TUTORIAL QUESTIONS

CASTING
MANU 2381

1. A disk 40 cm in diameter and 5 cm thick is to be cast of pure aluminum in an open mold casting
operation. The melting temperature of aluminum = 660C and the pouring temperature will be
800C. Assume that the amount of aluminum heated will be 5% more than what is needed to fill the
mold cavity. Compute the amount of heat that must be added to the metal to heat it to the pouring
temperature, starting from a room temperature of 25C. The heat of fusion of aluminum = 389.3 J/g.
Other properties can be obtained from Tables in the text. Assume the specific heat has the same value
for solid and molten aluminum.

2. The downsprue leading into the runner of a certain mold has a length = 175 mm. The cross-
sectional area at the base of the sprue is 400 mm2. The mold cavity has a volume = 0.001 m3.
Determine (a) the velocity of the molten metal flowing through the base of the downsprue, (b) the
volume rate of flow, and (c) the time required to fill the mold cavity.

3. The flow rate of liquid metal into the downsprue of a mold = 1 liter/sec. The cross-sectional area at
the top of the sprue = 800 mm2 and its length = 175 mm. What area should be used at the base of the
sprue to avoid aspiration of the molten metal?

4. Molten metal can be poured into the pouring cup of a sand mold at a steady rate of 1000 cm 3/s.
The molten metal overflows the pouring cup and flows into the downsprue. The cross-section of the
sprue is round, with a diameter at the top = 3.4 cm. If the sprue is 25 cm long, determine the proper
diameter at its base so as to maintain the same volume flow rate.

5. The cavity of a casting mold has dimensions: L = 250 mm, W = 125 mm and H = 20 mm.
Determine the dimensions of the final casting after cooling to room temperature if the cast metal is
aluminum. Assume that the mold is full at the start of solidification and that shrinkage occurs
uniformly in all directions. Use the shrinkage values given in Table.

6. An aluminum-copper alloy casting is made in a sand mold using a sand core that weighs 20 kg.
Determine the buoyancy force in Newtons tending to lift the core during pouring.

7. A sand core used to form the internal surfaces of a steel casting experiences a buoyancy force of 23
kg. The volume of the mold cavity forming the outside surface of the casting = 5000 cm3. What is the
weight of the final casting? Ignore considerations of shrinkage. Sand density = 1.6 g/cm3, steel
casting density = 7.82 g/cm3
 HOMEWORK # 1
CASTING
MME 2101
ANSWERS

1. A disk 40 cm in diameter and 5 cm thick is to be cast of pure aluminum in an open mold casting
operation. The melting temperature of aluminum = 660C and the pouring temperature will be
800C. Assume that the amount of aluminum heated will be 5% more than what is needed to fill
the mold cavity. Compute the amount of heat that must be added to the metal to heat it to the
pouring temperature, starting from a room temperature of 25C. The heat of fusion of aluminum
= 389.3 J/g. Other properties can be obtained from Tables 4.1 and 4.2 in the text. Assume the
specific heat has the same value for solid and molten aluminum.
Solution: Volume V = D2h/4= (40)2(5)/4 = 6283.2 cm3

Volume of aluminum to be heated = 6283.2(1.05) = 6597.3 cm3

From Table 4.1 and 4.2, density = 2.70 g/cm3 and specific heat C = 0.21 Cal/g-C = 0.88 J/g-C

Heat required = 2.70(6597.3){0.88(660-25) + 389.3 + 0.88(800-660)}

= 17,812.71{558.8 + 389.3 + 123.2} = 19,082,756 J

2. The downsprue leading into the runner of a certain mold has a length = 175 mm. The
cross-sectional area at the base of the sprue is 400 mm2. The mold cavity has a volume = 0.001
m3. Determine (a) the velocity of the molten metal flowing through the base of the downsprue,
(b) the volume rate of flow, and (c) the time required to fill the mold cavity.
Solution: (a) Velocity v = (2 x 9815 x 175)0.5 = (3,435,096)0.5 = 1853 mm/s

(b) Volume flow rate Q = vA = 1853 x 400 = 741,200 mm3/s

(c) Time to fill cavity TMF = V/Q = 1,000,000/741,200 = 1.35 s

3. The flow rate of liquid metal into the downsprue of a mold = 1 liter/sec. The cross-sectional
area at the top of the sprue = 800 mm2 and its length = 175 mm. What area should be used at the
base of the sprue to avoid aspiration of the molten metal?
Solution: Flow rate Q = 1.0 l/s = 1,000,000 mm3/s

Velocity v = (2 x 9815 x 175)0.5 = 1854 mm/s

Area at base A = 1,000,000/1854 = 540 mm2

 4. Molten metal can be poured into the pouring cup of a sand mold at a steady rate of 1000 cm3/s.
The molten metal overflows the pouring cup and flows into the downsprue. The cross-section of
the sprue is round, with a diameter at the top = 3.4 cm. If the sprue is 25 cm long, determine the
proper diameter at its base so as to maintain the same volume flow rate.
Solution: Velocity at base v = (2gh)0.5 = (2 x 981 x 25)0.5 = 221.5 cm/s

Assuming volumetric continuity, area at base A = (1000 cm/s)/(221.5 cm/s) = 4.51 cm2

Area of sprue A = D2/4; rearranging, D2 = 4A/ = 4(4.51)/ = 5.74 cm2

D = 2.39 cm

5. The cavity of a casting mold has dimensions: L = 250 mm, W = 125 mm and H = 20 mm.
Determine the dimensions of the final casting after cooling to room temperature if the cast metal
is aluminum. Assume that the mold is full at the start of solidification and that shrinkage occurs
uniformly in all directions. Use the shrinkage values given in Table 10.1.
Solution: For aluminum, solidification shrinkage = 6.6%, solid contraction during cooling =
5.6%.

Total volumetric contraction = (1-0.066)(1-0.056) = 0.8817

Linear contraction = (0.8817)0.333 = 0.9589

Final casting dimensions: L = 250(0.9589) = 239.725 cm

W = 125(0.9589) = 119.863 cm

H = 20(0.9589) = 19.178 cm

6. An aluminum-copper alloy casting is made in a sand mold using a sand core that weighs 20 kg.
Determine the buoyancy force in Newtons tending to lift the core during pouring.
Solution: Core volume V = 20/1605.4 = 0.01246 m3

Weight of displaced Al-Cu W = 35.17 kg

Difference = (35.17 - 20) x 9.815 = 149 N

7. A sand core used to form the internal surfaces of a steel casting experiences a buoyancy force of 23
kg. The volume of the mold cavity forming the outside surface of the casting = 5000 cm3. What is
the weight of the final casting? Ignore considerations of shrinkage.
Solution: Sand density = 1.6 g/cm3, steel casting density = 7.82 g/cm3

Fb = Wm - Wc = 7.82V - 1.6V = 6.22V = 23 kg = 23,000 g V = 3698 cm3.

Cavity volume V = 5000 cm3

Volume of casting V = 5000 - 3698 = 1302 cm3.

Weight of the final casting W = 1302(7.82) = 10,184 g = 10.184 kg

8. A horizontal true centrifugal casting operation will be used to make copper tubing. The lengths will
be 1.5 m with outside diameter = 15.0 cm, and inside diameter = 12.5 cm. If the rotational speed of
the pipe = 1000 rev/min, determine the G-factor.
Solution: From Eq. (11.4), GF = R(N/30)2/g = 7.5((1000)/30)2/981 = 83.8

9. A horizontal true centrifugal casting process is used to make brass bushings with the following
dimensions: length = 10 cm, outside diameter = 15 cm, and inside diameter = 12 cm. (a) Determine
the required rotational speed in order to obtain a G-factor of 70. (b) When operating at this speed,
what is the centrifugal force per square meter (Pa) imposed by the molten metal on the inside wall
of the mold?
Solution: (a) Using the outside wall diameter of the casting, which is equal to the inside wall
diameter of the mold, D = 15 cm

N = (30/)(2g x 70/15).5 = 913.7 rev/min.

(b) Use 1.0 cm of mold wall length as basis of area calculations.

Area of this length of mold wall A = DoL = (15 cm)(1 cm) = 15 cm2 = 15(10-4) m2

Volume of cast metal V = (Ro2 - Ri2)(1.0) = ((7.5)2 - (6)2)(1.0) = 63.62 cm3

Mass m = (8.62g/cm3)(63.62 cm3) = 548.4 g = 0.5484 kg

v = RN/30 Use mean radius R = (7.5 + 6.0)/2 = 6.75 cm

v = (6.75)(913.7)/30 = 645.86 cm/s = 6.4585 m/s

Centrifugal force per square meter on mold wall = Fc/A where Fc = mv2/R
Fc = (0.5484 kg)(6.4586 m/s)2/(6.75 x 10-2 m) = 338.9 kg-m/s2
Given that 1 N = 9.81 kg-m/s2, Fc = 338.9/9.81 = 34.55 N

Fc/A = (34.55 N)/(15 x 10-4 m2) = 0.7331(104) N/m2 = 7331 Pa

10. A vertical true centrifugal casting process is used to produce bushings that are 200 mm long and
200 mm in outside diameter. If the rotational speed during solidification is 500 rpm, determine the
inside diameter at the top of the bushing if the inside diameter at the bottom is 150 mm.
Solution: L = 200 mm = 0.2 m. Rb = 150/2 = 75 mm = 0.075 m.

N = (30/)(2gL/(Rt2-Rb2).5 = (30/)(2 x 9.8 x 0.2/(Rt2 - 0.0752)).5

N = (30/)(3.92/(Rt2 - 0.005625)).5 = 500 rev/min

(3.92/(Rt2- 0.005625)).5 = 500/30 = 52.36

3.92/(Rt2-.005625) = (52.36)2 = 2741.56

Rt2-.005625 = 3.92/2741.56 = 0.00143

Rt2 = .005625 + 0.001430 = 0.007055

Rt = (0.007055).5 = .08399 m = 83.99 mm.

Dt = 2(83.99) = 167.98 mm.