This set of Metal Casting Multiple Choice Questions & Answers (MCQs) focuses on “Steps Involved In Making a Mold”.
1. Which of the following processes is the first step involved in the sand casting?
a) Clamping
b) Cooling
c) Mould making
d) Pouring
View Answer
Explanation: The first step involved in the sand casting method is to produce the mould for the casting. In an expendable moulding process, this step should be done for each different casting. A sand mould is basically produced by packing sand mass into each half of the mould. The sand mass is rammed near at the pattern side; pattern is a replica of the casting to be made.
2. It is possible to provide any kind of internal features to the casting by the help of pattern.
a) True
b) False
View Answer
Explanation: It is not always possible to use pattern for generating internal features to the casting. Any kind of internal features of the casting which cannot be produced by the application of pattern are produced by using the separate cores which are mostly formed by the sand that can be green sand or dry sand, depending on the purpose.
3. In mould making process, moulding time is greatly affected by the shape and size of the casting components.
a) True
b) False
View Answer
Explanation: In mould making process, the moulding time generally involves positioning of pattern, sand ramming and pattern extraction from the moulding box. The mould making time is greatly affected by the size and shape of the casting components, number of cores, and the type of sand mould used in the process.
4. In mould making process, clamping is basically done to prevent any loss of material from the moulding box.
a) True
b) False
View Answer
Explanation: In mould making process, after placing of cores in the mould, the mould parts are closed and clamped together by a clamping operation. It is very essential that the mould parts remain closely clamped together to prevent any loss of molten metal. Clamping is a very important operation and must be performed with great care.
5. It is not possible to estimate solidification time by considering the wall thickness and temperature of the casting metal.
a) True
b) False
View Answer
Explanation: When the mould cavity is filled with molten metal and during its solidification, the final shape of the casting part is formed. The mould cannot be opened until the cooling time has elapsed. The desired cooling or solidification time can be estimated by considering the wall thickness and the temperature of the casting metal.
6. During the pouring process, filling time of molten metal should be short to avoid early solidification of the casting.
a) True
b) False
View Answer
Explanation: During pouring operation, the molten metal is poured into the mould by the application of ladle. The filling time of molten metal should be kept short in order to avoid early solidification of any part of the casting component. The filling of melt through the ladle can be performed manually or by an automated machine.
7. The process shakeout is generally referred to escaping of gases from the molten casting during the solidification.
a) True
b) False
View Answer
Explanation: After the solidification of the casting component, the sand mould is broken and the casting part is extracted from the broken mould. This process is also known as shakeout and it is commonly performed by a vibrating machine or tool that shakes the sand particles and then the casting comes out from the flask.
8. Quick solidification of the casting can cause defects like shrinkages, cracks or blow holes.
a) True
b) False
View Answer
Explanation: The molten metal is poured into the mould cavity that begins to cool and solidify. During solidification, most of the defects which may occur are a result of the solidification process. If the molten metal solidifies too quickly, then the casting parts may exhibit defects like shrinkage, cracks or blow holes.
9. Shot blasting operation is mainly done to identify the type of defects in the casting part.
a) True
b) False
View Answer
Explanation: After removing of casting part from the mould, the casting part is likely to have some sand particles and oxide layers which adhered to the surface. Shot blasting is an operation which is mainly performed to remove any remaining sand particles, especially from internal surfaces. This process also reduces the surface roughness of the casting part.
10. A trimming press is a machine tool which is widely used for removing the excess material from the casting part.
a) True
b) False
View Answer
Explanation: During solidification, the material from the channels in the mould solidifies and joined to the casting part. This excess material should be trimmed from the casting part, for which a trimming press is used that removes excess material very finely. The time needed for trimming the excess material can be estimated from the size of the casting’s envelope.
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