ppt 1

Question 1

Principal Methods in Shaping

Answer 1

1. casting
2. mechanical working
3. fabrication by joining
4. machining
5. powder metallurgy

Question 2

advantages of metal casting

Answer 2

a.No restriction on the type of metal or alloy for casting operation.
b. No restriction on the size of the component for casting.
c. The most intricate external and internal shapes can be formed
by casting process.
d. A wide RANGE OF PROPERTIES can be obtained in cast-parts by suitable
choice of alloy and heat-treatment.
e.The casting process is ECONOMICALLY SUITABLE for both small quantity
jobbing production as well as mass production by automatic machines.
f.The casting process is still the CHEAPEST AVAILABLE TECHNIQUE for
forming many components from raw materials to the final usage stage.

Question 3

disadvantages of metal casting

Answer 3

a.Metal casting involves melting of metal which is a high energy
consuming process.
b.Metal casting is still highly labour-intensive compared to other processes.
c.The quantum of raw materials required for producing a ton of casting is
quite high, needing exhaustive building, handling systems, large space and
inventory cost.
d.The time required for the process of making casting starting from the receipt
of drawing is quite long compared to other processes like machining
e.The working condition in foundries at different stages are quite bad
compared to other process industries.

Question 4

Classification of Foundries

Answer 4

1. According to the type of metal/alloy cast in the unit.
2. Nature of production
3. Basis of the casting process

Question 5

According to the type of metal/alloy cast in the unit

Answer 5

Ferrous or non- ferrous

Question 6

Nature of production

Answer 6

mass production or small quantity

Question 7

Basis of the casting process

Answer 7

expendable vs. permanent mold casting

Question 8

Types of Foundries according to the Nature of their
Production

Answer 8

jobbing
production
semi- production
captive
independent

Question 9

one having a physical plant such that it usually
contracts to produce a casting or a small number of
castings of a given kind

Answer 9

jobbing

Question 10

a highly mechanized shop which requires
that large numbers of a given kind of casting be made in
order to produce them at low cost

Answer 10

production

Question 11

are those in which a portion of the work
is a jobbing nature while the balance is production casting

Answer 11

semi- production

Question 12

one which is an integral part of some
manufacturing company and whose castings are consumed
mainly in the products of the parent organization

Answer 12

captive

Question 13

usually a separate company that produces
castings for any number of customers

Answer 13

independent

Question 14

Types of Foundries on the Basis of the casting Process

Answer 14

1. expendable mold process
2. permanent mold process

Question 15

uses an expendable mold which must be
destroyed to remove casting

Answer 15

expendable mold process

Question 16

uses a permanent mold which can be used
over and over to produce many castings

Answer 16

permanent mold process

Question 17

Mold materials: sand, plaster, and similar materials, plus binders

Answer 17

expendable mold process

Question 18

Made of metal (or, less commonly, a ceramic refractory material)

Answer 18

permanent mold process

Question 19

Challenges for Filipino Foundry Industry

Answer 19

a) Lack of quality of raw material
b) Shortage of electric power in many regions
c) Shortage of capital/finance (use of obsolete equipment causing
low productivity)
d) Lack of trained manpower
e) Metal casting is generally a low profit-making, low productive
industry with larger risks from capital, employees, power and
materials.
f) Environmental Pollution

Question 20

Important Industrial Sectors using castings

Answer 20

1. Mining and mineral processing
2. Core- sector
3. Chemicals, machine tools, transport, textile etc.

Question 21

Typical casting used are for excavators, earth moving machinery,
conveyors, crushers, grinders etc.

Answer 21

Mining and mineral processing

Question 22

Manufacture of items like steel, cement, thermal, hydro and nuclear power.
Typical components: ingot molds, rolls, furnace parts, turbine parts, kilntyres, drive-unit gears, crushing and grinding parts, etc.

Answer 22

Core- sector

Question 23

Industries like fertilizers plants, petrol refineries, sugar and chemicals
Typical parts: corrosion resistant castings, valves, heat-resistant castings

Answer 23

Chemicals, machine tools, transport, textile etc.