Question 1

In resistance spot welding for sheet metals, the electrodes are made with tips of which material to ensure very high electrical and thermal conductivity along with adequate strength?

Accepted Answer

Introduction / Context: Resistance spot welding (RSW) joins sheets by passing a high current through a localized contact area clamped between two water-cooled electrodes. Electrode material selection directly affects nugget formation, heat balance, and electrode life. Given Data / Assumptions: Standard industrial RSW of steels and common alloys. Need for low electrode resistivity and high thermal conductivity. Electrodes are typically water-cooled and shaped at the tip. Concept / Approach: Electrodes must conduct large currents with minimal heating and quickly extract heat from the weld zone. Copper and copper alloys (e.g., Cu-Cr-Zr) deliver very high electrical/thermal conductivity plus sufficient hardness when alloyed/heat-treated. Hence, the tips are copper-based. Step-by-Step Solution: 1) Goal: concentrate heat in the faying surfaces, not in electrodes.2) Choose a material with high conductivity → copper family.3) Result: electrodes (especially tips) are copper or copper-alloy; answer ‘‘copper’’ aligns with standard practice. Verification / Alternative check: Standards (RWMA classes) list copper alloys for RSW electrodes; stainless steel, aluminium, brass, or titanium do not meet the conductivity requirement. Why Other Options Are Wrong: Stainless steel: poor electrical/thermal conductivity; would overheat. Aluminium: better conductivity than steel but too soft and picks up; unsuitable as an electrode tip material. Brass: lower conductivity than copper; inferior for high-current duty. Titanium: low conductivity; inappropriate for RSW electrodes. Common Pitfalls: Confusing the material being welded with electrode material. Ignoring the need for water cooling and alloy-strengthened copper grades. Final Answer: copper

Question 2

In cold thread rolling, what should be the diameter of the cylindrical blank, relative to the finished thread dimensions, for correct metal flow and accurate profile formation?

Accepted Answer

Introduction / Context: Thread rolling forms threads by plastic deformation using dies, without material removal. Choosing the correct blank diameter is essential so that metal flows to create crests and roots to the specified major, minor, and pitch diameters. Given Data / Assumptions: Cold rolling of external threads on a cylindrical blank. Standard 60° metric/Unified profiles. Elastic spring-back and minor die penetration are accounted for by process practice. Concept / Approach: In thread rolling, the blank diameter is set approximately equal to the finished thread’s pitch diameter so that material displaced by the dies builds the crest to the major diameter and compresses the root to the minor diameter without excessive over-fill or under-fill. Step-by-Step Solution: 1) Let d, d2, d1 be major, pitch, and minor diameters respectively.2) Set blank diameter Db ≈ d2 to balance crest formation and root consolidation.3) Rolling pressure displaces material radially and axially, achieving the final profile with minimal stock error. Verification / Alternative check: Process handbooks recommend Db ≈ d2 with slight negative/positive corrections (on the order of a few micrometres per pitch) for material and die specifics, confirming the principle answer. Why Other Options Are Wrong: Equal to major diameter: starting too large; difficult metal flow, die overload. Equal to minor diameter or a little larger than minor: insufficient material to form crests; under-sized threads. A little larger than pitch diameter: risks over-filling and out-of-tolerance crests without careful compensation. Common Pitfalls: Confusing thread cutting allowances with rolling; rolling relies on displacement, not removal. Final Answer: equal to the pitch diameter of the thread

Question 3

In pattern making for foundry work, metal patterns are preferred for which application scenario considering durability, accuracy, and repeatability requirements?

Accepted Answer

Introduction / Context: Patterns create the cavity in the mould from which a casting is produced. The choice of pattern material (wood, plastic, metal) depends on production quantity, required accuracy, wear resistance, and dimensional stability. Given Data / Assumptions: Typical sand casting with separable moulds. Need to balance cost of pattern versus number of uses. Goal: maintain accuracy over many cycles. Concept / Approach: Metal patterns (often aluminium or cast iron) have superior wear resistance, dimensional stability, and surface finish compared with wood. The higher initial cost is justified when the pattern will be used repeatedly in large-scale production, where longevity and consistent tolerances are critical. Step-by-Step Solution: 1) Identify production volume: high → many mould pulls → pattern wear risk.2) Choose material that withstands abrasion and maintains dimensions → metal.3) Conclude: metal patterns are ideal for large-scale/quantity production. Verification / Alternative check: Foundry practice guides recommend wood for low volume, plastics for moderate volume/complex shapes, and metal for high volume and precision tooling. Why Other Options Are Wrong: Small/large castings: size alone does not dictate material. Complicated castings: complexity may favor plastics/segmenting; material choice is driven by volume and accuracy. Prototype one-off: wood or 3D-printed patterns are more economical. Common Pitfalls: Equating pattern material strictly with casting size rather than production quantity and wear. Final Answer: large scale production of castings

Question 4

For sand-casting patterns, what is the typical range of draft (taper) allowance specified per metre of pattern height to enable easy and clean withdrawal from the mould without damaging the sand?

Accepted Answer

Introduction / Context: Draft (taper) on patterns prevents the mould walls from scuffing and collapsing when the pattern is withdrawn from the sand. Correct draft reduces rework and improves surface quality. Given Data / Assumptions: Green-sand moulding with typical permeability and strength. Average surface finish and standard stripping techniques. Moderate pattern height and no severe undercuts. Concept / Approach: Draft allowance is commonly specified as millimetres per metre (or degrees). For general work, a draft of about 1–2 mm per metre (roughly 0.06°–0.11°) serves as a baseline, with larger values for rougher sands, deeper pockets, or vertical surfaces without rapping. Step-by-Step Solution: 1) Define purpose: ease withdrawal and protect mould faces.2) Adopt standard baseline: 1–2 mm/m as general recommendation.3) Adjust for special cases: higher drafts for fragile sands or intricate shapes. Verification / Alternative check: Foundry handbooks list similar ranges, often converting to degrees. The exact value depends on process capability, but 1–2 mm/m is a widely cited general allowance. Why Other Options Are Wrong: 2–5 mm/m and 5–10 mm/m: possible for difficult geometries but higher than typical general practice. 10–15 mm/m: excessive for ordinary sand casting surfaces. 0.1–0.5 mm/m: usually insufficient to guarantee clean withdrawal. Common Pitfalls: Confusing degree values with mm/m; both are used but must be consistent. Final Answer: 1 to 2 mm/m

Question 5

In pattern design, the intentional taper provided on the surfaces of a pattern to facilitate easy and clean withdrawal from the sand mould is known by which specific allowance term?

Accepted Answer

Introduction / Context: Patterns must be withdrawn from the mould without crumbling the sand. A small, intentional taper on vertical surfaces reduces friction and protects edges. This taper has a standard name in foundry practice. Given Data / Assumptions: Conventional green-sand moulding. Vertical surfaces on the pattern. No undercuts or complex cores considered. Concept / Approach: The taper that aids pattern withdrawal is called draft allowance. It differs from other allowances: shrinkage compensates solidification contraction; machining allows for material to be removed later; distortion allowance offsets warpage; core prints support cores. Step-by-Step Solution: 1) Identify the function: facilitate stripping of the pattern from sand.2) Map function to allowance: the taper = draft allowance.3) Exclude other allowances that serve different purposes (shrinkage, machining, distortion). Verification / Alternative check: Foundry standards and texts consistently label this taper as draft allowance; typical values are 1–2 mm/m (or small degrees). Why Other Options Are Wrong: Shrinkage allowance: compensates metal contraction, not withdrawal. Machining allowance: provides extra stock for finish machining. Distortion allowance: counters expected warpage. Core-print allowance: relates to seating of cores, not withdrawal. Common Pitfalls: Using shrinkage or machining allowances as a substitute for draft leads to damaged moulds and poor surfaces. Final Answer: draft allowance

Question 6

In which situation is the centrifugal casting process specifically suitable—considering how metal is forced against a mould to form parts that are symmetric about the axis of rotation?

Accepted Answer

Introduction / Context: Centrifugal casting uses rotation to generate a high radial head that forces molten metal against the mould wall, producing dense, fine-grained parts. It excels when geometry is symmetric about the rotation axis. Given Data / Assumptions: True (rotational) centrifugal casting, not centrifuging or semi-centrifugal variants. Common industrial applications like pipes, liners, and rings. Axis of rotation can be horizontal or vertical depending on component. Concept / Approach: Articles such as pipes and cylindrical sleeves are typically cast with a horizontal axis of rotation (longitudinal axis aligns with the part), enabling uniform distribution along the length. Vertical axis is also used (e.g., rings), but the most classic and widely referenced case in exams is symmetry about a horizontal axis (e.g., pipes). Step-by-Step Solution: 1) Identify geometry: hollow/cylindrical parts symmetric about an axis.2) Match process: true centrifugal casting rotates a cylindrical mould; for pipes and liners this is usually a horizontal axis.3) Conclude: suitable for symmetry about the horizontal axis. Verification / Alternative check: Reference examples include cast-iron pipes and bushings formed in rotating horizontal moulds, validating the answer. Why Other Options Are Wrong: Symmetrical about vertical axis: also feasible in some setups, but standard textbook association for pipes/liners is the horizontal axis. Irregular shape/only thin sheet sections: not suited to centrifugal forming. Non-ferrous only: process is used for both ferrous and non-ferrous alloys. Common Pitfalls: Confusing true centrifugal casting (for axisymmetric parts) with centrifuging (for small intricate shapes using radial feed). Final Answer: symmetrical shape about horizontal axis

Question 7

In a bilateral tolerance system used in engineering fits and limits, the permissible variation from the nominal (basic) size is provided on which side(s) of that nominal size?

Accepted Answer

Introduction / Context: Tolerancing specifies allowable size variation to ensure interchangeability and functional fit. Bilateral and unilateral systems differ in how this variation is distributed relative to the basic (nominal) size. Given Data / Assumptions: Limits and fits per standard practice (e.g., ISO system). Nominal size is the intended target dimension. Symmetric or asymmetric bilateral limits are both considered bilateral. Concept / Approach: In a bilateral tolerance, permissible deviation is allowed on both sides of the nominal size (e.g., ±0.02 mm or +0.03/−0.01 mm). In a unilateral tolerance, deviation lies on only one side (all plus or all minus) of the nominal. Step-by-Step Solution: 1) Identify the datum: the nominal (basic) size.2) Bilateral → deviations permitted above and below nominal.3) Therefore, the correct description is ‘‘both sides of the nominal size.’’ Verification / Alternative check: Dimensional callouts like 25.00 ± 0.02 mm or 25.00 +0.03/−0.01 mm are standard bilateral examples in drawings. Why Other Options Are Wrong: One side of nominal or above nominal only: describes unilateral tolerances. Actual measured size options: tolerances are defined about nominal, not post-measurement sizes. Common Pitfalls: Assuming bilateral must be symmetric; it may be asymmetric but still on both sides. Final Answer: both sides of the nominal size

Question 8

Foundry processes — in the centrifugal casting method used for pipes, sleeves, and rings, what is used to create the internal cavity of the casting?

Accepted Answer

Introduction / Context: In manufacturing technology, centrifugal casting is a moulding process in which molten metal is poured into a rotating mould. The high rotational speed generates a strong radial acceleration that forces the liquid metal outward against the mould wall. This question tests whether you know how the inner cavity is formed and whether a separate core is required, as is common in sand casting. Given Data / Assumptions: Hollow cylindrical shapes such as pipes, bushings, and sleeves are typical products. The mould is rotated at high speed during pouring and solidification. No additional statements about special cores or inserts are provided. Concept / Approach: The basic principle is that centrifugal force distributes the molten metal outward, forming a dense outer wall while the central region remains void. Because the inner cavity results naturally from the absence of metal at the center, a discrete core is not required in standard true centrifugal casting. Any inclusions or lighter impurities migrate toward the bore and can be machined away after solidification. Step-by-Step Solution: 1) Rotate the mould to a predetermined speed suitable for the alloy and diameter.2) Pour the molten metal into the rotating mould; metal is flung toward the outer wall.3) Allow solidification under rotation, which refines the grain structure and improves density at the periphery.4) After cooling, remove the casting; the inner void exists without a core. Verification / Alternative check: Process textbooks distinguish true centrifugal casting (no core for hollow axisymmetric parts) from semi-centrifugal and centrifuging methods. Only the latter may use cores for non-axisymmetric cavities. Why Other Options Are Wrong: Sand cores, ferrous cores, or non-ferrous cores are not normally used in true centrifugal casting because the rotation creates the bore automatically. Common Pitfalls: Confusing centrifugal casting with sand casting where cores are routine, or with semi-centrifugal methods that may include cores for hubs. Final Answer: no core is used

Question 9

Gas flames in welding — the temperature of an oxy-hydrogen flame compared with an oxy-acetylene flame is:

Accepted Answer

Introduction / Context: Oxy-fuel gas flames are widely used for welding, cutting, and brazing. This question checks familiarity with typical peak flame temperatures for common gas combinations and their relative capabilities in welding operations. Given Data / Assumptions: Oxy-acetylene flames reach approximately 3200–3500 °C at the inner cone under neutral settings. Oxy-hydrogen flames reach approximately 2600–2800 °C under comparable conditions. Comparisons are qualitative: less than, same as, or more than. Concept / Approach: Flame temperature depends on the heat of combustion and the specific heat of reaction products. Acetylene has a higher heat of combustion per unit oxygen and produces a hotter inner cone than hydrogen under typical oxy-fuel ratios, which is why oxy-acetylene is preferred for gas welding steel, while oxy-hydrogen is often used for brazing, glass working, and applications requiring a cleaner but cooler flame. Step-by-Step Solution: 1) Recall typical peak temperatures: oxy-acetylene ≈ 3300 °C; oxy-hydrogen ≈ 2800 °C.2) Compare directly: 2800 °C is lower than 3300 °C.3) Conclude the oxy-hydrogen flame is cooler than the oxy-acetylene flame. Verification / Alternative check: Handbooks and welding data sheets consistently list higher peak temperatures for oxy-acetylene than for oxy-hydrogen under neutral flames. Why Other Options Are Wrong: “Same as” contradicts widely published temperature data; “more than” is incorrect because oxy-acetylene is hotter. Common Pitfalls: Confusing cleanliness of flame with temperature; oxy-hydrogen is cleaner but not hotter than oxy-acetylene. Final Answer: less than

Question 10

Thread manufacturing — thread rolling as a process is primarily restricted to which class of materials due to required plastic flow at room temperature?

Accepted Answer

Introduction / Context: Thread rolling is a chipless cold-forming process that displaces material to create threads. Unlike thread cutting, which removes material, rolling requires plastic deformation under significant compressive stresses, demanding adequate ductility in the workpiece. Given Data / Assumptions: Cold forming by hardened dies imposes high contact pressure. No material is removed; material flows to form crests and roots. Process efficiency and surface integrity depend on material ductility. Concept / Approach: Materials suitable for thread rolling must exhibit sufficient ductility to plastically flow without cracking, typically low to medium carbon steels, aluminium alloys, copper alloys, and certain stainless steels in workable conditions. Very hard or brittle materials lack the plasticity to deform and are prone to surface cracking or die damage under rolling pressures. Step-by-Step Solution: 1) Identify process mechanism: plastic flow under compressive stress.2) Map material requirement: adequate elongation and reduction of area.3) Conclude that ductile materials are required for reliable thread formation. Verification / Alternative check: Industry practice specifies minimum ductility metrics for rollability, and suppliers often heat treat or select grades to ensure formability before rolling. Why Other Options Are Wrong: “Ferrous materials” is too narrow; many non-ferrous ductile alloys are rollable. “Hard materials” lack required plastic flow. “None of these” is incorrect because there is a clear correct class: ductile materials. Common Pitfalls: Assuming only steels can be rolled; overlooking that strength can be high yet ductility sufficient when properly processed. Final Answer: ductile materials

Question 11

Die casting fundamentals — in pressure die casting, is the statement “the molten metal is forced into the mould cavity under high pressure” correct?

Accepted Answer

Introduction / Context: Die casting is a high-production process for non-ferrous alloys such as aluminium, zinc, and magnesium. A key distinguishing feature is the application of high pressure to drive molten metal into steel dies, leading to fine detail, excellent surface finish, and tight dimensional control. Given Data / Assumptions: Pressure is applied by a plunger (hot-chamber or cold-chamber machines). Permanent metal moulds (dies) are used rather than expendable sand moulds. High injection and intensification pressures are typical during filling and solidification. Concept / Approach: The essence of pressure die casting is forcing molten metal into a closed die at pressures that can range from several MPa to tens of MPa. This pressure reduces porosity, produces rapid filling of thin sections, and improves surface finish. The question directly restates this defining attribute. Step-by-Step Solution: 1) Identify die casting as a permanent mould process using metallic dies.2) Note the plunger-driven injection of molten metal at high pressure.3) Recognize that maintaining pressure during solidification aids quality. Verification / Alternative check: Comparative processes such as gravity die casting rely on gravity, not pressure, confirming that pressure die casting is distinct because of the applied high pressure. Why Other Options Are Wrong: “Incorrect” would contradict the formal definition of pressure die casting. Common Pitfalls: Confusing gravity die casting with pressure die casting; assuming all die processes are pressure-assisted when gravity versions exist. Final Answer: Correct

Question 12

Pattern design — the machining allowance provided on patterns depends on which of the following factors for practical casting operations?

Accepted Answer

Introduction / Context: Machining allowance is an intentional extra material added to the casting dimensions to permit removal of surface irregularities and achieve final tolerances by machining. Correctly sizing this allowance is crucial for cost, quality, and avoiding undersized parts after finishing. Given Data / Assumptions: Different alloys exhibit different casting surface qualities and dimensional stability. Larger and more complex shapes risk higher distortion and surface defects. Casting methods vary in accuracy and surface finish, influencing required stock for machining. Concept / Approach: Allowance selection is multi-factor. Metals that oxidize heavily or have poor surface finish need more stock. Large castings accumulate more defects and may require greater allowances. Precision processes like investment casting need less; sand casting often needs more. Therefore, the allowance depends on all listed factors and not a single one in isolation. Step-by-Step Solution: 1) Evaluate the casting process capability (e.g., investment vs green sand).2) Consider material behavior (e.g., aluminium versus cast iron).3) Account for part size, section thickness, and geometry-induced distortion risk.4) Assign machining stock accordingly to meet final tolerances economically. Verification / Alternative check: Foundry handbooks provide allowance tables indexed by alloy, size range, and process, confirming the multi-factor dependence. Why Other Options Are Wrong: Each single factor alone is necessary but not sufficient; only “all of these” captures the complete practical basis for allowance selection. Common Pitfalls: Using a fixed allowance regardless of size or process; ignoring extra stock for heavy scale or distortion-prone geometries. Final Answer: all of these

Question 13

Hand tools — cold chisels used by fitters and smiths are manufactured by which primary forming process?

Accepted Answer

Introduction / Context: Cold chisels are impact tools used for chipping, cutting, and trimming metals at room temperature. Their manufacture must produce a tough shank, a durable striking head, and a hard, wear-resistant cutting edge. The question asks for the primary process used to make such tools. Given Data / Assumptions: Cold chisels require directional grain flow for strength. Final properties depend on heat treatment after forming. Tool steels or medium-carbon steels are typical base materials. Concept / Approach: Forging plastically deforms heated metal to shape while aligning and consolidating the grain structure in the direction of the tool profile, improving toughness and resistance to impact. Rolling and drawing produce prismatic stock but not the final tool geometry with heads and cutting edges. Piercing is a forming operation for holes, not for shaping chisels. Step-by-Step Solution: 1) Start from bar stock of suitable steel grade.2) Heat to forging temperature and forge to rough chisel shape (head, body, tip).3) Normalize, harden, and temper to achieve a hard edge and tough body. Verification / Alternative check: Commercial cold chisels are commonly marked as drop-forged, confirming forging as the standard route for mass production with consistent properties. Why Other Options Are Wrong: Drawing and rolling are preliminary stock shaping processes; piercing is unrelated to chisel manufacture. Common Pitfalls: Assuming rolling equals forging strength; forging provides advantageous grain flow around critical features like the head and blade. Final Answer: forging

Question 14

Surface protection — galvanising is best described as which of the following surface treatment processes for steel?

Accepted Answer

Introduction / Context: Protective coatings extend the life of steel structures and hardware by preventing corrosion. Galvanising is one of the most economical and widely used methods to provide sacrificial protection via zinc. The question probes recognition of the correct definition among related processes. Given Data / Assumptions: Consider conventional hot-dip galvanising on structural steel. Distinguish from diffusion-based or conversion coatings. Focus on the core process definition. Concept / Approach: In hot-dip galvanising, cleaned steel is immersed in molten zinc, forming metallurgically bonded zinc-iron alloy layers topped with zinc. The coating provides barrier protection and sacrificial (cathodic) protection at damaged spots. Zinc diffusion into steel at lower temperatures is a different process called sherardising. Phosphate coatings are thin conversion layers used primarily as paint bases and for wear reduction, not as thick sacrificial coatings. Step-by-Step Solution: 1) Identify galvanising as hot-dip coating with molten zinc.2) Differentiate from sherardising (zinc diffusion) and phosphating (conversion coating).3) Select the description that matches hot-dip application. Verification / Alternative check: Standards such as ISO 1461 and ASTM A123 define galvanising as hot-dip zinc coating of iron and steel products. Why Other Options Are Wrong: “Zinc diffusion process” describes sherardising; “thin phosphate coating” describes phosphating; “none of the above” is incorrect because hot-dip is correct. Common Pitfalls: Confusing various zinc-related treatments; assuming all zinc processes are the same in mechanism and coating thickness. Final Answer: process of coating zinc by hot dipping

Question 15

Casting accuracy — the typical dimensional tolerance achievable with the shell moulding casting process is:

Accepted Answer

Introduction / Context: Different casting processes offer different levels of dimensional accuracy and surface finish. Shell moulding uses a thin resin-bonded sand shell formed on heated patterns, giving better precision than green sand and approaching permanent-mould processes for many parts. Given Data / Assumptions: Small to medium-sized castings typical for shell moulding. Standard process capabilities without special secondary operations. Tolerances expressed as symmetric or unilateral values in millimetres. Concept / Approach: Published capability data for shell moulding generally indicate tolerances around ±0.3 mm down to ±0.1–0.2 mm depending on size, making ±0.2 mm a representative average for exam purposes. Options like +0.05 mm are unrealistically tight for typical shell castings, while ±1 mm is more characteristic of conventional sand casting. Step-by-Step Solution: 1) Compare process capability ranges across casting methods.2) Select the value that aligns with standard shell moulding practice.3) Conclude that ±0.2 mm is the best representative tolerance from the given options. Verification / Alternative check: Vendor datasheets and handbooks list shell moulding accuracy between green sand and investment casting, supporting ±0.2 mm as a reasonable benchmark. Why Other Options Are Wrong: +0.05 mm is too tight for typical shell; +0.5 mm and ±1 mm are looser than the known capability of shell moulding. Common Pitfalls: Confusing investment casting tolerances with shell moulding; overlooking that unilateral tolerances in options may be distractors. Final Answer: ±0.2 mm

Question 16

Investment casting (lost-wax) — for average-quality work, the typical dimensional tolerance that can be achieved is:

Accepted Answer

Introduction / Context: Investment casting, also known as lost-wax casting, is renowned for excellent surface finish and high dimensional accuracy, enabling near-net-shape parts and reduced machining. This question asks for a representative tolerance achievable in average practice. Given Data / Assumptions: Small to medium parts typical of investment casting. Standard wax pattern control and ceramic shell quality. “Average work” implies typical, not extreme best-case laboratory results. Concept / Approach: Compared to sand and shell moulding, investment casting provides the tightest tolerances among common casting processes. Typical capability is on the order of ±0.05 mm to ±0.1 mm for small features, scaling with size. Therefore, ±0.05 mm is a reasonable representative value from the available options for average high-quality industrial practice. Step-by-Step Solution: 1) Rank processes by accuracy: sand < shell moulding < permanent mould ≲ investment casting.2) Map known capability values to options.3) Select ±0.05 mm as the best match for investment casting tolerances. Verification / Alternative check: Process handbooks and supplier specifications often cite ±0.05 mm for fine features on small castings, with looser tolerances for larger dimensions, confirming this choice. Why Other Options Are Wrong: “+0.2 mm”, “+05 mm”, and “+1 mm” are unilateral and relatively loose; they do not reflect typical symmetric precision achievable by investment casting. Common Pitfalls: Assuming a single tolerance applies to all sizes; in practice tolerance scales with length, but ±0.05 mm is representative for small dimensions. Final Answer: ±0.05 mm

Question 17

Metrology for patterns — a pattern maker’s shrinkage rule is designed to account for which allowance during pattern making for metal castings?

Accepted Answer

Introduction / Context: When molten metal solidifies and cools to room temperature, it contracts. Patterns must therefore be made slightly larger than the final required size to compensate for this linear shrinkage. Pattern maker’s shrinkage rules are modified scales used to build this compensation directly into layout and measurement. Given Data / Assumptions: Shrinkage varies by casting alloy (e.g., grey iron versus aluminium). Other allowances also exist: machining, draft, shake (rapping), and distortion allowances. The question asks specifically what the shrinkage rule “considers”. Concept / Approach: A shrinkage rule has graduations that are slightly enlarged relative to a standard scale by a factor corresponding to the alloy’s linear contraction. It does not inherently include machining, draft, or other allowances, which the pattern maker must add separately in the pattern design or by documentation on the drawing. Step-by-Step Solution: 1) Recognize that the rule’s purpose is to offset metal shrinkage only.2) Note that other allowances are applied by geometry changes, not by the scale factor.3) Conclude that the shrinkage rule accounts exclusively for shrinkage allowance. Verification / Alternative check: Foundry standards provide different shrinkage rule factors for different alloys, confirming the rule’s dedicated function. Why Other Options Are Wrong: “All pattern allowances” overstates the function; “all materials to be cast” and “all materials of the pattern” are irrelevant to what the rule’s graduations encode. Common Pitfalls: Assuming the rule magically includes draft or machining stock; those allowances must be added separately during pattern design. Final Answer: only shrinkage allowance

Question 18

In limit, fit, and tolerance terminology for manufacturing metrology, what is the quantity called that equals the algebraic difference between the minimum limit (the lower permissible size) and the basic (nominal) size of a feature?

Accepted Answer

Introduction / Context: In engineering metrology and the ISO system of limits and fits, the terms basic size, limits of size, and deviations precisely describe how far an actual or permissible size can vary from its intended nominal (basic) value. Correctly identifying which deviation is measured from the minimum or maximum limit is essential for interpreting drawings and calculating fits between mating parts like holes and shafts. Given Data / Assumptions: Basic (nominal) size is the target dimension used to derive limits and tolerances. Lower limit is the smallest permissible size; upper limit is the largest permissible size. Deviations are algebraic differences taken with signs relative to the basic size. Concept / Approach: The lower deviation is defined as the algebraic difference between the lower limit of size and the basic size. Similarly, the upper deviation is the algebraic difference between the upper limit and the basic size. The term fundamental deviation denotes the deviation (upper or lower, depending on the letter position such as H or h) that defines the position of a tolerance zone relative to zero line in the ISO system. Step-by-Step Solution: 1) Identify the quantity asked: difference between minimum (lower) limit and basic size.2) By definition, this is the lower deviation (can be negative, zero, or positive based on fit class).3) Therefore, the correct term is ‘‘lower deviation.’’ Verification / Alternative check: On a drawing, if a 25 H7 hole is specified, the basic size is 25 mm. The lower deviation for ‘‘H’’ holes is 0, so lower limit − basic size = 0 → lower deviation = 0, matching the definition. For shafts (e.g., h), the upper deviation is 0, and the lower deviation is negative. Why Other Options Are Wrong: Upper deviation: uses the upper limit, not the lower limit. Fundamental deviation: a positional deviation defining the tolerance zone location; not specifically the lower-limit difference here. Actual deviation: difference of an actual measured size from the basic size, not a limit-based quantity. Limit of size: the permissible extreme sizes themselves, not their difference from basic size. Common Pitfalls: Forgetting the sign convention (algebraic differences may be negative). Confusing actual measurement deviations with limit-based deviations used in specifications. Final Answer: lower deviation

Question 19

In precision layout and inspection, which multi-purpose instrument integrates the functions of a try-square, a bevel protractor, a steel rule, and a scriber into one adjustable tool for accurate setting-out and angle measurement?

Accepted Answer

Introduction / Context: Layout work and inspection in manufacturing often require squareness checks, angle measurements, height marking, and scribing reference lines. A compact tool that merges several of these capabilities improves accuracy and productivity at the bench or surface plate. Given Data / Assumptions: Need to check 90° and other angles, set bevels, and scribe lines using a steel rule. Use in fitting, machining, and metrology contexts on a surface plate. Desire for a modular tool with interchangeable heads. Concept / Approach: A combination set typically includes: (1) a stainless steel rule, (2) a square head (try-square function) with spirit level and scriber, (3) a protractor head (bevel protractor function) for angle setting, and (4) a centre head for marking centers on cylinders. This versatility allows accurate marking, gauging angles, and checking squareness with one tool. Step-by-Step Solution: 1) Identify the list of functions: try-square, bevel protractor, rule, scriber.2) Match to instrument: a standard combination set provides all these in modular heads.3) Conclude: the required instrument is the ‘‘combination set.’’ Verification / Alternative check: Manufacturer catalogs consistently describe combination sets with square, protractor, and center heads, confirming functional overlap with the tools named in the question. Why Other Options Are Wrong: Outside/Inside micrometer: precision measuring instruments for external/internal sizes; not used for squareness or angle layout. Depth gauge micrometer: measures depths; not a layout square/protractor. Universal bevel gauge: angle-setting tool, but lacks integrated try-square, scriber, and rule functions of a full combination set. Common Pitfalls: Confusing measurement tools (micrometers) with layout tools (squares/protractors). Overlooking the center head component commonly included in a combination set. Final Answer: combination set

Question 20

In gas–tungsten arc welding (GTAW/TIG) of copper and copper alloys, which current and polarity configuration is generally preferred to achieve adequate penetration and heat concentration considering copper’s very high thermal conductivity?

Accepted Answer

Introduction / Context: TIG (GTAW) welding requires selecting a current type and polarity appropriate to the base metal. Copper and its alloys conduct heat rapidly; thus, achieving sufficient penetration and stable arc characteristics demands a polarity that concentrates heat in the workpiece rather than in the tungsten electrode. Given Data / Assumptions: Base metal: copper or copper alloys. TIG process with inert shielding gas (typically argon or helium mixes). Objective: adequate penetration and reasonable electrode life. Concept / Approach: With DCEN (electrode negative), about two-thirds of the arc heat is directed into the workpiece, giving deeper penetration and keeping the tungsten cooler—ideal for high-conductivity metals like copper. DCEP concentrates more heat on the electrode and is mainly used for limited oxide cleaning on materials like aluminum when using GTAW; however, copper does not require the cathodic cleaning action of AC or DCEP as aluminum does. AC is preferred for aluminum/magnesium because of alternating cathodic cleaning and moderated heat distribution, not typically for copper penetration needs. Step-by-Step Solution: 1) Recognize copper’s high thermal conductivity demands greater heat input to the work.2) Choose polarity that puts more heat into the work: DCEN.3) Conclude that DCEN is the standard choice for TIG welding copper alloys for penetration and stability. Verification / Alternative check: Welding handbooks specify DCEN for copper and most steels; AC is reserved primarily for oxide film disruption on aluminum/magnesium. Why Other Options Are Wrong: AC: mainly for materials needing oxide cleaning; not optimal for copper penetration. DCEP: overheats electrode and limits penetration on copper. Any one of these / Pulsed EP only: process physics, not preference, dictates DCEN for copper. Common Pitfalls: Assuming AC is universally best in TIG due to aluminum practices. Confusing cleaning action requirements with penetration requirements. Final Answer: direct current with straight polarity (DCEN: electrode negative)

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