They are heavy and brittle</p> Signup and view all the answers

    What is a limitation of the sand casting process?

    <p>Dimensional accuracy and surface finish</p> Signup and view all the answers

    What is the purpose of facing sand in the sand casting process?

    <p>To give a better surface finish to the castings</p> Signup and view all the answers

    What is the name of the upper molding flask in the sand casting process?

    <p>Cope</p> Signup and view all the answers

    What is the purpose of vent holes in the sand casting process?

    <p>To permit the escape of gases generated during pouring and solidification</p> Signup and view all the answers

    What is the replica of the final object to be made in the sand casting process?

    <p>Pattern</p> Signup and view all the answers

    What is the purpose of the gating system in the sand casting process?

    <p>To create a pathway for the molten metal to flow into the mold cavity</p> Signup and view all the answers

    What is the role of the drag in the sand casting process?

    <p>To form the lower part of the mold</p> Signup and view all the answers

    What is the purpose of molding sand in the sand casting process?

    <p>To bind strongly without losing its permeability to air or gases</p> Signup and view all the answers

    What is the primary function of a core in a mold?

    <p>To create openings and various shaped cavities in the castings</p> Signup and view all the answers

    What is the purpose of a pouring basin in a mold?

    <p>To receive the molten metal and direct it into the mold</p> Signup and view all the answers

    What is the role of a sprue in a mold?

    <p>To carry the molten metal from the pouring basin to the gate</p> Signup and view all the answers

    What is the purpose of a gate in a mold?

    <p>To create a channel for the molten metal to enter the mold cavity</p> Signup and view all the answers

    What is the role of chaplets in a mold?

    <p>To support the cores inside the mold cavity</p> Signup and view all the answers

    What is the primary function of a pattern in casting?

    <p>To create a cavity in the molding sand</p> Signup and view all the answers

    Which of the following is a common material used for making patterns?

    <p>Wood</p> Signup and view all the answers

    What is the advantage of using wooden patterns in casting?

    <p>It is cheap and can produce highly smooth surfaces</p> Signup and view all the answers

    What is the primary advantage of aluminum alloy patterns?

    <p>Good surface finish and low melting point</p> Signup and view all the answers

    Which of the following is a disadvantage of White Metal patterns?

    <p>Softness and requirement of proper care for storage and transportation</p> Signup and view all the answers

    What is the primary advantage of plastic patterns?

    <p>Lighter, stronger, moisture and wear resistant, and non-sticky to molding sand</p> Signup and view all the answers

    What is the primary advantage of plaster patterns?

    <p>High compressive strength and high expansion setting type</p> Signup and view all the answers

    What is the primary advantage of wax patterns?

    <p>Ability to impart a high degree of surface finish and dimensional accuracy</p> Signup and view all the answers

    What is a disadvantage of aluminum alloy patterns?

    <p>They can be damaged by sharp edges</p> Signup and view all the answers

    What is a common type of plastic used for making patterns?

    <p>Phenolic resin</p> Signup and view all the answers

    What is a common method of making wax patterns?

    <p>Injecting liquid wax into a split die</p> Signup and view all the answers

    Study Notes

    Metal Casting

    • Metal casting is a vital industry that plays a key role in all major sectors of the economy.
    • It is one of the oldest materials shaping methods known, where molten metal is poured into a mold to create a desired shape.
    • The mold is made of a heat-resistant material, such as sand, and is broken or taken apart to reveal the solidified metal object, known as a casting.

    Advantages of Metal Casting

    • Intricate shapes can be made with high accuracy.
    • Practically any material can be cast, including ferrous and non-ferrous metals.
    • Weight can be saved by placing metal exactly where it is needed.
    • Simple and inexpensive tools are required for casting molds.
    • Certain parts can only be made using this process.
    • There is no limitation to the size and weight of the product.

    Limitations of Metal Casting

    • Dimensional accuracy and surface finish can be limited by the sand casting process.
    • New casting processes, such as die casting, investment casting, and vacuum-sealed molding, have been developed to improve accuracy and surface finish.

    Components Used for Making a Mould Cavity

    • Molding box: A suitable size of molding box is selected for creating a suitable wall thickness.
    • Pattern: A replica of the final object to be made, used to create the mold cavity.
    • Parting line: The dividing line between the two molding flasks that make up the mold.
    • Molding sand: A mixture of silica sand, clay, and moisture, used to bind the mold.
    • Facing sand: A small amount of carbonaceous material used to give a better surface finish to the castings.
    • Core: A separate part of the mold, used to create openings and shaped cavities in the castings.
    • Pouring basin: A small funnel-shaped cavity at the top of the mold, used to pour the molten metal.
    • Sprue: A passage through which the molten metal reaches the mold cavity.
    • Runner: A channel that carries the molten metal from the sprue to the gate.
    • Gate: A channel through which the molten metal enters the mold cavity.
    • Chaplets: Used to support the cores inside the mold cavity.
    • Riser: A column of molten metal placed in the mold to feed the castings as they shrink and solidify.
    • Vent: A small opening in the mold to facilitate the escape of air and gases.

    Pattern Making

    • A pattern is a model or replica of the object to be cast.
    • It is used to create a mold cavity in the molding sand.
    • Pattern materials include wood, metal, plastic, plaster, wax, and mercury.
    • The choice of pattern material depends on the quality of the casting required, the number of castings to be produced, and the cost.

    Common Pattern Materials

    • Wood: A popular and commonly used material for pattern making, due to its low cost, ease of fabrication, and light weight.
    • Metal: Preferred when the number of castings required is large, due to its durability, strength, and resistance to corrosion and wear.
    • Plastic: A newer material being used for pattern making, due to its light weight, strength, and durability.
    • Plaster: A material used for producing highly intricate castings, due to its high compressive strength and high expansion setting type.
    • Wax: Used for investment casting, due to its ability to impart a high degree of surface finish and dimensional accuracy to castings.

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    Description

    This quiz covers the basics of metal casting, its importance in various industries, and its applications in daily life.

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