Q1.

Explain/elaborate to your roommate from the Built

Environment course, three (3) reasons which make the
casting process more preferred than metal forming
process or metal cutting process for making compressor
frames that weighs 680kg each as shown in the figure!

Answer:
-Large size product production might produce a huge amount of waste in the cutting
process while in casting process this situation can be avoided
- Large size product require a very big forming machine with a very high forming
energy which is very expensive process
- Casting has a capacity to create external and internal shapes as the case of this
products in on time process while machining process requires several step of work
for accomplishing this job
- the nature of molten metal that can filled the complex shape die cavity make
casting process is the preferred process for the production of complex shape of
product as the case of compressor frame
1
• Q2. The following figure shows casting that a
was cast and removed from its mould. Label f e
the parts marked by arrow. Then sketch the
b
steps involved in the making this component,
and in their proper sequence, using the sand
casting process.

d c
Answer:
a: pouring cup/basin, b: downsprue, c: runner, d:ingate, e: riser, f: casting
Step of process:
- Production mold which is consist of cope and drag
- Pattern and cores that form the mold cavity
- Pouring the molten metal
- Trimming

2
• Q3. Describe the features (advantage, disadvantage and application) two (2) of the
following processes:
(i) shell moulding casting (iii) lost wax (investment) casting
(ii) evaporative pattern casting (iv) pressure die casting
Answer:
(i) Shell moulding:
Advantages: - smoother cavity surface permits easier flow of molten metal and better
surface finish on casting
-Good dimensional accuracy
-Machining often not required
-molds collapsability usually avoids cracks in casting

Disadvantages:
-More expensive metal pattern
-Difficult to justify for small quantities

Application:
- Crankshaft fabrication
-Steel casting parts, fittings
-Moulded tubing fabrication
-Hydraulic control housing fabrication
-Automotive castings (cylinder head and ribbed cylinder fabrication).
3
Q4. This product is produced by a casting process. Below is a
list of three casting processes. Select the most appropriate
process for producing the given product and explain three
(3) reasons for your selection!
i. Sand casting; ii. Pressure die casting,
iii. loss wax (investment)

Answer:
Sand casting is preferred for the production of this product, the
reason is as follow:
- for the case of sand pressure die casting and loss
wax/investment casting there is a limitation in the size of
Fig. Ductile iron electric
product (20 kg for die casting and 5 kg for investment casting)
housing, 141 kg, smallest
- Ductile iron as the cast materials of this product is not
section thickness 6 mm
appropriate for die casting process
-Sand casting can handle the section thickness of this product
-Cheaper price of production

4
Q5. Define the metal forming process, two competitive characteristics and
two disadvantages

Answer:
Metal forming is a group of manufacturing process in which the material is
shaped by applying external forces large enough to cause permanent
deformation
Competitive characteristics:
- Mass conservation – material is deformed to certain shape of product
without changing its volume
- Better material properties à grain structure or fibre
- Fast production

Disadvantages:
- Limited for ductile material
- Difficult to form complex shape of product

5
Q6. Define cold working and give three advantages and three disadvantages
of cold working operation on metal

Cold working is a type of forming process where deformation process to shape the
material is conducted at room temperature/below 0.3 melting temperature of the
material

Advantages:
-Better dimensional control
-Better surface finish
-No heating is needed --.easier handling

Disadvantages:
-Higher forces and power required
-Strain hardening limit the extent of forming process
-Limited to low yield strength material

6
Q7. with the help of a simple sketch explain strain hardening during metal
working and two consequences of this phenomena

Strain hardening is the strengthening of a metal by plastic deformation. This

strengthening occurs because of dislocation movements within the crystal
structure of the material

Consequences:
- Greater forces are required
- Heavier and more powerful equipment and
stronger tooling are required
- Metal is less ductile
- Intermediate anneals may be required to
compensate for loss of - ductility that
accompanies strain hardening
- Undesirable residual stress may be
produced

7
Q8. List four parameters in rolling operation which can be decided by the
engineer to ensure the operation is successful

Answer:
List of parameters:
- Cross-sectional reduction
- Strain
- Strain rate
- Temperature
- Elongation
- Force
- Forming resistance
- Power

8
Q9. Metal forming processes, for example the shape rolling operation, need
to be carried out in stages before final shape is achieved. Give three
reasons why it is so.

-Plastic deformation limitation of material

-Better control of the process
-To avoid crack or failure
-Better surface finish

9
Q10. Make a simple sketch and briefly explain the applications of open die
forging and closed die forging

Open die forging is normally used for normally large objects or when the
number of parts produced is small, and frequently it is also used to pre-
form the workpiece for close die forging

Closed die forging is normally used for smaller component which

required high precision or close dimensional tolerance, therefore this
process is expensive
10
Q11. Make a sketch of direct and indirect extrusion of solid bar. List two
advantages for both types of operations
Advantages of direct extrusion:
Complex Integral Shapes
Cost-Effective
Design Flexibility
Simple fastening and assembly
Easy fabrication
Low Tooling Costs Good
Machinability
Precision Tolerances

Advantages of indirect extrusion:

-Eliminate the frictional force between the
container walls and the billet
- lower pressure of load as compared with
direct extrussion

11
 Q12. Describe with simple sketch, any one of the following type of tube
drawing processes
(i) Fixed flug drawing (ii) floating plug drawing (iii) moving mandrel drawing

Answer:
-Fixed plug drawing is a type of tube
drawing that uses a mandrel at the
end of the die to shape the inner
diameter of the tube

-Floating plug drawing, also known

as floating mandrel drawing uses a
mandrel that is not anchored
whatsoever to shape the inner
diameter of the tube

-Moving mandrel drawing is a type

of tube drawing that use of a long
internally disposed rod which moves
with a circumscribed tube hollow
through the die 12