Welding Processes - Basics & MCQs

Introduction to Welding

Welding is a process of joining metals by applying heat, pressure, or both.

Classification of Welding Processes:

- Fusion Welding (No Pressure Applied): Gas Welding, Arc Welding, Resistance Welding, Thermit
Welding
- Pressure Welding (With Pressure Applied): Forge Welding, Friction Welding, Ultrasonic Welding

Gas Welding:

Uses oxy-acetylene flame to join metals.

Advantages: Simple, portable, good for thin materials.
Disadvantages: Slow process, not for heavy welding.

Arc Welding:

Uses an electric arc between an electrode and metal to generate heat.

Types of Arc Welding:

- Shielded Metal Arc Welding (SMAW): Uses a coated electrode (stick welding)
- Tungsten Inert Gas Welding (TIG): Uses non-consumable tungsten electrode
- Metal Inert Gas Welding (MIG): Uses continuous consumable wire electrode

Resistance Welding:

- Spot Welding: Used for thin sheets like car bodies.

- Seam Welding: Continuous weld for leak-proof joints like fuel tanks.
- Projection Welding: Uses small projections for welding.

Thermit Welding:

Uses aluminum powder and iron oxide to create high temperatures.

Used for railway track welding and heavy castings.

Common Welding Defects:

- Porosity (Gas holes in weld)

- Cracks (Brittle cracks in weld)
- Undercut (Groove at the weld toe)
- Incomplete Fusion (Poor bonding between metal parts)

Multiple Choice Questions (MCQs)

1. What is welding?
A. Cutting metals
B. Joining metals using heat/pressure
C. Painting metals
D. Cooling metals
Answer: B

2. Which welding process uses an oxy-acetylene flame?

A. Arc Welding
B. Gas Welding
C. TIG Welding
D. MIG Welding
Answer: B

3. What is the main heat source in Arc Welding?

A. Gas Flame
B. Friction
C. Electric Arc
D. Chemical Reaction
Answer: C

4. Which electrode is used in TIG welding?

A. Copper
B. Tungsten
C. Aluminum
D. Carbon
Answer: B

5. Which welding process is used in automobile industries?

A. MIG Welding
B. Thermit Welding
C. Gas Welding
D. Friction Welding
Answer: A

6. Which resistance welding method is used for car bodies?

A. Spot Welding
B. Seam Welding
C. Projection Welding
D. Friction Welding
Answer: A
7. What is used in Thermit Welding?
A. Iron Powder
B. Aluminum Powder + Iron Oxide
C. Zinc Powder
D. Copper Oxide
Answer: B

8. Which defect occurs due to trapped gas in welding?

A. Undercut
B. Porosity
C. Incomplete Fusion
D. Crack
Answer: B

9. What is a major disadvantage of Gas Welding?

A. High cost
B. Slow process
C. Weak joints
D. Requires special electrodes
Answer: B

10. What protects the weld pool in MIG welding?

A. Inert Gas
B. Oxygen
C. Flux
D. Water
Answer: A

11. Which welding is best for thin metal sheets?

A. Arc Welding
B. Resistance Welding
C. Thermit Welding
D. Friction Welding
Answer: B

12. What does SMAW stand for?

A. Shielded Metal Arc Welding
B. Standard Metal Arc Welding
C. Solid Metal Arc Welding
D. Strong Metal Arc Welding
Answer: A
13. What is the role of flux in welding?
A. To increase heat
B. To remove impurities
C. To add strength
D. To create electric arc
Answer: B

14. What is the purpose of a welding electrode?

A. To protect the weld
B. To conduct electricity and melt metal
C. To cool down the weld
D. To clean the surface
Answer: B

15. Which welding is used in railway track repair?

A. Arc Welding
B. Thermit Welding
C. Resistance Welding
D. Gas Welding
Answer: B

16. Which welding process does NOT require an external filler metal?
A. TIG Welding
B. MIG Welding
C. Gas Welding
D. Resistance Welding
Answer: D

17. What causes cracks in welding?

A. Too much gas
B. Rapid cooling
C. Slow cooling
D. Lack of flux
Answer: B

18. Which welding defect creates a groove at the weld toe?

A. Porosity
B. Undercut
C. Cold Shut
D. Cracks
Answer: B
19. What is the key advantage of TIG welding?
A. High speed
B. High-quality welds
C. Cheap cost
D. No electricity required
Answer: B

20. Which welding method is most commonly used in shipbuilding?

A. Gas Welding
B. MIG Welding
C. Arc Welding
D. Resistance Welding
Answer: C
 Welding Processes - Basics & MCQs

Welding:

Welding is a fabrication process that joins materials, usually metals or thermoplastics, by melting
and fusing them together.

Classification of Welding Processes:

1. Fusion Welding - Melts base metals to form a joint.

2. Solid-State Welding - Uses pressure or heat without melting.
Common types: Gas Welding, Arc Welding, TIG, MIG, and Resistance Welding.

1. Gas Welding:

Uses a flame from burning gases (like oxygen-acetylene) to melt and join metals.
Common in sheet metal work and repair jobs.

2. Arc Welding:

Uses an electric arc between an electrode and metal to produce heat.

Commonly used for structural welding and industrial applications.

3. TIG (Tungsten Inert Gas) Welding:

Uses a non-consumable tungsten electrode with inert gas shielding.

Produces high-quality, precise welds in aerospace and automotive industries.

4. MIG (Metal Inert Gas) Welding:

Uses a continuously fed wire electrode with inert gas shielding.

Ideal for fast, automated welding in industries like shipbuilding and pipelines.

5. Resistance Welding:

Uses electrical resistance to generate heat and fuse metals.

Common types: Spot Welding and Seam Welding, widely used in automotive manufacturing.

Advantages of Welding:

1. Strong and permanent joints.

2. High efficiency and material savings.
3. Can be automated for mass production.

Disadvantages of Welding:

1. Requires skilled operators.

2. Welded joints can be brittle if improperly done.
3. Produces fumes that require proper ventilation.

Applications of Welding:

Used in construction, automotive, aerospace, shipbuilding, and heavy machinery industries.

Multiple Choice Questions (MCQs)

1. Which welding process uses a non-consumable tungsten electrode?

A. MIG
B. TIG
C. Arc Welding
D. Gas Welding
Answer: B

2. Which welding method is most suitable for welding thin sheets?

A. TIG
B. Arc Welding
C. Resistance Welding
D. Gas Welding
Answer: A

3. Which gas is commonly used in gas welding?

A. Oxygen
B. Acetylene
C. Argon
D. Both A & B
Answer: D

4. What is the main advantage of MIG welding?

A. High welding speed
B. Low heat input
C. No shielding gas needed
D. Requires no electricity
Answer: A

5. Which welding method uses electrical resistance to generate heat?

A. Arc Welding
B. Resistance Welding
C. Gas Welding
D. Plasma Welding
Answer: B
6. TIG welding is preferred for:
A. Fast welding
B. High-precision welds
C. Welding thick metals
D. Automated welding
Answer: B

7. Which welding process is commonly used in automobile industries?

A. Resistance Welding
B. Gas Welding
C. Stick Welding
D. Plasma Welding
Answer: A

8. Which shielding gas is used in MIG welding?

A. Oxygen
B. Acetylene
C. Argon
D. Hydrogen
Answer: C

9. In resistance welding, heat is generated due to:

A. Electric arc
B. Gas combustion
C. Electrical resistance
D. Friction
Answer: C

10. What is the major disadvantage of welding?

A. Weak joints
B. Produces harmful fumes
C. High material cost
D. Difficult automation
Answer: B

11. Spot welding is a type of:

A. Gas Welding
B. Resistance Welding
C. Arc Welding
D. MIG Welding
Answer: B
12. Which welding process uses a wire electrode continuously fed through a nozzle?
A. Arc Welding
B. MIG Welding
C. TIG Welding
D. Resistance Welding
Answer: B

13. What is the main purpose of shielding gas in welding?

A. Increase heat
B. Prevent oxidation
C. Reduce spatter
D. Increase arc length
Answer: B

14. Which welding process is best for welding aluminum?

A. TIG
B. Arc
C. Gas
D. Resistance
Answer: A

15. What is the main function of a flux in welding?

A. Increase heat
B. Remove impurities
C. Improve joint strength
D. Reduce cooling time
Answer: B

16. Which welding method is known as stick welding?

A. TIG
B. Arc
C. MIG
D. Resistance
Answer: B

17. In which welding method is filler material optional?

A. MIG
B. TIG
C. Resistance
D. Gas Welding
Answer: B
18. What is the major cause of porosity in welding?
A. Gas contamination
B. High voltage
C. High welding speed
D. Lack of filler material
Answer: A

19. The purpose of preheating in welding is to:

A. Reduce residual stress
B. Increase cooling rate
C. Decrease weld strength
D. Prevent oxidation
Answer: A

20. Which welding method is commonly used in shipbuilding?

A. MIG
B. Arc
C. TIG
D. Gas Welding
Answer: A
 Special Casting Processes & Casting Defects - Basics & MCQs

Special Casting Processes:

Special casting techniques are used to improve casting quality and suit specific applications.

1. Die Casting:

Involves forcing molten metal into a metal mold under high pressure. Produces high-precision parts
with smooth surfaces.
Commonly used for making automobile parts, electronic housings, and kitchen utensils.

2. Centrifugal Casting:

Molten metal is poured into a rotating mold, forcing it outward by centrifugal force.
Used for making pipes, cylinders, and rings with uniform properties.

3. Investment Casting:

A wax model is coated with ceramic material and then melted out, leaving a mold.
Used for making complex and high-precision components like turbine blades and jewelry.

Casting Defects:

Defects occur due to improper pouring, cooling, or mold conditions. Common defects include:

1. Porosity:

Gas bubbles trapped in the metal cause holes and weak spots.

2. Shrinkage Defect:

Occurs when metal contracts as it solidifies, leading to cavities.

3. Cold Shut:

Happens when two metal streams fail to fuse properly, forming a weak joint.

4. Misrun:

Occurs when the molten metal does not fill the entire mold, causing incomplete casting.

5. Inclusion Defect:

Foreign materials like slag or sand get trapped in the casting, weakening it.

Multiple Choice Questions (MCQs)

1. Which casting method uses high-pressure metal molds?

A. Sand Casting
 B. Die Casting
C. Investment Casting
D. Shell Molding
Answer: B

2. Which casting process is best for producing pipes?

A. Die Casting
B. Centrifugal Casting
C. Investment Casting
D. Continuous Casting
Answer: B

3. Which casting method is also known as the lost-wax process?

A. Sand Casting
B. Investment Casting
C. Die Casting
D. Shell Molding
Answer: B

4. What causes porosity in casting?

A. High pressure
B. Gas entrapment
C. Low temperature
D. Slow pouring
Answer: B

5. Which defect occurs when molten metal does not fill the mold?
A. Misrun
B. Porosity
C. Shrinkage
D. Inclusion
Answer: A

6. Centrifugal casting is primarily used for making:

A. Thin sheets
B. Cylindrical objects
C. Complex jewelry
D. Engine blocks
Answer: B

7. Investment casting is mainly used for:

A. Large and simple parts
 B. High-precision complex shapes
C. Porous materials
D. Fast production
Answer: B

8. Die casting is preferred for:

A. Small batch production
B. High-volume production
C. Low-pressure casting
D. Non-metallic parts
Answer: B

9. Shrinkage defects in casting occur due to:

A. Rapid cooling
B. Uneven solidification
C. High pouring temperature
D. Slow cooling
Answer: B

10. Inclusions in casting are caused by:

A. Trapped gases
B. Foreign materials
C. High cooling rate
D. Excessive mold temperature
Answer: B
 Solidification of Casting & Types of Solidification - Basics & MCQs

Solidification of Casting:

Solidification is the process in which molten metal changes into a solid state after being poured into
a mold. The solidification process affects the structure, mechanical properties, and defects in the
casting.

Stages of Solidification:

1. Nucleation - Tiny solid particles (nuclei) begin to form in the liquid metal.
2. Growth - Nuclei grow into grains, forming the solid metal structure.
3. Cooling - The metal continues to cool and solidify completely.

Types of Solidification:

1. Directional Solidification - Metal solidifies from one end to the other, reducing defects.
2. Equiaxed Solidification - Grains form in all directions, giving a uniform structure.
3. Progressive Solidification - Solidification starts from the mold walls and progresses inward.

Factors Affecting Solidification:

1. Cooling Rate - Faster cooling produces finer grains.

2. Mold Material - Affects heat dissipation and solidification time.
3. Metal Composition - Different alloys solidify at different rates.

Applications:

Used in all casting processes like sand casting, die casting, and investment casting.
Essential in manufacturing engine blocks, turbine blades, and machine components.

Multiple Choice Questions (MCQs)

1. What is the process of changing molten metal into a solid state called?
A. Evaporation
B. Condensation
C. Solidification
D. Melting
Answer: C

2. Which stage of solidification involves the formation of small solid particles?

A. Growth
B. Cooling
C. Nucleation
 D. Crystallization
Answer: C

3. Which type of solidification occurs when metal solidifies from one end to the other?
A. Equiaxed
B. Directional
C. Progressive
D. Rapid
Answer: B

4. What factor affects the solidification time of a casting?

A. Mold material
B. Pouring height
C. Metal density
D. All of the above
Answer: D

5. Which solidification method helps reduce casting defects?

A. Equiaxed
B. Directional
C. Progressive
D. None of these
Answer: B
 Moulding Materials & Properties of Moulding Sand - Basics & MCQs

Moulding Materials:

Moulding materials are used to create molds for casting. The most common material is sand, but
other materials like plaster, ceramics, and metals are also used.

Types of Moulding Materials:

1. Green Sand - A mixture of silica sand, clay, water, and organic additives.
2. Dry Sand - Green sand that is dried before pouring molten metal.
3. Loam Sand - A highly plastic material used for large castings.
4. Facing Sand - A special layer of sand applied to the mold surface for better finish.
5. Parting Sand - Used to prevent sticking between mold parts.

Properties of Moulding Sand:

1. Permeability - Allows gases to escape from the mold.

2. Strength - Holds its shape under pressure.
3. Refractoriness - Withstands high temperatures without melting.
4. Cohesiveness - Binds particles together for mold stability.
5. Flowability - Fills mold cavities properly.

Applications:

Used in sand casting for automotive, aerospace, and industrial machinery parts.
Ensures high-quality casting with minimal defects.

Multiple Choice Questions (MCQs)

1. What is the primary material used in sand moulding?

A. Clay
B. Silica Sand
C. Plaster
D. Metal
Answer: B

2. Which property of moulding sand allows gases to escape?

A. Strength
B. Cohesiveness
C. Permeability
D. Hardness
Answer: C
3. Which type of sand is used for large castings?
A. Green Sand
B. Dry Sand
C. Loam Sand
D. Parting Sand
Answer: C

4. What is the role of facing sand?

A. Prevent sticking
B. Provide a smooth surface
C. Bind particles
D. Absorb moisture
Answer: B

5. Which property of sand ensures it retains its shape?

A. Refractoriness
B. Strength
C. Flowability
D. Hardness
Answer: B
 Patterns, Pattern Materials & Allowances - Basics & MCQs

Patterns in Casting:

A pattern is a replica of the final casting that is used to create the mold cavity in casting processes.

Types of Patterns:

1. Single Piece Pattern - Simple and used for small production.

2. Split Pattern - Made in two halves for complex shapes.
3. Gated Pattern - Multiple cavities connected by a gating system.
4. Match Plate Pattern - Patterns mounted on a plate for mass production.
5. Loose Piece Pattern - Used when parts of the pattern need to be removed separately.

Pattern Materials:

1. Wood - Lightweight and cheap but has a short life.

2. Metal - Durable and precise but expensive.
3. Plastic - Resistant to moisture but can deform with heat.

Pattern Allowances:

1. Shrinkage Allowance - Compensates for metal contraction during cooling.

2. Machining Allowance - Extra material added for finishing operations.
3. Draft Allowance - Taper added to remove the pattern from the mold easily.
4. Distortion Allowance - Adjusts for shape changes due to stress.
5. Shake Allowance - Extra material for patterns that need to be shaken out.

Applications of Patterns:

Used in sand casting and investment casting to form mold cavities.

Essential in industries like automotive, aerospace, and heavy machinery.

Multiple Choice Questions (MCQs)

1. What is the purpose of a pattern in casting?

A. To melt the metal
B. To form the mold cavity
C. To cool the metal
D. To clean the casting
Answer: B

2. Which pattern type is best for complex shapes?

A. Single Piece Pattern
 B. Split Pattern
C. Gated Pattern
D. Match Plate Pattern
Answer: B

3. Which material is most commonly used for patterns?

A. Glass
B. Rubber
C. Wood
D. Concrete
Answer: C

4. What is the main disadvantage of using wooden patterns?

A. High cost
B. Heavy weight
C. Short lifespan
D. Poor surface finish
Answer: C

5. Which pattern type is best for mass production?

A. Single Piece
B. Loose Piece
C. Gated Pattern
D. Match Plate Pattern
Answer: D

6. What does a shrinkage allowance compensate for?

A. Mold expansion
B. Metal contraction
C. Rough surface finish
D. Gas defects
Answer: B

7. Which allowance is given for machining operations?

A. Shrinkage Allowance
B. Draft Allowance
C. Machining Allowance
D. Shake Allowance
Answer: C

8. Why is a draft allowance provided?

A. To reduce shrinkage
 B. To remove the pattern easily
C. To avoid surface defects
D. To improve cooling
Answer: B

9. What type of pattern consists of multiple cavities?

A. Match Plate Pattern
B. Loose Piece Pattern
C. Gated Pattern
D. Split Pattern
Answer: C

10. Which metal is commonly used for durable patterns?

A. Aluminum
B. Lead
C. Zinc
D. Copper
Answer: A

11. What is the primary advantage of metal patterns?

A. Lightweight
B. Cheap cost
C. High durability
D. Easy to modify
Answer: C

12. What is the purpose of a shake allowance?

A. Reduce cooling time
B. Allow easy removal of the pattern
C. Improve casting strength
D. Prevent porosity
Answer: B

13. Which material is least likely to be used for a pattern?

A. Wood
B. Metal
C. Plastic
D. Paper
Answer: D

14. What is the main function of a pattern in sand casting?

A. To shape the molten metal
 B. To improve surface finish
C. To make the mold cavity
D. To remove gases
Answer: C

15. Which type of pattern is used when the casting requires internal cavities?
A. Split Pattern
B. Gated Pattern
C. Core Pattern
D. Match Plate Pattern
Answer: C

16. Which allowance is needed to prevent distortion in thin-walled castings?

A. Shrinkage Allowance
B. Distortion Allowance
C. Machining Allowance
D. Draft Allowance
Answer: B

17. Which of the following is NOT a function of a pattern?

A. Forming the mold cavity
B. Providing allowances
C. Pouring molten metal
D. Creating internal cores
Answer: C

18. Why are plastic patterns used in casting?

A. High strength
B. Moisture resistance
C. High thermal conductivity
D. Low cost
Answer: B

19. Which casting process commonly uses investment patterns?

A. Sand Casting
B. Investment Casting
C. Die Casting
D. Centrifugal Casting
Answer: B

20. Which type of pattern is best suited for automated molding machines?
A. Single Piece
 B. Match Plate
C. Split Pattern
D. Loose Piece
Answer: B

21. What is the main problem if an improper shrinkage allowance is provided?

A. Casting distortion
B. Excess material waste
C. Metal expansion
D. Poor surface finish
Answer: A

22. Which pattern type is best suited for large-scale production with high accuracy?
A. Loose Piece
B. Match Plate
C. Split Pattern
D. Gated Pattern
Answer: B
 Foundry Process / Casting - Basics & MCQs

Foundry Process / Casting:

Casting is a process where molten metal is poured into a mold to form a desired shape.

Steps in the Casting Process:

1. Pattern Making - Creating a replica of the final product.

2. Mould Preparation - Forming a mold using sand or other materials.
3. Melting and Pouring - Molten metal is poured into the mold.
4. Solidification and Cooling - The metal hardens inside the mold.
5. Shakeout and Cleaning - The casting is removed and cleaned.
6. Inspection and Finishing - The casting is checked for defects and finished.

Types of Casting Processes:

1. Sand Casting - Uses sand molds; economical but rough surface finish.
2. Die Casting - Metal is forced into a metal mold under pressure.
3. Investment Casting - Uses a wax pattern coated with ceramic.
4. Centrifugal Casting - Molten metal is poured into a rotating mold.

Applications of Casting:

- Used for making engine blocks, pipes, gears, and sculptures.

- Essential in automobile, aerospace, and heavy machinery industries.

Multiple Choice Questions (MCQs)

1. What is the first step in the casting process?

A. Melting
B. Pattern Making
C. Mould Preparation
D. Pouring
Answer: B

2. Which casting method uses sand molds?

A. Die Casting
B. Investment Casting
C. Sand Casting
D. Centrifugal Casting
Answer: C

3. Which material is commonly used in investment casting?

 A. Wax
B. Clay
C. Plastic
D. Aluminum
Answer: A

4. What is the main advantage of die casting?

A. Cheap cost
B. High precision and smooth finish
C. Requires no mold
D. Uses low pressure
Answer: B

5. Which type of casting is best for making cylindrical parts?

A. Sand Casting
B. Die Casting
C. Centrifugal Casting
D. Shell Molding
Answer: C

6. What happens during the solidification phase of casting?

A. The metal melts
B. The metal cools and hardens
C. The mold is removed
D. The metal is poured
Answer: B

7. What is the purpose of shakeout in casting?

A. To remove gases
B. To remove the mold
C. To pour molten metal
D. To heat the metal
Answer: B

8. Which metal is commonly used in die casting?

A. Copper
B. Zinc
C. Lead
D. Titanium
Answer: B

9. What is the disadvantage of sand casting?

 A. High cost
B. Rough surface finish
C. High precision
D. Cannot be used for large parts
Answer: B

10. Which casting process involves rotating the mold?

A. Sand Casting
B. Investment Casting
C. Die Casting
D. Centrifugal Casting
Answer: D

11. Which property is essential for moulding sand?

A. High brittleness
B. Low porosity
C. High permeability
D. Low strength
Answer: C

12. What is a pattern in casting?

A. The metal used in casting
B. The furnace for melting metal
C. A replica of the final casting
D. A machine used for shaping metal
Answer: C

13. What does the gating system in casting do?

A. Helps in metal cooling
B. Directs molten metal into the mold
C. Improves surface finish
D. Strengthens the metal
Answer: B

14. Which casting method provides the highest precision?

A. Sand Casting
B. Die Casting
C. Investment Casting
D. Centrifugal Casting
Answer: C

15. What is the function of risers in casting?

 A. To remove impurities
B. To store extra molten metal
C. To shape the mold
D. To support the pattern
Answer: B

16. Which casting method uses a ceramic mold?

A. Sand Casting
B. Die Casting
C. Investment Casting
D. Centrifugal Casting
Answer: C

17. What is shrinkage in casting?

A. Expansion of metal
B. Reduction in metal volume during solidification
C. Mold cracking
D. Excess material formation
Answer: B

18. Why is venting important in sand casting?

A. Removes excess metal
B. Prevents gas defects
C. Increases cooling time
D. Strengthens the mold
Answer: B

19. Which process is called lost-wax casting?

A. Sand Casting
B. Die Casting
C. Investment Casting
D. Centrifugal Casting
Answer: C

20. Which defect occurs due to trapped air in casting?

A. Shrinkage
B. Blowholes
C. Misrun
D. Cold Shut
Answer: B

21. What is the role of binders in moulding sand?

 A. Improve permeability
B. Increase strength of the mold
C. Reduce shrinkage
D. Remove gas defects
Answer: B

22. Which casting process is best for making engine blocks?

A. Sand Casting
B. Investment Casting
C. Die Casting
D. Centrifugal Casting
Answer: C

23. What is the primary purpose of a core in casting?

A. Improve surface finish
B. Shape internal cavities
C. Reduce metal wastage
D. Increase cooling rate
Answer: B

24. Which of the following is NOT a casting defect?

A. Porosity
B. Cold Shut
C. Flash
D. Welding Bead
Answer: D

25. Which casting method requires high pressure?

A. Sand Casting
B. Die Casting
C. Investment Casting
D. Centrifugal Casting
Answer: B
 Lathe, Milling, and Drilling Machines - Basics & MCQs

Lathe Machine:

A lathe is used to rotate a workpiece against a cutting tool to shape it.

Components of a Lathe Machine:

- Bed: Supports all parts.

- Headstock: Holds the spindle and motor.
- Tailstock: Supports the end of the workpiece.
- Carriage: Holds and moves the cutting tool.
- Chuck: Clamps the workpiece.

Types of Lathe Machines:

- Engine Lathe: Common workshop lathe.

- Turret Lathe: Used for mass production.
- CNC Lathe: Computer-controlled for high precision.

Applications of Lathe:

- Used for turning, facing, drilling, and threading.

- Used in metalworking, woodworking, and plastics industries.

Milling Machine:

A milling machine removes material using a rotating cutter.

Types of Milling Machines:

- Vertical Milling Machine: Cutter moves up and down.

- Horizontal Milling Machine: Cutter moves sideways.
- CNC Milling Machine: Automated and precise.

Applications of Milling Machine:

- Used for cutting gears, slots, and complex shapes.

- Used in automobile and aerospace industries.

Drilling Machine:

A drilling machine is used to create holes in materials.

Types of Drilling Machines:

- Bench Drilling Machine: Small, for light work.

- Radial Drilling Machine: Large, adjustable arm.
- CNC Drilling Machine: Computer-controlled.

Applications of Drilling Machine:

- Used in manufacturing, construction, and metalworking.

Multiple Choice Questions (MCQs)

1. Which machine is used to rotate a workpiece against a cutting tool?

A. Milling Machine
B. Lathe Machine
C. Drilling Machine
D. Grinding Machine
Answer: B

2. What is the function of the chuck in a lathe?

A. Holds the cutting tool
B. Supports the tailstock
C. Clamps the workpiece
D. Controls spindle speed
Answer: C

3. Which lathe is used for mass production?

A. Engine Lathe
B. CNC Lathe
C. Turret Lathe
D. Bench Lathe
Answer: C

4. What does a milling machine do?

A. Rotates the workpiece
B. Removes material using a rotating cutter
C. Creates threads
D. Holds the workpiece
Answer: B

5. Which type of milling machine has a cutter moving up and down?

A. Horizontal Milling Machine
B. Vertical Milling Machine
C. CNC Milling Machine
D. Radial Milling Machine
Answer: B
6. Which drilling machine is best for heavy-duty work?
A. Bench Drilling Machine
B. Radial Drilling Machine
C. Hand Drill
D. CNC Drilling Machine
Answer: B

7. What is the purpose of the tailstock in a lathe?

A. To rotate the spindle
B. To hold and support the workpiece
C. To clamp the tool post
D. To adjust speed
Answer: B

8. Which machine is commonly used to cut gears?

A. Lathe
B. Milling Machine
C. Drilling Machine
D. Planer Machine
Answer: B

9. Which part of the lathe moves the cutting tool?

A. Headstock
B. Tailstock
C. Carriage
D. Chuck
Answer: C

10. What is the advantage of a CNC lathe?

A. Low cost
B. High precision
C. Manual operation
D. Slow process
Answer: B

11. Which machine is mainly used for hole-making?

A. Milling Machine
B. Drilling Machine
C. Lathe Machine
D. Shaping Machine
Answer: B
12. What is the function of the bed in a lathe?
A. Supports all machine parts
B. Rotates the spindle
C. Holds the cutting tool
D. Adjusts the feed rate
Answer: A

13. Which milling machine is controlled by a computer?

A. Vertical Milling Machine
B. Horizontal Milling Machine
C. CNC Milling Machine
D. Universal Milling Machine
Answer: C

14. Which machine is used for cutting slots and keyways?

A. Lathe
B. Drilling Machine
C. Milling Machine
D. Grinding Machine
Answer: C

15. What is the main function of a radial drilling machine?

A. Drilling holes in small parts
B. Cutting metal sheets
C. Drilling large and heavy workpieces
D. Threading
Answer: C

16. Which part of the lathe holds and rotates the workpiece?
A. Tailstock
B. Chuck
C. Carriage
D. Bed
Answer: B

17. Which machine is used for shaping wood and metals?

A. Lathe
B. CNC Milling
C. Drilling Machine
D. Grinding Machine
Answer: A
18. Which part of the milling machine holds the cutting tool?
A. Table
B. Arbor
C. Column
D. Spindle
Answer: D

19. Which process is used to enlarge an existing hole?

A. Drilling
B. Boring
C. Reaming
D. Tapping
Answer: B

20. Which type of milling machine is best for heavy workpieces?

A. Bench Milling Machine
B. Vertical Milling Machine
C. CNC Milling Machine
D. Horizontal Milling Machine
Answer: D

21. What does CNC stand for?

A. Computerized Numerical Control
B. Centralized Numerical Control
C. Continuous Network Control
D. Controlled Numeric Code
Answer: A

22. Which lathe machine is fully automated?

A. CNC Lathe
B. Engine Lathe
C. Turret Lathe
D. Speed Lathe
Answer: A

23. Which machine uses a rotating drill bit to create holes?

A. Milling Machine
B. Drilling Machine
C. Lathe Machine
D. Planer Machine
Answer: B
24. What is a key advantage of CNC milling?
A. Requires no programming
B. Higher precision and automation
C. Lower material cost
D. Faster than all other machines
Answer: B

25. Which part of a lathe adjusts the speed of the spindle?

A. Chuck
B. Tailstock
C. Headstock
D. Bed
Answer: C
 Casting and Foundry Processes - Basics & MCQs

Foundry Process (Casting)

Casting is a process where molten metal is poured into a mold to create a shape.

Steps in Casting:

- Pattern Making
- Molding
- Melting & Pouring
- Solidification
- Removing the Casting
- Finishing & Inspection

Patterns in Casting:

Patterns are used to create molds.

Types of Patterns:

- Single Piece Pattern (Simple Shapes)

- Split Pattern (Complex Shapes)
- Match Plate Pattern (Mass Production)
- Gated Pattern (Includes Metal Flow System)

Pattern Materials:

- Wood (Cheap, wears out fast)

- Metal (Strong, durable)
- Plastic (Lightweight, long-lasting)

Pattern Allowances:

- Shrinkage Allowance (Compensates for cooling shrinkage)

- Machining Allowance (Extra material for finishing)
- Draft Allowance (Sloped sides for easy removal)

Molding Materials:

Molds are made using sand, clay, and water.

Properties of Molding Sand:

- Refractoriness (Withstands high temperatures)

- Permeability (Allows gases to escape)
- Cohesiveness (Holds shape well)
- Plasticity (Easily shaped)

Solidification of Casting:

Solidification is the cooling and hardening of molten metal.

Types of Solidification:

- Directional Solidification (Cooling from one end to another)

- Progressive Solidification (Cooling layer by layer)

Special Casting Processes:

- Die Casting (High-pressure casting for precision)

- Centrifugal Casting (Used for making pipes)
- Investment Casting (Lost wax process for complex parts)

Casting Defects:

- Porosity (Gas bubbles in metal)

- Shrinkage (Cracks due to cooling)
- Misrun (Metal does not fill mold)
- Cold Shut (Two metal streams fail to fuse)

Multiple Choice Questions (MCQs)

1. Which process involves pouring molten metal into a mold?

A. Forging
B. Casting
C. Welding
D. Rolling
Answer: B

2. What is the purpose of a pattern in casting?

A. To shape the mold
B. To melt metal
C. To strengthen the casting
D. To remove impurities
Answer: A

3. Which of the following is NOT a type of pattern?

A. Split Pattern
B. Match Plate Pattern
C. Blow Pattern
D. Gated Pattern
 Answer: C

4. Why is shrinkage allowance given in patterns?

A. To prevent cracking
B. To allow metal expansion
C. To compensate for cooling shrinkage
D. To avoid air bubbles
Answer: C

5. What is the key property of molding sand that allows gases to escape?
A. Refractoriness
B. Cohesiveness
C. Permeability
D. Plasticity
Answer: C

6. Which casting process is best for making pipes?

A. Die Casting
B. Sand Casting
C. Centrifugal Casting
D. Investment Casting
Answer: C

7. In investment casting, which material is used for patterns?

A. Metal
B. Wax
C. Plastic
D. Clay
Answer: B

8. What defect occurs due to gas trapped in the metal?

A. Shrinkage
B. Misrun
C. Porosity
D. Cold Shut
Answer: C

9. Which casting method uses high pressure to force molten metal into a mold?
A. Sand Casting
B. Investment Casting
C. Die Casting
D. Centrifugal Casting
 Answer: C

10. Which solidification type cools layer by layer?

A. Directional Solidification
B. Progressive Solidification
C. Instant Solidification
D. Random Solidification
Answer: B
 Lathe, Milling, and Drilling Machines - Basics & MCQs

Lathe Machine

A lathe is used for shaping materials by rotating them while a cutting tool removes material.

Main Components:

- Headstock: Holds and rotates the workpiece

- Tailstock: Supports the other end of the workpiece
- Carriage: Moves the cutting tool
- Bed: Provides support
- Chuck: Clamps the workpiece

Types of Lathe:

- Engine Lathe (general machining)

- Turret Lathe (mass production)
- CNC Lathe (computer-controlled)

Applications:

- Cutting, drilling, threading metals

- Shaping wood & plastic
- Manufacturing machine parts

Milling Machine

A milling machine removes material using a rotating cutter, with the workpiece remaining still.

Main Components:

- Column & Base: Support the machine

- Table: Holds the workpiece
- Spindle: Rotates the cutter
- Knee & Saddle: Allow movement

Types of Milling Machine:

- Vertical Milling (cutter moves up & down)

- Horizontal Milling (cutter moves side-to-side)
- CNC Milling (computer-controlled)

Applications:

- Making gears
- Cutting slots & shapes
- Drilling holes in metal

Drilling Machine

A drilling machine makes holes in materials using a rotating drill bit.

Main Components:

- Base: Supports the machine

- Column: Holds the spindle & motor
- Spindle: Rotates the drill bit
- Table: Holds the workpiece

Types of Drilling Machine:

- Bench Drill (small, light work)

- Radial Drill (for large workpieces)
- CNC Drill (automated, high precision)

Applications:

- Making holes in metal & wood

- Tapping (creating threads in holes)
- Reaming (finishing holes with precision)

Multiple Choice Questions (MCQs)

1. Which part of a lathe holds and rotates the workpiece?

A. Tailstock
B. Carriage
C. Headstock
D. Tool Post
Answer: C

2. In a milling machine, which operation creates a flat surface?

A. Face milling
B. Peripheral milling
C. End milling
D. Form milling
Answer: A

3. The process of enlarging an existing hole is called:

A. Drilling
B. Boring
C. Reaming
 D. Tapping
Answer: C

4. Which type of drilling machine is used for large workpieces?

A. Bench Drill
B. Radial Drill
C. CNC Drill
D. Vertical Drill
Answer: B

5. What does CNC stand for?

A. Computer Numeric Control
B. Central Numerical Calculation
C. Computerized Network Control
D. Controlled Numerical Cutting
Answer: A