PES INSTITUTE OF TECHNOLOGY - BANGALORE SOUTH CAMPUS (Hosur Road, 1KM before Electronic City, Bangalore ) Department of Mechanical Engg.
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1 Third Semester B.E. 1 st IA Test, 2016 USN 1 P E PES INSTITUTE OF TECHNOLOGY - BANGALE SOUTH CAMPUS (Hosur Road, 1KM before Electronic City, Bangalore ) Department of Mechanical Engineering Subject & Code: Metal Casting & Welding (15ME35A) Max Marks: 40 Section: A,B,C Time: 90 Min. Name of faculty: CA/SJ/MQ ANSWER ONE QUESTION FROM EACH : = 40 Define manufacturing process and write notes on concept of manufacturing process and its importance. 1 Explain the basic steps in casting process.
2 2 Write the advantages, disadvantages & applications of casting process. Advantages of Sand Casting Use is widespread; technology well developed. Materials are inexpensive, capable of holding detail and resist deformation when heated. Process is suitable for both ferrous and non-ferrous metal castings. Handles a more diverse range of products than any other casting method. Produces both small precision castings and large castings of up to 1 tonne. Can achieve very close tolerances if uniform compaction is achieved. Mould preparation time is relatively short in comparison to many other processes. The relative simplicity of the process makes it ideally suited to mechanisation. Disadvantages of Sand Casting Typically limited to one or a small number of moulds per box.. Sand: metal ratio is relatively high. High level of waste is generated Applications Turbine vanes, Power Generators, Railways, Agricultural Components, Construction equipments. Explain any three pattern allowances with sketches. Pattern allowance is a vital feature as it affects the dimensional characteristics of the casting. Thus, when the pattern is produced, certain allowances must be given on the sizes specified in the finished component drawing so that a casting with the particular specification can be made. The selection of correct allowances greatly helps to reduce machining costs and avoid rejections. The allowances usually considered on patterns and core boxes are as follows: 1. Shrinkage or contraction allowance 2. Draft or taper allowance 3. Machining or finish allowance 4. Distortion or camber allowance 5. Rapping allowance 3 Explain different types of patterns used in casting process. Single piece, Split Pattern, Match Plate Pattern, Cope & Drag Pattern, Sweep pattern, Follow Board pattern, Skeleton Pattern
3 Write notes on about binders and additives used in casting process. Binders are added to base sand to bond the sand particles together (i.e. it is the glue that holds the mold together). Clay and water - A mixture of clay and water is the most commonly used binder. There are two types of clay commonly used: bentonite and kaolinite, with the former being the most common. Oil -Oils, such as linseed oil, other vegetable oils and marine oils, used to be used as a binder, however due to their increasing cost, they have been mostly phased out. The oil also required careful baking at 100 to 200 C (212 to 392 F) to cure (if overheated the oil becomes brittle, wasting the mold). Resin-Resin binders are natural or synthetic high melting point gums. The two common types used are urea formaldehyde (UF) and phenol formaldehyde (PF) resins. PF resins have a higher heat resistance than UF resins and cost less. Resin binders are quite popular because different properties can be achieved by mixing with various additives. Other advantages include good collapsibility, low gassing, and they leave a good surface finish on the casting. Sodium silicate -Sodium silicate [Na2SiO3 or (Na2O)(SiO2)] is a high strength binder used with silica molding sand. To cure the binder carbon dioxide gas is used, which creates the following reaction: The advantage to this binder is that it can be used at room temperature and it's fast. The disadvantage is that its high strength leads to shakeout difficulties and possibly hot tears in the casting Additives are added to the molding components to improve: surface finish, dry strength, refractoriness, and "cushioning properties". 1. Sea Coal Its addition ranges from 2-8% by weight of sand Enhances peeling property of castings Improves surface finish of coatings Prevents sand burn out 2. Silica Flour It is pulverized silica added in ranges of 5-10% based on sand weight Resists metal penetration in the mould walls Improves surface finish
4 Write short notes on base sand requirements. 4 With sketch explain the working of jolt and squeeze machine.
5 With sketch explain the working of sand slinger. 5 With sketches explain investment casting.
The properties that are generally required in molding materials are:
Molding Sand Molding sands may be of two types namely natural or synthetic. Natural molding sands contain sufficient binder. Whereas synthetic molding sands are prepared artificially using basic sand molding
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