Forging and Foundry Process | Interview Question and Answers Part 2

Forging and Foundry Process | Interview , Viva ,Oral Question and Answers

Forging and Foundry process : Part 1  | Part 2  | Part 3  | Part 4 

41. Give the classification of Gas & Oil fired furnace.

1. Box type
2. Semi-continuous or batch type
3. Continuous furnace.

42. Mention the fuels used in furnaces.

1. Solid fuels: Eg. Coal, coke & charcoal etc.
2. Liqid fuels: Eg. They include different types of fuel oils
3. Gaseous fuels: Eg. Natural gas and producer gas.

43. Mention the forging temperature.

Temperature generally ranging form 1200 – 1350 degree C.

44. What is the use of blowers in forging?

Efficient and adequate supply of air at proper pressure is always a vital necessity for combustion of the fuel.

45. Which type of Blowers are widely used?

Roots blowers and centrifugal blower are widely used.

46. Mention the forgeable materials

Aluminium & Magnesium alloys, Copper, Brass & Bronze, Mild steel, Wrought iron, Medium & High carbon an d alloy steel, Stainless steels.

47. Mention forgeable materials temperature

48. List forging operation.

Upsetting, Drawing out, cutting, Bending, Punching, Setting down and finishing, Welding.

49. What do you mean by Upsetting or Jumping?

Is the forging process through which the cross-section of a metal piece is increased with a corresponding reduction in its length. .

50. What is Drawing out?

Is also known as Drawing down. It is exactly a reverse process to tha of upsetting or jumping. Thickness is reduced with the increase in length.

51. What if Setting down & finishing in forging?

Setting down is the operation through which the rounding of a corner is removed to make it square, by means of set hammer.

52. What do you meant by Welding in forging?

Welding in smithy is an imp. Operation carried out in this shop. Two pieces of the same metal which are to be joined together are heated in the hearth to the proper temperature. When they have acquired the welding heat they are withdrawn from the furnace and joined together by the application of external pressure, generally Hammering.

53. What main considerations will you make in designing a forging?

1. The forged component should ultimately be able to achieve a radial flow of grains or fibres.
2. As far as possible, the parting line of a forging should lie in one plane.
3. Sufficient draft on surfaces should be provided to facilitate easy removal of forgings from the dies.
4. High & thin ribs should not be designed.
5. Too thin sections should be avoided to facilitate an easy flow of metal.

54. Mention the furnaces for heat treatment.

1. Hearth type
2. Bath type

55. What is the purpose of heat treatment?

To impart certain desired properties to metal so as to render it suitable for a particular use.

56. What is Hardening?

To harden the metal to make it wear resitant and render it capable of cutting other metals.

57. What is the purpose of Annealing?

To softening the metal.

58. What is Tempering?

Generally followed after hardening to reduce brittleness, particularly in case of cutting tools.

59. Mention the function of Normalising?

For refining the structure of the metal after cold working.

60. What is case hardening?

For making a metal to have a hard outer surface with a comparatively soft but tough core.

61.List the tools and equipment used in foundry.

They are, Hand tools, Containers, Mechanical tools, Sand testing & conditioning equipment, Metal melting equipment, Fettling & finishing equipment.

62. List the Hand tools used in Foundry.

Shoel, Hand riddle, Rammers, Strike off bar, Towels, Slicks, Lifters or cleaners, Drag Spike, Draw screws and rapping plate, Smoothers and corner slicks, Mallet, Swab, Sprue pin, Sprue cutter, Goggers, Bellow.

63. What are Power hammers?

The blows obtained by hand hammering will nt be sufficient enough to effect the proper plastic flow in medium or heavy forging. For this a power hammer is usually employed.

64. What is the weight of these power hammers?

200 kg hammer will be one of which the falling weight is 200kg. The heavier these parts and greater the height from which they fall, the higher will be intensity of blow the hammer will provide.

65. List the common Power hammers in use.

Spring power hammers, Pneumatic power hammers, Steam hammers and Drop or Forge hammers.

66. What do you mean by Press forging?

Forging of parts by presses involves slow squeezing of plastic metal in closed impression dies, instead of applying repeated severe blows by hammers.

67. Mention the types of Press forging.

1. Hydraulic press
2. Mechanical press

68. Give an example to Roll forging.

This process is employed for producing long slender forged components. Eg. Axles, & Leaf springs.

69. Why forging defects occurs?

1. Improper heating of component for forging
2. Faulty die design
3. Improper placement of metal in the die
4. Forging operation not carried out properly.
5. Faulty forging design.

70. Why the forged parts are heat treated?

1. To relieve internal stresses set up during working and cooling
2. to normalize the internal structure of the metal
3. To improve its Machinability
4. To improve hardness, strength and other mechanical properties.

71. Mention common heat treatments given to forged components.

Annealing, Normalising and Tempering. Are the common heat treatments given to forged components.

72. What main considerations will you make in designing a forging?

1. The forged component should ultimately be able to achieve a radial flow of grains or fibres.
2. As far as possible, the parting line of a forging should lie in one plane.
3. Sufficient draft on surfaces should be provided to facilitate easy removal of forgings from the dies.
4. High & thin ribs should not be designed.
5. Too thin sections should be avoided to facilitate an easy flow of metal.

73. Mention the furnaces for heat treatment.

1. Hearth type
2. Bath type

74.. What is the purpose of heat treatment?

To impart certain desired properties to metal so as to render it suitable for a particular use.

75. What is Hardening?

To harden the metal to make it wear resitant and render it capable of cutting other metals.

76. What is the purpose of Annealing?

To softening the metal.

77. What is Tempering?

Generally followed after hardening to reduce brittleness, particularly in case of cutting tools.

78. Mention the function of Normalising?

For refining the structure of the metal after cold working.

79. What is case hardening?

For making a metal to have a hard outer surface with a comparatively soft but tough core.

80. List the tools and equipment used in foundry.

They are, Hand tools, Containers, Mechanical tools, Sand testing & conditioning equipment, Metal melting equipment, Fettling & finishing equipment.

Forging and Foundry process : Part 1  | Part 2  | Part 3  | Part 4 

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