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BT-106 · Manufacturing Practices/Important Questions

Manufacturing Practices (BT-106) - Important Questions

  1. Unit 25 Marks High Priority

    Define a pattern in casting. Describe the different types of patterns and the commonly used pattern materials. Discuss the applications of each pattern type.

    Core conceptual question on pattern fundamentals in Unit 2; commonly asked to assess understanding of pattern types and materials.

  2. Unit 27 Marks High Priority

    Explain the essential properties of moulding sand. Describe the composition of green sand and the role of each constituent (silica sand, clay, water, and additives). How do these properties influence the quality of sand castings?

    Fundamental topic frequently examined: properties and composition of molding sand and their influence on casting quality.

  3. Unit 210 Marks High Priority

    Describe in detail the sand casting process. Include the sequence of operations from pattern making to fettling and finishing. Draw and label the stages of a typical sand casting operation.

    Syllabus core question: sequence and explanation of sand casting stages; typical long-answer or descriptive question.

  4. Unit 214 Marks High Priority

    Explain Chvorinov's rule for solidification time. Using Chvorinov's rule $t = C \left(\frac{V}{A}\right)^{2}$, describe how it is used to design a riser. For a casting of volume $V_{c}$ and surface area $A_{c}$ and a riser of volume $V_{r}$ and surface area $A_{r}$, derive the inequality condition that ensures the riser solidifies after the casting.

    Core design/calculation topic: riser and solidification design using Chvorinov's rule — a standard numerical question in exams.

  5. Unit 210 Marks High Priority

    What is a gating system in casting? Describe the functions of each element of a gating system (pouring basin, sprue, runner, gate, and well). Explain the principles of gating system design to minimize defects and control flow.

    Standard descriptive question on gating systems; often combined with a small numerical or design rationale.

  6. Unit 27 Marks High Priority

    List and explain common casting defects (such as blow holes, porosity, cold shuts, shrinkage, misruns, inclusion) and discuss the causes and preventive measures for each defect.

    Commonly asked: classification of casting defects and preventive measures — tests both theory and problem solving in manufacturing practice.

  7. Unit 210 Marks Medium Priority

    Compare and contrast the following casting processes: sand casting, die casting, investment (lost-wax) casting, and centrifugal casting. For each process mention typical applications, advantages and limitations.

    Comparative question across casting processes; assesses understanding of advantages, limitations and suitable applications.

  8. Unit 27 Marks Medium Priority

    Describe shell moulding and the CO2 moulding process. Explain the process steps, advantages and typical applications of each.

    Syllabus topic: alternative moulding processes; medium frequency in exams.

  9. Unit 25 Marks High Priority

    What are pattern allowances? Explain shrinkage allowance, machining allowance, draft allowance and distortion allowance. Give typical numerical values or ranges for each allowance and justify their necessity.

    Important conceptual point: allowances in pattern making — regularly tested as short/long answer.

  10. Unit 27 Marks Medium Priority

    Describe the common laboratory tests for moulding sand: sieve analysis, clay content determination, green compression strength, permeability, and moisture content. Explain the significance of each test and how results affect moulding performance.

    Laboratory/inspection topic: sand testing — asked to test understanding of quality control in moulding sands.

  11. Unit 25 Marks Low Priority

    Explain the types of mechanized moulding processes and moulding machines used in foundries (e.g., jolt-squeeze, sand slinger, muller, and greensand moulding machines). Discuss the advantages of mechanized moulding over manual moulding.

    Less frequently asked: mechanized moulding and moulding machines; included for completeness and exam preparedness.

  12. Unit 25 Marks Low Priority

    Discuss the typical heat treatment operations applied to cast components (normalizing, annealing, stress relieving) and explain why these treatments may be necessary after casting.

    Supplementary topic linking casting to post-processing; occasionally appears in applied questions.

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