UNIT – I

Pattern Making
1. Which of the following statement is true?
a) Casting is the replica of the object to be cast
b) Pattern is the replica of the casting object
c) Casting and the pattern are same things
d) Molten material is casted into the casting cavity
View Answer
Answer: b
Explanation: Pattern is the replica of the object. Except for the core prints and
allowances, the pattern exactly resembles the casting.

2. Which of the following carries the mould cavity where the metal is to be
poured?
a) Casting
b) Pattern
c) Sand
d) Core
View Answer
Answer: b
Explanation: For casting to be made, the pattern is filled with the molten
material and then it is allowed to be solidified, using proper cooling rates before
it is extracted out.

3. Which of the following is ‘not’ an allowance given to the pattern for casting?
a) Shrinkage
b) Draft
c) Hole
d) Machining
View Answer
Answer: c
Explanation: A hole is made during the machining or finishing of the casting
and is not a type of allowance given to the pattern.

4. The following diagram shows the application of which of the allowances

given to a pattern?

a) Shrinkage allowance
b) Draft allowance
c) Shake allowance
d) Distortion allowance
View Answer
Answer: b
Explanation: Draft allowance is given so as to ease the removal of casting from
the pattern without damaging the pattern. Hence, tapering the vertical faces with
some draft allowance is provided which is machined later.

5. What will be the machining allowance for a bore of a 405mm cast iron object
to be casted?
a) 1.0mm
b) 2.0mm
c) 3.0mm
d) 5.0mm
View Answer
Answer: d
Explanation: The machining allowance for cast iron of various dimensions is
shown in the table below.

DIMENSIONS(mm) ALLOWANCE(mm)

COPE
BORE SURFACE
SIDE

upto 300 3.0 3.0 5.5

301-500 5.0 4.0 6.0

501-900 6.0 5.0 6.0

Functions of Patterns

1. Which of the following is not a part of the pattern at most times?

a) Mould cavity
b) Cope
c) Molten metal
d) Core
View Answer
Answer: c
Explanation: Molten material is poured into the mould cavity to make a casting,
after solidification and hence, it does not constitute the pattern.

2. Which of the following does not serve the purpose of using patterns in sand
casting?
a) Contain core prints if the casting requires a core and need to be made hollow
b) To give the exact shape and size (in addition to the allowances) to the casting
as that of the final object
c) Reduces the cost of production while used in mass production
d) Sometimes used to carry the mechanism to melt the metal/material which is
to be poured into the cavity
View Answer
Answer: d
Explanation: The pattern never carries or includes the mechanism to melt the
metal, which needs to be poured into the cavity. This job needs to be done
externally.

3. Name the missing part of the pattern in the diagram labelled as (?)?

a) Core
b) Riser
c) Sprue
d) Mould cavity
View Answer
Answer: a
Explanation: The illustrated part in the diagram is core. The core in a pattern is
used to create holes or hollow cavities.
4. The function of a gated pattern is ___________
a) To produce small castings in mass production
b) To create castings of a very heavy mass
c) To create castings containing complex design
d) To create symmetrical castings
View Answer
Answer: a
Explanation: Gated pattern manufactures huge no. of products using single time
casting using a common gating inlet system. Hence, the casting needs to be
small and simple and is only justified for mass production, as the pattern is used
for 1-2 times only.

5. Which of the following factors affect the choice of a pattern at most times?
a) Size and complexity of the casting
b) Characteristics of castings
c) Type of molding and castings method to be used
d) Type of cooling rates to be provided
View Answer
Answer: d
Explanation: The type of cooling rates depends upon the required strength in the
casting, which cannot be controlled by the type of any pattern. Proper chills are
to be used for that purpose.

Pattern Materials

1. Pattern cannot be constructed out of which of the following materials?

a) Wood
b) Wax
c) Oil
d) Metal
View Answer
Answer: c
Explanation: Oil is used as fuels for melting metals in various furnaces. It
cannot be used for constructing a pattern, while all other materials are used for
making patterns.

2. Which of the following is not a criteria for selecting pattern materials?

a) Method of moulding
b) Establishment of parting line
c) Chances of repeat orders
d) Complexity of the casting
View Answer
Answer: b
Explanation: While selecting a pattern, pattern establishing a part line is counted
under functions of the pattern, and not under the criteria for selecting it.
Whereas all the other remaining are factors used for choosing the right pattern
materials.

3. Which among the following wood is most widely used for making patterns?
a) White Pine
b) Mahogany
c) Teak
d) Maple
View Answer
Answer: a
Explanation: White Pine is used most widely for making patterns because, white
pine wood is soft and it is also observed that, it is comparatively easy to work
on this wood. Also, this wood is comparatively cheap.
4. Which of the following is considered to be light wood?
a) Mahogany
b) Maple
c) Birch
d) White Pine
View Answer
Answer: d
Explanation: Among these four woods, White Pine is considered to be the
lightest wood. White Pine is used most widely for making patterns because,
white pine wood is soft and it is also observed that, it is comparatively easy to
work on this wood.

5. Steel is an alloy of which two elements?

a) Iron and Brass
b) Brass and aluminium
c) Iron and carbon
d) Carbon and aluminium
View Answer
Answer: c
Explanation: Steel is an alloy of carbon and iron. Carbon is present in the alloy
up to 2% by weight and it takes up interstitial sites of the microstructure of iron.
There are three types of alloys classified in this, high alloy steel, low alloy steel
and medium alloy steel.

Pattern Types

1. Which of the following factor is not considered while selecting a kind of

pattern?
a) Quantity of casting
b) Types of moulding method
c) Shape of the casting
d) Nature of moulding process
View Answer
Answer: d
Explanation: Nature of moulding process is a factor used selecting pattern
materials, whereas the quantity of casting, types of moulding method and shape
of the casting are used for selecting a type of pattern.

2. Which type of pattern should be used for making stuffing box of the steam
engine?
a) One piece pattern
b) Split Pattern
c) Sweep pattern
d) Gated pattern
View Answer
Answer: a
Explanation: One piece pattern operations for moulding are used for
manufacturing a small number of casting only. Hence, a stuffing box can be
casted with this type of pattern.

3. The following figure represents which type of pattern?

a) One piece pattern

b) Split Pattern
c) Sweep pattern
d) Gated pattern
View Answer
Answer: a
Explanation: The given figure here is depicting a one piece pattern. Here, as we
see, there are no loose pieces available or any joints that bring it together. As
there are no components or loose pieces attached to it, it is a one piece pattern.

4. The following figure represents which pattern?

a) Follow board pattern

b) Gated pattern
c) Match plate pattern
d) Segmental pattern
View Answer
Answer: d
Explanation: The following figure we see there is a pivot. This pivot rotates in
two directions namely, clockwise and anti-clockwise directions. A pattern with
such an apparatus is called as Segmental pattern.

5. In a three piece pattern moulding arrangement, what keeps the alignment

between the two parts of the pattern?
a) Cope
b) Drag
c) Dowel pins
d) Cheek
View Answer
Answer: c
Explanation: Cope and drag are the portions of upper and lower part of the split
and cheek form the middle one. Dowel pins are used for the alignment work in
the pattern.

Pattern Design

1. The designing of a pattern does not include which of the following feature?
a) To locate the direction of the parting line and adjust the component
accordingly
b) To determine regions and measurement of draft angles and radii of the sharp
edges where allowances are to be given
c) To recognize and abolish the region of or where the defects could take place
during casting
d) To 3D print the design for making the pattern
View Answer
Answer: d
Explanation: The printing of a design is executional operation of that casting
design. The design is meant for study the casting structure and modify it
accordingly if needed.

2. Calculate the size of cylindrical riser (height and dia equal) to feed a steel
slab casting 25x25x5 cm.
a) 10cm
b) 12.5cm
c) 14cm
d) Data insufficient
View Answer
Answer: b
Explanation: a = 25cm b = 5cm c = 25cm
Modulus Mc = (a×b)/2(a+b) = Mc = (25×5)/2(25+5) = 125/60 = 2.0833cm
The riser diameter D = 6 x Mc = 6×2.0833 = 12.5cm.

3. Calculate the riser diameter for an annular cylinder of 30 cm outer diameter,

10 cm inner diameter and 30cm height. ( correction factor = 1.14)
a) 22cm
b) 20cm
c) 22.6cm
d) 20.6cm
View Answer
Answer: c
Explanation: Core dia = 10cm Plate thickness = 10cm Correction factor = 1.14

Riser Volume = 0.48 x 18849 = 907.52 cm3

∴ Riser diameter = 22.585cm = 22.6cm.
5. The preferred shape of a runner in a sand casting is ___________
a) Cylindrical
b) Spherical
c) Rectangular
d) Trapezoidal
View Answer
Answer: d
Explanation: Trapezoidal runner is most preferable in sound sand casting as it
provides good flow with less distortion or splattering of molten metal.

Pattern Making

1. Which of the following is not measuring, marking or layout tools?

a) Caliper
b) Trisquare
c) T-bevel
d) Compass Saw
View Answer
Answer: d
Explanation: A caliper, a trisquare and a T-bevel are few of the tools used for
measuring, marking and layout tools used by a pattern maker for making
pattern. A compass saw is not a part of it.

2. Which of the following tool is not used for clamping purpose?

a) C-clamp
b) Trammels
c) Bar clamp
d) Hand Vice
View Answer
Answer: b
Explanation: A trammel is a measuring, marking and layout tool. While C-
clamp, bar clamp, and hand vice are tools which are used for clamping process.

3. Which of the following is not a sawing tool?

a) Coping saw
b) Pinch dog
c) Panel saw
d) Bow saw
View Answer
Answer: b
Explanation: Pinch dog is one of the tools used for clamping processes. While
coping saw, panel saw and bow saw are the different types of sawing tools.

4. Gimlet is which of the following tool?

a) Clamping tools
b) Drilling tool
c) Sawing tool
d) Wood planing tool
View Answer
Answer: b
Explanation: Gimlet is one of the drilling and boring tools. Gimlet is used for
making patterns but is not counted under clamping, sawing or wood planing
tool.

5. Which of the following is not a drilling or boring tool?

a) Brace
b) Counter sink bit
c) Auger bit
d) Hand vice
View Answer
Answer: d
Explanation: Hand vice is one of the tools used for clamping processes. While,
brace, counter sink bit and ager bit are counted among drilling tools or boring
tools.

Pattern Colours

1. While imparting colours to the patterns, which colour scheme is followed?

a) Indian
b) American
c) Australian
d) Britain
View Answer
Answer: b
Explanation: Colours are imparted to the patterns for recognising different parts
and has many other advantages. During impartation certain colours and shades
to the pattern, it is the American colour scheme that is followed.

2. Which of the following reason is not valid for pattern colouring?

a) Identification of main body
b) Visualising the to be machined surface
c) Indication of the type of metal
d) Locating parting surface
View Answer
Answer: d
Explanation: Locating pattern surface is one of the steps of pattern construction,
whereas the identification of the main body, visualising the, to be machined
surface and indication of the type of metal are the reasons as to why a pattern is
imparted colour.

3. Green colour is used for machined cast surface.

a) True
b) False
View Answer
Answer: b
Explanation: Green colour is not given to any of the casting surfaces. Cast
surfaces which are yet to be machined are imparted with red colour. Green
colour, as a matter of fact, is not provided to any pattern.

4. Which colour is given to the cast surfaces which are to be left not-machined?
a) Red
b) Blue
c) Black
d) Yellow
View Answer
Answer: c
Explanation: Provision of colour scheme makes it easy for one to detect the part
and the operation to be performed on it. According to the American pattern
colour scheme, black colour is to be given for cast surface left to be not-
machined.

5. Which colour is given to loose pieces and seatings?

a) Red strip on yellow base
b) Yellow strip on red base
c) Black strip on yellow base
d) Yellow strip on black base
View Answer
Answer: a
Explanation: Provision of colour scheme makes it easy for one to detect the part
and the operation to be performed on it. According to the American pattern
colour scheme, red strip on yellow base is to be given for loose pieces and
seatings.

Moulding

1. Which of the following properties must a material possess to be used in mold

making?
a) High refractoriness
b) Chemical and thermal stability
c) High permeability
d) All of the mentioned
View Answer
Answer: d
Explanation: A material must have all of the above properties so as to be a good
mold making material.

2. Which of the following group of material type is used in mold making?

a) Metallic only
b) Non-Metallic only
c) Both metallic as well as non-metallic
d) Neither metallic nor non-metallic
View Answer
Answer: c
Explanation: Both metallic as well as non-metallic materials are used for
making molds.

3. Which of the following non-metallic material is not used in the synthesis of

molds?
a) Magnesite
b) Silimanite
c) Zircon
d) Valcanised rubber
View Answer
Answer: d
Explanation: Valcanised rubber has a very low refractoriness, hence, using
valcanised rubber for making molds can cause damage to the mold cavity or
metallic structure so formed.

4. High refractoriness of a material refers to its __________

a) Slipperyness of the material
b) Chemical strength towards other material
c) Strength to withstand at high temperature
d) Ability to get dissolved in molten metal
View Answer
Answer: c
Explanation: Refractoriness is the resistance to self deformation at high working
temperatures. A material must possess such property in order to withstand the
temperature of molten metal during casting.

5. Which of the following is a perfect composition of clay (Bentonite) used in

moulding sand?
a) Al2O3
b) Al2O3.2SiO2
c) Al2O3.2H2O
d) Al2O3.2SiO2.2H2O
View Answer
Answer: d
Explanation: Bentonite is one type of clay used in moulding sand as a binder. Its
chemical formula is represented as Al2O3.2SiO2.2H2O.

Moulding Sand

1. Which of the following is not a source of moulding sand?

a) Sea
b) Lakes
c) Desert
d) Forests
View Answer
Answer: d
Explanation: There are a variety of soils which can be found in forests. But the
soils found there cannot be used for casting purposes. Hence forests are not a
source for finding moulding sand, whereas sea, lakes and deserts are a source of
finding them.

2. Which of the following is not a type of moulding sand?

a) Red sand
b) Natural sand
c) Synthetic sand
d) Loam sand
View Answer
Answer: a
Explanation: Red sand is not counted among the moulding sands, whereas
natural sand, synthetic sand and loam sand are various other types of moulding
sand, which can be effectively used for casting processes.
3. What is the percentage composition of clay in natural sand?
a) 22-31%
b) 3-10%
c) 5-20%
d) 18-29%
View Answer
Answer: c
Explanation: In natural sands, the percentage composition of clay is
approximately 5-20% as the binding material. If the percentage composition is
less than that like 3 to 10%, then the binding action will not take place
effectively.

4. What is the percentage composition of water in natural sands?

a) 2-4%
b) 5-8%
c) 6-9%
d) 10-13%
View Answer
Answer: b
Explanation: Water is an important agent used in sands, but its composition
should be inside the desired range. The percentage composition of water in
natural sands is around 5-8% for mixing before making a mould.

5. What is mixed with natural sand to make it semisynthetic sand?

a) Bentonite
b) Barelelne
c) Cubane
d) Prismane
View Answer
Answer: a
Explanation: The addition of a material like bentonite in its sand form, is
because of the need to enhance the sand properties. Bentonite is mixed with
natural sand to make it semisynthetic sand and thus improving its properties.

Moulding Sand Properties

1. Which of the following is not a characteristic property of any moulding sand?

a) Flowability
b) Hardenability
c) Green strength
d) Dry strength
View Answer
Answer: b
Explanation: Flowability, green strength and dry strength are few of the
characteristic properties of moulding sand, but not hardenability.

2. What does a mould having adequate green strength, does not have?
a) Ability to retain its shape
b) Ability not to get distorted
c) Ability not to collapse
d) Ability to retain hardness
View Answer
Answer: d
Explanation: For a mould to be having an adequate amount of green strength, it
must have retaining ability or the ability to get distorted or to collapse. A mould
having adequate green strength does not have the ability to retain hardness.

3. Dry sand does not have the strength for what functions?
a) To withstand corrosion forces
b) To withstand pressure of molten metal
c) To be able to retain its shape
d) To be able to retain the hardenability
View Answer
Answer: d
Explanation: Dry sand has its strength for various purposes like, to withstand a
pressure of molten metal, to withstand corrosion forces and to be able to retain
its shape. But it does not have it for being able to retain the hardenability.

4. Hot strength is seen at what temperature?

a) Above 212°F
b) Above 312°F
c) Above 412°F
d) Above 512°F
View Answer
Answer: a
Explanation: Hot strength basically is the strength of the sand which is present
inside the mould cavity. It is observed that, the hot strength of any material is at
212°F or above it.

5. Which of the following would not happen if hot strength is not enough?
a) The mould may get hardened
b) The mould may get enlarged
c) The mould may get eroded
d) The mould may crack
View Answer
Answer: a
Explanation: If there is not an adequate amount of hot strength provided, then
the mould may get enlarged, the mould may get eroded and the mould may
crack, but the mould will not get hardened.
 Testing of Moulding Sands

1. High moisture causes what in molding sands?

a) Increase in permeability
b) Decrease in permeability
c) Increase in hardness
d) Increase in strength
View Answer
Answer: b
Explanation: Permeability is basically the magnitude of pores present in the
sands and its capacity of moisture it can hold. High moisture content causes a
decrease in permeability of the sand and hence causes other problems in it.

2. The pressure of which gas gives the reading of water content on the pressure
gauge?
a) Methane
b) Acetone
c) Acetylene
d) Carbon dioxide
View Answer
Answer: c
Explanation: Methane, carbon dioxide and acetone are not very useful when it
comes to take readings on the pressure gauge. Acetylene gas helps in getting a
direct reading on the pressure gauge of the water content.

3. Calcium carbide reacts with moisture to give out which gas?

a) Acetylene gas
b) Methane
c) Carbon dioxide
d) Carbon monoxide
View Answer
Answer: a
Explanation: According to the chemical reaction, Calcium carbide when reacts
with moisture, that is water, it is observed to give out calcium hydroxide and
acetylene gas.

4. In a moisture content test, what amount of prepared sand is placed on the

pan?
a) 10-40 grams
b) 20-50 grams
c) 30-60 grams
d) 40-70 grams
View Answer
Answer: b
Explanation: When the tests for composition present in the pan are taken, sands
are a very important factor in it. In a moisture content test, approximately 20
grams to 50 grams of prepared sand is taken in the pan.

5. In a moisture content test, how is the prepared sand heated?

a) Flame heating
b) Ultraviolet heating
c) Infrared heating
d) Conduction heating
View Answer
Answer: c
Explanation: In a moisture content test, the prepared sand is taken in a pan,
about 20 to 50 grams, and then heated using infrared heating.

Core Making
1. Which of the labeled part of the following diagram is a core?

a) a
b) b
c) c
d) d
View Answer
Answer: c
Explanation: A core is that element which is used in moulding processes to
make hollow cavities or holes or to give special contours on the casting which
are difficult or expensive to be machined.

2. Which of the following is not a function of a core?

a) It is used to form internal cavities
b) It is used to form a part of green sand mould
c) It is used as a part of gating system
d) It is used as a part of furnace
View Answer
Answer: d
Explanation: All of the above functions are that of a core except that the core is
never a part of the furnace. somehow it may be used to a path to enhance the
flow of molten metal.

3. Cores are subjected to severe thermal and mechanical conditions.

a) Completely true
b) Partially true
c) Completely false
d) Partially false
View Answer
Answer: a
Explanation: Due to the direct pouring of molten metal (of elevated
temperature) the cores are subjected to severe thermal and mechanical
conditions and proper steps must be taken to avoid pattern or mold spoliation.

4. Which of the following is a function of a core in casting?

a) Interior cavitational passages in a casting
b) To shape an external part of a more intricate casting
c) To strengthen and improve inner and outer surface of the mold
d) All of the mentioned
View Answer
Answer: d
Explanation: A core has versatility of its functions, all the listed functions a core
can perform. Moreover, a core has more functions as well.

5. A permeability of a core should be _________

a) Low
b) Moderate
c) High
d) Has no effect on casting
View Answer
Answer: c
Explanation: The permeability of the material should be high so as to ease the
flow of fluids through it during solidification, may work as gas exchanger or
water absorber.

Solidification of Castings

1. Which of the following is mostly analyzes during the casting and

solidification of casting material?
a) Mould coating
b) Mould material
c) Mould aesthetics
d) Heat transfer
View Answer
Answer: d
Explanation: The quality of final casting mainly dependent on the rate of
solidification as rapid solidification makes fine grains structures with better
mechanical properties. The analysis of heat transfer during the casting and
solidification of casting is mainly carried out to have better properties of casting
material.

2. The solidification time can be increased by increasing the thickness of the

mould.
a) True
b) False
View Answer
Answer: a
Explanation: The temperature variation with time of the casting is generally
recorded by which cooling curves are obtained for the determination of
solidification time of the cast. This shows that the moulding thickness increases
the solidification time of the casting material during solidification.

3. A large shape of a riser is mainly used for the casting of grey cast iron.
a) True
b) False
View Answer
Answer: b
Explanation: Grey cast iron is an interesting exception where solidification
occurs in two stages. The shrinkage associated with the first stage can be
compensated by the expansion of the casting due to the presence of graphite
flakes in the material. Due to this, there is no use of riser in the casting system.

4. Feeding of an alloy in the mould is considered to be difficult if centre-line

feeding resistance (CFR) is_____
a) greater than 70%
b) less than 70%
c) less than 20%
d) 0%
View Answer
Answer: a
Explanation: The difficulty of feeding an alloy in a mould is expressed by a
quantity which is commonly known as centre-line feeding resistance (CFR). It
is basically defined as the ratio of a time interval between start and end of
freezing at centre line to the total solidification time of casting. Normally,
feeding is considered to be difficult if CFR is greater than 70%.
5. Which of the following is independent of the solidification time of the
casting?
a) Mould material
b) Chaplets
c) Heat transfer coefficient
d) Mould wall temperature
View Answer
Answer: b
Explanation: The solidification time of the casting is generally dependent on the
various parameters like mould wall temperature, heat transfer coefficient at the
metal and mould interface, mould wall thickness and material of the mould.
Chaplets are another part used for supporting the core in the mould.

Moulding Machines

1. Which of the following is not a process of ramming?

a) Squeezing
b) Quenching
c) Jolting
d) Slinging
View Answer
Answer: b
Explanation: Ramming of sands is considered to be one of the most important
operations of molding machines. Ramming is done in a molding box. A few
types of ramming operations are, squeezing, jolting, slinging and blowing.

2. Which machine is most useful for making shallow patterns?

a) Squeeze machine
b) Sand slinger
c) Jolt-squeeze machine
d) Jot-squeeze roll over
View Answer
Answer: a
Explanation: In a squeeze machine, there is a squeezer head or a plate which is
used as a pressing board to force the sand inside or compress it. This machine is
mostly used for shallow patterns.

3. Which of the following is not a power operated molding machine?

a) Squeeze machine
b) Sand slinger
c) Jolt-squeeze machine
d) Jot-sand machine
View Answer
Answer: d
Explanation: In the power operated molding machines, there is a use of
compressed air and hydraulic machinery. There are also electromagnets used in
it. These machines are classified as, squeeze machine, sand slinger, jolt-squeeze
machine and sand slinger.

4. At what pressure, does the compressed air enter in squeezing machine?

a) 6 kg(f)/cm2
b) 7 kg(f) /cm2
c) 8 kg(f) /cm2
d) 9 kg(f) /cm2
View Answer
Answer: b
Explanation: In squeezing machines, the sand used is rammed very hard. It has
a greater density at the surface than at the interiors. The air required for
compression of the sand, enters at 7 kg(f) /cm2.
5. Up to what depth of molds is a squeezing machine used?
a) 10 cm
b) 12 cm
c) 15 cm
d) 18 cm
View Answer
Answer: c
Explanation: It is considered among one of the limitations of squeezing molding
machines, that they can only be used if the mold is shallow. The depth up to
which a squeezing molding machine can be used is 15 cm.