Problems on Casting & Solidification

Q.1
A certain mold has a sprue whose length is 20 cm and the cross-sectional area at the base of
the sprue is 2.5 cm
2
. The sprue feeds a horizontal runner leading into a mold cavity whose
volume is 1560 cm
3
. Determine: (a) velocity of the molten metal at the base of the sprue, (b)
volume rate of flow, and (c) time to fill the mold.
Solution: (a) The velocity of the flowing metal at the base of the sprue is given by Eq. (10.4):

(b) The volumetric flow rate is
Q = (2.5 cm
2
) (198.1 cm/s) = 495 cm
3
/s
(c) Time required to fill a mold cavity of 1560 in.
3
at this flow rate is
MFT = 1560/495 = 3.2 s.

Q.2
A cylindrical riser must be designed for a sand-casting mold. The casting itself is a steel
rectangular plate with dimensions 7.5 cm x 12.5 cm x 2.0 cm. Previous observations have
indicated that the total solidification time (TST) for this casting = 1.6 min. The cylinder for
the riser will have a diameter-to-height ratio = 1.0. Determine the dimensions of the riser so
that its TST = 2.0 min.



Solution: First determine the V/A ratio for the plate. Its volume V = 7.5 x 12.5 x 2.0 =187.5 cm
3
and
its surface area A =2(7.5 x 12.5 + 7.5 x 2.0 + 12.5 x 2.0) =267.5 cm
2
Given that TST = 1.6 min,
we can determine the mold constant C
m
from Eq. (10.7), using a value of n = 2 in the equation.



Next we must design the riser so that its total solidification time is 2.0 min, using the same value
of mold constant. Since both the casting and the riser are in the same. The volume of the riser is
given by



And the surface area is given by A =
Since we are using a D/H ratio = 1.0, then D = H. Substituting D for H in the volume and area
formulas, we get


and A=
Thus the V/A ratio = D/6. Using this ratio in Chvorinov's equation, we have


D = 4.7 cm
Since H = D, then H = 4.7 cm also.
The riser represents waste metal that will be separated from the cast part and remelted to make
subsequent castings. It is desirable for the volume of metal in the riser to be a minimum. Since
the geometry of the riser is normally selected to maximize the V/A ratio, this tends to reduce the
riser volume as much as possible. Note that the volume of the riser in our example problem is V
= (4.7)
3
/4 = 81.5 cm
3
only 44% of the volume of the plate (casting), even though its total
solidification time is longer by 25%.




Risers can be designed in different forms. The design shown in Figure 10.2(b) a side riser. It is
attached to the side of the casting by means of a small channel. A riser is one that is connected to
the top surface of the casting. Risers can be open or blind: An open riser is exposed to the
outside at the top surface of the cope. This has the disadvantage of allowing more heat to escape,
promoting faster solidification. A blind riser is entirely enclosed within the mold, as in Figure
10.1(b).








Q.3

A true centrifugal casting operation is to be performed horizontally to make copper tube sec
tions with OD = 25 cm and ID = 22.5 cm. What rotational speed is required if a G-factor of
65 is used to cast the tubing?

Solution: The inside diameter of the mold D = OD of the casting = 25 cm = 0.25 m. we can
computer the required rotational speed as follows.



In vertical centrifugal casting, the effect of gravity casting on the liquid metal causes the casting
wall to be thicker at the base than that at the top. The inside profile of the casting wall takes on a
parabolic shape. The difference in inside radius between top and bottom is speed of rotation as
follow:


Where L = vertical length of the casting, m (ft); R
t
= inside radius at the top of the casting m (ft);
and R
b =
inside radius at the bottom of the casting, m (ft). Eq. (11.6) can be used to determine the
required rotational speed for vertical centrifugal casting, given specifications on the inside radii
at top and bottom. One can see from the formula that for R
t
to equal R
b
, the speed of rotation N
would have to be infinite, which is impossible, of course. As a practical matter, part length made
by vertical centrifugal casting are usually no more than have large diameters relatively to their
lengths, especially if machining will be used to accurately size inside diameter.




Q. 4
Solidification times for various shapes
Three pieces being cast have the same volume but different shapes. One is a sphere, one a
cube, and the other a cylinder with equal to its diameter. Which piece will solidify the
faster and which one the slowest?

Solution: The volume is unity, so we have from Eq. (5.9):

Solidification time
The respective surface areas are



Cube:

Cylinder:


Thus the respective solidification times t are



Hence the cube-shaped casting will solidify the fastest and the sphere-shaped casting will
solidify the slowest.







Q.5

A cylindrical riser must be designed for a sand-casting mold. The casting itself is a steel
rectangular plate with dimensions 7.5 cm 12.5 cm 2.0 cm. previous observations have
indicated that the total solidification time (TST) for this casting = 16 min. the cylinder for
the riser will have a diameter to height ratio = 1.0. Determine the dimensions of the
riser so that its TST = 2.0 min.

Solution: First determine the V/A ratio for the plate. Its volume V = 7.5 12.5 2.0 = 187.5
cm
3
, and its surface area A = 2(7.5 12.5 7.5 2.0 + 12.5 2.0) = 267.5 cm
2
. Given that
TST = 16 min, we can determine the molt constant C
m
from Eq. (10.7), using a value of n = 2 in
the equation.



Next we must design the riser so that its total solidification time is 2.0 min, using the some value
of mold constant since both the casting and the riser are in the same mold. The volume of the
riser is given by



And the surface area is given by

Since we are using D/H ratio = 1.0, then D = H. Substituting D for H in the volume and area
formulas, we get



And
Thus, the V/A ratio = D/6. Using this ratio in Chvorinovs equation, we have










Since H =D, then H = 4.7 cm also.

The riser represents waste metal that will be separated from than cast part and remelted to
make subsequent castings. It is desirable for the volume of metal in the riser to be a minimum.
Since the geometry of the riser is normally selected to maximize the V/A ratio, this tends to
reduce the riser volume as much as possible, Note that the volume of the riser in our example
problem is only 44% of the volume of the plate (casting), even
though its total solidification time is longer by 25%.

Risers can be designed in different forms. The design shown in figure 10.2(b) is a side riser.
It is attached to the side of the casting by means of a small channel. A top riser is one that is
connected to the surface of the casting. Risers can be open of blind. An open riser is exposed to
the outside at the top surface of the cope. This has the disadvantage of allowing more heat to
escape, promoting faster solidification. A blind riser is entirely enclosed within the mold, an in
Figure 10.1(b).