Manufacturing Practices (BT-106) - Important Questions
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Unit 27 Marks High Priority
Explain the principle of casting and describe the general steps involved in the casting process. Discuss the advantages and limitations of casting as a manufacturing method.
Core derivation from Unit 2: Fundamental concept frequently examined in casting theory and process comparison.
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Unit 210 Marks High Priority
Describe the sand casting process in detail. Explain the functions of pattern, core, cope and drag, and list the sequence of operations from pattern making to fettling.
Core process question from Unit 2; basic expected question on sand casting operations.
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Unit 27 Marks High Priority
Define the following pattern allowances and explain why each is provided: (a) shrinkage allowance, (b) draft (taper) allowance, (c) machining allowance, and (d) distortion allowance.
Core technical question: pattern design allowances are standard topic in Unit 2.
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Unit 27 Marks High Priority
State the desired properties of molding sand used in green-sand casting. Explain how each property (grain size, clay content, moisture, permeability, refractoriness, strength) affects the quality of castings.
Core material-property knowledge from Unit 2; commonly asked as short or long answer.
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Unit 210 Marks High Priority
State and explain Chvorinov's rule for solidification time. Using Chvorinov's rule, show how the solidification time $t_s$ of a riser relates to its volume $V$ and surface area $A$ by the formula $$t_s = C \left(\frac{V}{A}\right)^2$$ and describe the significance of the constant $C$.
Core theoretical derivation used in gating and riser design; Chvorinov's rule is essential.
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Unit 210 Marks Medium Priority
Explain the design considerations of a gating system and riser. Define riser modulus and derive how the riser volume and surface area influence its ability to feed the casting during solidification.
Design and calculation topic frequently examined for practical gating and feeding analysis.
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Unit 27 Marks High Priority
Explain the concept of directional solidification in casting. Describe methods used to ensure directional solidification and avoid shrinkage defects in castings.
Core solidification control topic; directional solidification is key to defect avoidance.
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Unit 210 Marks High Priority
List and explain the common casting defects such as shrinkage cavity, porosity, blowholes, sand inclusion, cold shut, misrun and hot tears. For each defect give its main cause and typical remedial measures.
Commonly asked: identification, causes and remedies of casting defects are high-yield.
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Unit 27 Marks Medium Priority
Compare and contrast sand casting, die casting and investment (lost-wax) casting in terms of process steps, material suitability, surface finish, dimensional accuracy, production rate and typical applications.
Comparative question often used to test understanding of process selection in Unit 2.
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Unit 27 Marks Medium Priority
Explain the principle and types of centrifugal casting. Describe typical applications and advantages of centrifugal casting over static mold casting.
Process-specific question with applications; centrifugal casting topic in Unit 2.
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Unit 27 Marks Medium Priority
Describe the shell moulding process. Explain its advantages and limitations compared to conventional sand casting and typical applications where shell moulding is preferred.
Specific molding technique question; shell moulding is standard in Unit 2 syllabus.
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Unit 210 Marks Medium Priority
Discuss common melting furnaces used in foundries such as induction furnace and cupola. Explain fluxing, degassing and refining practices used during melting to improve melt quality and reduce casting defects.
Furnace and melting practices topic; important for metallurgical quality control in Unit 2.
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