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EMAE 160 Final Review CWRU| Questions with 100% Correct Answers
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EMAE 160 Final Review CWRU|Questions with 100% Correct Answers
What is the shell molding process? - ✔A casting process using metal masters and a resin
to bind the molding sand.
What is the parting line in injection molding? - ✔The joint between the two mold halves.
In terms of casting work, what is a runner? - ✔A chamber to transfer molten metal to
the mold cavity.
What type of mold is used in sand casting? - ✔Expendable mold casting
Which types of casting qualify as precision casting processes? - ✔Shell molding,
lost wax/foam, investment casting, and maybe die casting.
In casting, what is a flask? - ✔The outer framework of the mold. Holds the mold in
metal casting. No top or bottom.
In sand casting, how does the volumetric size of the pattern compare to the finished cast part? -
✔The finished part is much smaller after being machined down and having the risers
removed.
,Describe shell molding. - ✔Resin and sand sticks to a heated surface then is placed in
a furnace to set.
Name another term for investment casting and explain the origin. - ✔Lost wax casting. People
used beeswax 1000's of years ago.
List metals that are typically die cast. - ✔Aluminum & Magnesium
In terms of die casting, what is flash? - ✔Extra material from between the two plates.
What is the symbol for surface finish? What parameters may be included? - ✔√. Can
include roughness height, waveness height, waveness width, roughness width cutoff, and
roughness width.
What are ribs and gussets? - ✔Ribs- Square supports. Gussets- Triangular supports.
What is the significance of draft on a part? - ✔So that it can easily come out of the mold.
How are internal features created in a sand casting? - ✔A core supported by chaplets.
What type of sand is most often used for sand casting? What type of sand is used for core
creation? - ✔Green/silica sand. Cores are often made with green sand mixed with core
oil.
What material is used to create the pattern in shell molding? Why? - ✔Iron or steel. This is
so it can heat up to stick to the resin and sand.
In die casting, what is the ejection system and how does it operate? - ✔The ejection
system pops the part away from the mold so that it doesn't stick to the mold.
, What materials may be used in hot chamber die casting? What about cold chamber? -
✔Hot Chamber- Zinc, Lead, Tin. Cold Chamber- Aluminum and Magnesium.
What is the function of a sprue and riser? - ✔Riser- Space for excess molten metal to
flow into. Sprue- The vertical passage for molten metal to enter the mold.
What is the function of a runner and gate? - ✔Runner- For molten metal to reach the mold
cavity. Gate- To ensure that molten metal enters the cavity at the same rate as solidification.
What are the differences between centrifugal casting and semi-Centrifugal casting? -
✔Centrifugal only wants metal to stick to the walls. Semi-Centrifugal wants to evenly
spread material through molds.
What is bend allowance? What sort of materials does it apply to? - ✔Bend allowance is the
length a part gains when it is unbent. This is equal to the arc length of the bend. This applies
to all bent parts.
Name the three basic types of forging operations. - ✔Open die, closed die, impression die
Does the flash produced in impression die forging serve a useful purpose? Is it desirable? Why?
- ✔Yes. This flash cools quicker than the part in the cavity and thus keeps the rest of the
metal fixed where it needs to be.
Define spring-back in sheet metal bending. - ✔When a bent piece of sheet metal bends back
a bit after releasing the force that bend it in the first place.
Name the three types of forging processes. - ✔Hydraulic, mechanical, impact.
Explain the difference between a mechanical press and a hydraulic press for forging. -
✔Hydraulic- Slow with a constant force. Mechanical- Quick bursts of force.
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