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Metal Casting Fundamentals and Calculations

The document discusses various problems related to metal casting, including calculations for solidification times and flow rates of molten metal in different shapes and configurations. It presents scenarios involving round and elliptical castings, as well as the effects of riser sizes on feeding. Additionally, it addresses the flow characteristics of aluminum in molds and the implications of sprue dimensions on casting efficiency.

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92 views9 pages

Metal Casting Fundamentals and Calculations

The document discusses various problems related to metal casting, including calculations for solidification times and flow rates of molten metal in different shapes and configurations. It presents scenarios involving round and elliptical castings, as well as the effects of riser sizes on feeding. Additionally, it addresses the flow characteristics of aluminum in molds and the implications of sprue dimensions on casting efficiency.

Uploaded by

Anas Tubail
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Islamic University of Gaza

Faculty of Engineering
Industrial Engineering Department
Product Design and Manufacturing: EIND 5053

CH#10
Fundamentals of Metal Casting

Second Semester 2020/2021


10.40 A round casting is 0.2 m in diameter and 0.5 m in length. Another casting
of the same metal is elliptical in cross-section with a major to minor axis ratio of
2 and has the same length and cross-sectional area as the round casting. Both
pieces are cast under the same conditions. What is the difference in the
solidification times of the two castings?

2
10.41 A 4 m thick square plate and a right circular cylinder with a radius of 4 m
and a height of 2 m each have the same volume. If each is to be cast using a
cylindrical riser, will each part require the same size riser to ensure proper
feeding? Explain.

3
• A right circular cylinder is a cylinder whose base is a circle and whose
elements are perpendicular to its base.

4
10.43 Pure aluminum is poured into a sand mold. The metal level in the pouring
basin is 200 mm above the metal level in the mold, and the runner is circular
with a 7.5 mm diameter. What are the velocity and rate of the flow of the metal
into the mold? Is the flow turbulent or laminar?

❖ Assuming that the


pressure at the top of the
sprue is equal to the
pressure at the bottom,
and that there are no
frictional losses.

5
10.44 A cylinder with a diameter of 40 mm. and height of 80 mm. solidifies in
three minutes in a sand casting operation. What is the solidification time if the
cylinder height is doubled? What is the time if the diameter is doubled?

6
10.45 The volume flow rate of metal into a mold is 0.02 m3 /s The top of the
sprue has a diameter of 20 mm, and its length is 200 mm. What diameter should
be specified at the bottom of the sprue to prevent aspiration? What is the
resultant velocity and Reynolds number at the bottom of the sprue if the metal

being cast is aluminum with a viscosity of 0.004 N.s/m2 ?


❖ Assuming that the
pressure at the top of the
sprue is equal to the
pressure at the bottom,
and that there are no
frictional losses.

7
Aspiration a process whereby air
is sucked in or entrapped in the liquid.

8
9

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