Manufac. Process

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ANSWER SCHEME EXERCISE 1 BMM 3643 MANUFACTURING PROCESS Prepared by: Puan Nurul Shahida Mohd Shalahim Questions 1. Identify some of the important advantages of metal casting processes? Answer: Advantages include: (1) complex part geometries are possible; (2) some casting operations are net shape processes, meaning that no further manufacturing operations are needed to accomplish the final part shape; (3) very large parts are possible; (4) applicable to any metal that can be melted; and (5) some casting processes are suited to mass production. 2. What are some of the limitations and disadvantages of casting? Answer: Disdvantages include: (1) limitations on mechanical strength properties; (2) porosity; (3) poor dimensional accuracy; (4) safety hazards due to handling of hot metals; and (5) environmental problems. 3. What is a factory that performs casting operations? Answer: A foundry. 4. What is the difference of an open mold and a closed mold? Answer: An open mold is open to the atmosphere at the top; it is an open container in the desired shape which must be flat at the top. A closed mold has a cavity that is entirely enclosed by the mold, with a passageway (called the gating system) leading from the outside to the cavity. Molten metal is poured into this gating system to fill the mold. 5. Name the two basic mold types that distinguish casting processes? Answer: The two types are: (1) expendable molds and (2) permanent molds 6. Which casting process is the most important commercially? Answer: The most important casting process is sand casting. 7. What is the difference between a pttern and a core in sand casting? Answer: The pattern determines the external shape of the casted part, while a core determines its internal geometry. 8. Why should turbulent flow of molten metal into the mold be avoided?

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