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BT-106 · Manufacturing Practices/Important Questions

Manufacturing Practices (BT-106) - Important Questions

  1. Unit 27 Marks High Priority

    Explain the different types of patterns used in foundry practice. Discuss single piece, split, cope and drag, gated, loose piece, and match plate patterns with their typical applications and advantages.

    Core topic on types and selection of patterns used in foundry practice.

  2. Unit 210 Marks High Priority

    Define pattern allowances. A cylindrical casting is required to have a finished diameter of $100\,\text{mm}$. If the linear shrinkage allowance is $1.2\%$, calculate the required pattern diameter. Use the appropriate allowance formula.

    Standard numerical problem on pattern allowances and calculation using shrinkage allowance formula.

  3. Unit 27 Marks High Priority

    Discuss the essential properties of moulding sand used in green sand moulding. Describe the tests used to determine moisture content, permeability, green strength, compactibility, and clay content and explain the significance of each property.

    Fundamental concepts and laboratory tests for moulding sand properties.

  4. Unit 210 Marks Medium Priority

    Explain the components of a gating system used in sand casting. Discuss the design objectives of gating systems and describe various types of gates and runners used to control metal flow and reduce defects.

    Core design of gating systems is a recurring conceptual question in Unit 2.

  5. Unit 214 Marks High Priority

    Explain the function of a riser (feeder) in casting. Describe open and blind risers and explain how riser placement ensures directional solidification. Using Chvorinov's rule, discuss how to estimate relative riser size compared to the casting.

    Key design question combining solidification theory and practical riser sizing using standard rules.

  6. Unit 27 Marks High Priority

    Describe the process of solidification in metal casting. Explain how solidification behaviour leads to common casting defects such as shrinkage cavities, cold shuts, misruns and hot tears, and suggest remedial measures.

    Core conceptual question about solidification phenomena and related defects.

  7. Unit 27 Marks Medium Priority

    Describe the principle, construction and applications of the following melting furnaces used in foundries: cupola furnace, induction furnace and electric arc furnace. Mention advantages and limitations of each.

    Covers practical knowledge of melting equipment used in foundries.

  8. Unit 210 Marks Medium Priority

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

    Comparative question on casting processes and selection criteria.

  9. Unit 27 Marks Medium Priority

    What is a core in casting? Explain types of cores, core-making processes, materials and binders used for core sands. Describe the purpose and design considerations of core prints and core boxes.

    Focused topic on cores, core-making materials and core prints — routinely asked.

  10. Unit 210 Marks High Priority

    List and explain common casting defects such as gas porosity, blow holes, sand inclusion, scabs, cold shuts, and shrinkage defects. For each defect, provide the principal causes and practical remedies.

    High-value question listing defects, causes and countermeasures — frequently appears in examinations.

  11. Unit 214 Marks Medium Priority

    Derive Chvorinov's rule for solidification time and explain each term. Show how Chvorinov's rule can be used to determine the minimum riser volume required to feed a casting. State the rule as a formula.

    Derivation and application of Chvorinov's rule — important theoretical question.

  12. Unit 25 Marks Low Priority

    Explain the importance of core ventilation and gassing control in casting. Describe methods used to provide venting for cores and the effects of inadequate venting.

    Narrow topic on core venting and gassing — sometimes asked as short question.

  13. Unit 27 Marks Medium Priority

    Explain the use of chills, insulating sleeves and risers to achieve directional solidification. Describe how chills influence local solidification and list situations where external chills are preferred.

    Practical methods to ensure directional solidification and prevent shrinkage — applied design question.

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