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Questions on the forging process

Sr Questions

Define the following terms and state whether they apply to foundry or forging
fetting 2-strikele 3-bloom 4-drag 5-vent -1
A replacement bolt is required to the following specifications : shank 20 mm
diameter and 150 mm long, head 40mm square and 20 mm thick. Describe the
process of forging the head of the bolt (the bolt is to be made from 20mm diameter
black steel bar)
What is the deference between a casting and a forging

State and briefly describe two types of forging methods

Name and briefly describe ,giving a reason in each case ,three defects which may be
found in drop forgings
State the range of temperature at which forging is carried out on a plain carbon steel
and explain the reason for the particular temperature range
What is meant by draft on a forging and why it is necessary


Drop forging is a manufacturing process often used to produce components which

are subject to severe stresses. describe briefly the technique of drop forging and
what type of material associated with it
State two reasons why certain components cannot be produced by the drop forging
Write brief account of the relative advantages of drop forging
Write brief notes on the following terms used in a forging processes
flash up set forging top and bottom die Give resons of excessive grain size in a steel forging


Questions on the casting process

Sr Questions
a labelled skech of a section through the prepared mould (ready for
1 Make
pouring) for making a cast iron long 80mm outside diameter,10 mm


thickness,200 mm long with a circular flange at one end. And describe the
preparation of the mould
Explain briefly what is ment by plate molding using sketches to show
the plate in relation to the mould -1
the way in which several castings can be made at one pouring-2
give two important advantages and two disadvantages of this method of -3
If any component is made by sand casting outline in some detail the essential
stages employed at the foundry if 250 castings are to be produced per week
What is the purpose of a core when used in sand casting
List four important characteristics of a good core sand casting
Describe briefly what is meant by
binder 2- blowing 3- baking 4- dressing 5 chaplet as applied to core making -1
Describe the process of chilling a sand casting, give reasons for the application
of this process and compare the structure obtain with that associated with a
slowly- cooled cast iron
Describe briefly the difference between a sand casting and a die casting
Describe two materials which are usually cast in sand and two which are
usually die casting
Tabulate, in order of importance, the main factors that determine whether
engineering components are to be supplied as casting or forgings
Why is it inadvisable for a casting to have sudden changes of sections
For what purpose are steel chills sometimes inserted in a sand mould intended
for grey cast iron casting
Describe the process of sand moulding and the material associated with it
Give the reasons for stresses and cracks in castings
Explain briefly the advantages of investment moulding and give an example of
a typical product
Briefly describe and illustrate the cold chamber pressure die casting process
State the advantages of die casting by this method and indicate the type of
work and range of materials for which it is suitable
Outline the fundamental considerations that determine the choice of casting
process for a particular component. Indicate the scope of limitations of the
common casting processes