Casting Process- Mechanical Interview Questions with answers

Mechanical Interview Questions with For Casting Manufacturing Process.

1. What Do you know about Casting ? 
The Process of producing metal parts by pouring molten metal in to the mould cavity of
the required shape and allowing the metal to solidify. The solidified metal piece is called as
casting.

Steps In Casting
Steps In Casting
2. What is draft allowance?  How is it provided for patterns?
It the vertical faces of pattern are perpendicular to parting line, the edges of mould may damaged when the pattern is removed from the sand. Hence the vertical faces are mode taper for easy removal of pattern. This slight taper given on the vertical sides of pattern in caused draft allowance.

3. What are the common allowances provided on pattern?
The various types of pattern allowances normally given are;
1. Shrinkage allowance
2. Machining or finish allowance
3. Draft or taper allowance
4. Distortion or camber allowance
5. Rapping or shake allowance

4. Is pattern differ from casting?
Pattern is slightly larger in size as compared to the casting. Pattern may be in two or three pieces where as a casting is in one piece.

5. Name the various pattern materials.
Wood – Teak wood, white pine etc.
Metal – cast iron, brass, aluminium etc.
Plaster
Plastic
Wax

6. What are the different types of patterns used in foundries?
Solid or single piece pattern, match plate pattern, split pattern, sweep pattern, skeleton Pattern, segmental pattern, loose piece pattern, shell pattern.

7. What are the uses of runner and riser?
Runner:
  • It is used to make a sprue a hole in the cope.
  • It receives the molten metal from the pouring basin and passes to the cavity.

Riser:
  • It supplies excess molten metal to the solidifying casting.
  • It allows the escape of air.

8. What are chaplets?
Some times it is not possible to provide sufficient support for a core in the mould being
poured, if the cores are bigger in size. In such cases the core is supported with rigid metal
pieces called chaplets.

9. Name four different casting defects.
  • Shifts - Two halves mismatching or casting
  • Hot tear - Internal or external cracks
  • Fins - Thin projection of parting line
  • Inclusions - Foreign material present in casting

10. What function of core ?

Functions of core are:

  • Core provides a means of forming the main internal cavity for hollow casting.
  • Core provides external undercut feature.
  • Cores can be inserted to obtain deep recesses in the casting.
  • Cores can be used to increase the strength of the mould.

10. Explain the term fettling.

Fettling is the name given to cover all those operations which help the casting to give a good appearance. It includes the removal of cores, sand, gates, risers, runners and other Unwanted projections from the casting.

11. Classify moulding Machines.

1.Squeezer Machine.
2.Jolt machine.
3.Jolt – squeezer Machine.
4.Slinging Machines.
5. Patten draw Machines.

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