Metal Casting Fundamentals
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Questions and Answers

What is the primary reason for using sand as a mold material in metal casting?

  • It is a corrosion-resistant material
  • It is a cost-effective material
  • It is a heat-conducting material
  • It resists the high temperature of the molten metal (correct)

    • Which of the following is NOT an advantage of the metal casting process?

  • It can produce intricate shapes
  • It can achieve large weight savings
  • It can cast practically any material
  • It requires complex and expensive tools (correct)

    • What is the primary benefit of using metal casting in manufacturing?

  • It minimizes or eliminates machining, forging, and welding (correct)
  • It is a low-cost process
  • It produces high-strength materials
  • It allows for large production quantities

    • What is the name of the solidified object obtained after pouring molten metal into a mold?

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

    Why is metal casting used extensively in manufacturing?

    <p>Due to its many advantages, including intricacy and weight savings</p> Signup and view all the answers

    What is a major limitation of the casting process?

    <p>The options listed above are incorrect, there is only one limitation listed in the content</p> Signup and view all the answers

    What is the benefit of being able to place metal exactly where it is required in the casting process?

    <p>Large saving in weight</p> Signup and view all the answers

    Why is metal casting considered one of the oldest materials shaping methods?

    <p>Due to its historical roots</p> Signup and view all the answers

    What is a major limitation of the sand casting process?

    <p>The lack of 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 provide a better surface finish to the castings</p> Signup and view all the answers

    What is the term for the dividing line between the two molding flasks?

    <p>Parting line</p> Signup and view all the answers

    What is the name of the frame in which the mold is formed?

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

    What is the purpose of vent holes in the cope?

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

    What is the term for the replica of the final object to be made?

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

    What is the mixture of silica sand, clay, and moisture in appropriate proportions?

    <p>Molding sand</p> Signup and view all the answers

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

    <p>To form suitable sized cavities for pouring molten metal</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 sprue in a mold?

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

    What is the primary function of a pattern in casting?

    <p>To prepare a mold cavity for casting</p> Signup and view all the answers

    What is the purpose of chaplets in a mold?

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

    What is the purpose of a riser in a mold?

    <p>To feed the casting as it solidifies and shrinks</p> Signup and view all the answers

    What is a common problem with wooden patterns?

    <p>They are susceptible to shrinkage and warpage</p> Signup and view all the answers

    What is the purpose of a gate in a mold?

    <p>To allow molten metal to enter the mold cavity</p> Signup and view all the answers

    What is a characteristic of shisham wood, commonly used in pattern making?

    <p>It is very hard and difficult to work with</p> Signup and view all the answers

    Which of the following types of wood is most preferred for making patterns for production of small size castings in small quantities?

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

    Which of the following metals is most resistant to corrosion and wear?

    <p>Brass and Bronzes</p> Signup and view all the answers

    Which of the following is NOT a disadvantage of wooden patterns?

    <p>It is easy to join.</p> Signup and view all the answers

    Which of the following types of wood is available in golden yellow or dark brown color?

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

    Which of the following is an advantage of cast iron patterns?

    <p>It has good resistance against sand abrasion.</p> Signup and view all the answers

    Which of the following is a disadvantage of metallic patterns?

    <p>It is more expensive than wooden patterns.</p> Signup and view all the answers

    Which of the following types of wood has a close grain structure and is unlikely to warp?

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

    Which of the following metals is used for making match plate patterns?

    <p>Brass and Bronzes</p> Signup and view all the answers

    Which of the following materials is best suited for making large castings?

    <p>Aluminum alloy</p> Signup and view all the answers

    What is the primary reason for using plaster as a pattern material?

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

    Which of the following materials is not suitable for lining and stripping plates?

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

    What is the primary benefit of using wax patterns in investment casting?

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

    Which of the following materials is most prone to damage by sharp edges?

    <p>All of the above</p> Signup and view all the answers

    What is the primary advantage of using thermosetting resins in plastic pattern making?

    <p>Moisture and wear resistant, non sticky to molding sand</p> Signup and view all the answers

    Which of the following materials is most suitable for producing small size intricate castings?

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

    What is the primary advantage of using foam plastic in pattern making?

    <p>Made from benzene and ethyl benzene, foam plastic is a new material in the field of plastic</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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    Explore the importance of metal casting in various industries and its role in shaping metal parts. Learn about the basics of metal casting and its applications.

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