Tutorial questions
Module 1
1. Explain the classification of manufacturing processes with suitable examples. Provide examples
of different processes under each classification.
2. Describe the fundamental steps involved in sand casting. Illustrate your answer with a neat
schematic.
3. Compare sand casting, die casting, and investment casting in terms of process steps,
advantages, disadvantages, and industrial applications.
4. List the key considerations in the preparation of patterns and moulds? Explain the different
types of patterns used in casting.
5. Explain the function and importance of moulding sand in sand casting. Discuss the desirable
properties of moulding sand.
6. Describe the steps involved in die casting. What are the differences between hot chamber and
cold chamber die casting?
7. Explan the sand casting process in detail, explaining the steps involved from pattern making to
final finishing.
8. Explain the different types of patterns used in sand casting. How do they influence the molding
process?
9. Explain the die casting process and differentiate between hot chamber and cold chamber die
casting with neat sketches.
10. What is sand casting? Explain the process in detail along with its advantages and limitations.
11. Compare and contrast sand casting, die casting, and investment casting.
12. Define investment casting (lost-wax casting). Explain the step-by-step process
13. What are the common defects in metal casting? Explain their causes and remedies.
14. Compare die casting with sand casting based on accuracy, surface finish, production speed, and
cost. Discuss advantages and disadvantages of die casting.
15. Explain the physics of metal pouring in casting. How does Bernoulli’s theorem apply to the flow
of molten metal?
16. Define the function of a riser in casting? How does it help in compensating for shrinkage during
solidification?
17. What are the common defects in metal casting? Classify and explain different casting defects
with their causes and remedies.
18. Explain how does the shape of the casting influence solidification time? Compare solidification
times for cylindrical, spherical, and plate-like castings.
19. A casting mould has a cavity volume of 1500 cm³. The molten metal is poured from a height of
20 cm above the sprue base. The cross-sectional area of the sprue base is 2 cm². Calculate the
mould filling time.
20. A mould cavity of 2000 cm³ is filled using two different pouring heights: 30 cm and 10 cm. The
sprue base area is 2.5 cm². Compare the mould filling times for both cases.
21. A mould having dimensions 100mm x 90mm x 20mm is filled with molten metal through a gate
(top gate) with height 'h' and C.S area A, the mould filling time is t1. The height is now
quadrupled and the cross-sectional area is halved. The corresponding filling time is t2. The ratio
t2/t1 is
22. Explain Chvorinov’s Rule in detail. What is its significance in the casting process?
23. Explain how does Chvorinov’s Rule help in reducing casting defects? Explain with examples.
24. Three metal pieces being cast have the same volume, but different shapes: One is a sphere, one
a cube, and the other a cylinder with its height equal to its diameter. Which piece will solidify
the fastest, and which one the slowest? Assume that n = 2.
25. Define thermoplastics and thermosetting plastics. How do their properties influence their
selection for different industrial applications?
26. Compare and contrast thermoplastics and thermosetting plastics based on their structure,
properties, and recyclability.