Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) © MPGroover 2010

03-12-09, 03-13-09

9 FUNDAMENTALS OF METAL CASTING

Review Questions
9.1 Identify some of the important advantages of shape-casting processes.
Answer. Advantages include (1) complex part geometries are possible; (2) some casting operations
are net shape processes, meaning that no further manufacturing operations are needed to accomplish
the final part shape; (3) very large parts are possible; (4) they are applicable to any metal that can be
melted; and (5) some casting processes are suited to mass production.
9.2 What are some of the limitations and disadvantages of casting?
Answer. Disadvantages include (1) limitations on mechanical strength properties; (2) porosity; (3)
poor dimensional accuracy; (4) safety hazards due to handling of hot metals; and (5) environmental
problems.
9.3 What is a factory that performs casting operations usually called?
Answer. A foundry.
9.4 What is the difference between an open mold and a closed mold?
Answer. An open mold is open to the atmosphere at the top; it is an open container in the desired
shape which must be flat at the top. A closed mold has a cavity that is entirely enclosed by the
mold, with a passageway (called the gating system) leading from the outside to the cavity. Molten
metal is poured into this gating system to fill the mold.
9.5 Name the two basic mold types that distinguish casting processes.
Answer. The two mold types are (1) expendable molds and (2) permanent molds.
9.6 Which casting process is the most important commercially?
Answer. Sand casting is the most important casting process.
9.7 What is the difference between a pattern and a core in sand molding?
Answer. The pattern determines the external shape of the cast part, while a core determines its
internal geometry if the casting includes a cavity.
9.8 What is meant by the term superheat?
Answer. Superheat is the temperature difference above the melting point at which the molten metal
is poured. The term also refers to the amount of heat that is removed from the molten metal
between pouring and solidification.
9.9 Why should turbulent flow of molten metal into the mold be avoided?
Answer. Turbulence causes the following problems: (1) it accelerates formation of oxides in the
solidified metal, and (2) it causes mold erosion or gradual wearing away of the mold due to impact
of molten metal.
9.10 What is the continuity law as it applies to the flow of molten metal in casting?
Answer. The continuity law, or continuity equation, indicates that the volumetric flow rate is
constant throughout the liquid flow.
9.11 What are some of the factors that affect the fluidity of a molten metal during pouring into a mold
cavity?

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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) © MPGroover 2010
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Answer. The factors include (1) pouring temperature above the melting point, (2) metal alloy
composition, (3) viscosity of the liquid metal, and (4) heat transfer to the surroundings.
9.12 What does heat of fusion mean in casting?
Answer. Heat of fusion is the amount of heat energy required to transform the metal from solid
state to liquid state.
9.13 How does solidification of alloys differ from solidification of pure metals?
Answer. Pure metals solidify at a single temperature equal to the melting point. Most alloys
(exceptions are eutectic alloys) start to solidify at the liquidus and complete solidification occurs at
the solidus, where the liquidus is a higher temperature than the solidus.
9.14 What is a eutectic alloy?
Answer. A eutectic alloy is a particular composition in an alloy system for which the solidus and
liquidus temperatures are equal. The temperature is called the eutectic temperature. Hence,
solidification occurs at a single temperature, rather than over a temperature range.
9.15 What is the relationship known as Chvorinov's rule in casting?
Answer. Chvorinov's rule is summarized: TTS = Cm(V/A)2, where TTS = total solidification time, Cm =
mold constant, V = volume of casting, and A = surface area of casting.
9.16 Identify the three sources of contraction in a metal casting after pouring.
Answer. The three contractions occur due to (1) contraction of the molten metal after pouring, (2)
solidification shrinkage during transformation of state from liquid to solid, and (3) thermal
contraction in the solid state.
9.17 What is a chill in casting?
Answer. A chill is a heat sink placed to encourage rapid freezing in certain regions of the casting.
Multiple Choice Quiz
There are 15 correct answers in the following multiple choice questions (some questions have multiple
answers that are correct). To attain a perfect score on the quiz, all correct answers must be given. Each
correct answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point, and
each additional answer beyond the correct number of answers reduces the score by 1 point. Percentage score
on the quiz is based on the total number of correct answers.
9.1 Sand casting is which of the following types: (a) expendable mold or (b) permanent mold?
Answer. (a).
9.2 The upper half of a sand-casting mold is called which of the following: (a) cope or (b) drag?
Answer. (a).
9.3 In casting, a flask is which one of the following: (a) beverage bottle for foundrymen, (b) box which
holds the cope and drag, (c) container for holding liquid metal, or (d) metal which extrudes between
the mold halves?
Answer. (b).
9.4 In foundry work, a runner is which one of the following: (a) channel in the mold leading from the
downsprue to the main mold cavity, (b) foundryman who moves the molten metal to the mold, or
(c) vertical channel into which molten metal is poured into the mold?
Answer. (a).

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9.5 Turbulence during pouring of the molten metal is undesirable for which of the following reasons
(two best answers): (a) it causes discoloration of the mold surfaces, (b) it dissolves the binder used
to hold together the sand mold, (c) it increases erosion of the mold surfaces, (d) it increases the
formation of metallic oxides that can become entrapped during solidification, (e) it increases the
mold filling time, and (f) it increases total solidification time?
Answer: (c) and (d).
9.6 Total solidification time is defined as which one of the following: (a) time between pouring and
complete solidification, (b) time between pouring and cooling to room temperature, (c) time
between solidification and cooling to room temperature, or (d) time to give up the heat of fusion?
Answer. (a).
9.7 During solidification of an alloy when a mixture of solid and liquid metals is present, the
solid-liquid mixture is referred to as which one of the following: (a) eutectic composition, (b) ingot
segregation, (c) liquidus, (d) mushy zone, or (e) solidus?
Answer. (d).
9.8 Chvorinov's rule states that total solidification time is proportional to which one of the following
quantities: (a) (A/V)n, (b) Hf, (c) Tm, (d) V, (e) V/A, or (f) (V/A)2; where A = surface area of casting,
Hf = heat of fusion, Tm = melting temperature, and V = volume of casting?
Answer. (f).
9.9 A riser in casting is described by which of the following (three correct answers): (a) an insert in the
casting that inhibits buoyancy of the core, (b) gating system in which the sprue feeds directly into
the cavity, (c) metal that is not part of the casting, (d) source of molten metal to feed the casting and
compensate for shrinkage during solidification, and (e) waste metal that is usually recycled?
Answer. (c), (d), and (e).
9.10 In a sand-casting mold, the V/A ratio of the riser should be (a) equal to, (b) greater than, or (c)
smaller than the V/A ratio of the casting itself?
Answer. (b).
9.11 Which of the following riser types are completely enclosed within the sand mold and connected to
the main cavity by a channel to feed the molten metal (two correct answers): (a) blind riser, (b) open
riser, (c) side riser, and (d) top riser?
Answer. (a) and (c).

Problems
Heating and Pouring
9.1 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 = 660°C, and the pouring temperature will be
800°C. 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 25°C. 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 = πD2h/4= π(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 ρ = 2.70 g/cm3 and specific heat C = 0.21 Cal/g-°C = 0.88 J/g-°C
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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) © MPGroover 2010
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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
9.2 A sufficient amount of pure copper is to be heated for casting a large plate in an open mold. The plate
has dimensions: length = 25 cm, width = 50 cm, and thickness = 7.5 cm. Compute the amount of heat
that must be added to the metal to heat it to a temperature of 1175°C for pouring. Assume that the
amount of metal heated will be 10% more than what is needed to fill the mold cavity. Properties of
the metal are: density = 0.009 kg/cm3, melting point = 1083°C, specific heat of the metal = 0.395/g°C
in the solid state and 0.38 J/g°C in the liquid state, and heat of fusion = 186 kJ/Kg.
Solution: Volume V = (50 × 25 × 7.5)(1 + 10%) = 9375(1.1) = 10312.5 cm3
Assuming To = 24°C and using Eq. (10.1),
H = 9 × 10312.5 {0.39(1083 − 24) + 186 + 0.38 (1175 − 1083)} = 92812 {413.01 + 186 + 34.96}
H = 58.84 MJ
9.3 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
9.4 A mold has a downsprue of length = 15 cm. The cross-sectional area at the bottom of the sprue is
3.125 cm2. The sprue leads into a horizontal runner which feeds the mold cavity, whose volume =
1172 cm3. 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 × 9.8 × 100 × 15)0.5 = 171.46 cm/sec
(b) Volume flow rate Q = vA = 171.46 × 3.125 = 535.81 cm3/sec
(c) Time to fill cavity TMF = V/Q = 1172/535.81 = 2.2 sec.
9.5 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
9.6 The volume rate of flow of molten metal into the downsprue from the pouring cup is 780 cm3/sec. At
the top where the pouring cup leads into the downsprue, the cross-sectional area = 6.25 cm2.
Determine what the area should be at the bottom of the sprue if its length = 20 cm. It is desired to
maintain a constant flow rate, top and bottom, in order to avoid aspiration of the liquid metal.
Solution: Velocity at base v = (2gh)0.5 = (2 × 9.8 × 100 × 20)0.5 = 197.9 cm/sec
Assuming volumetric continuity, area at base A = (780 cm3/sec)/(197.9 cm/sec) = 3.941 cm2
9.7 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 = πD2/4; rearranging, D2 = 4A/π = 4(4.51)/π = 5.74 cm2
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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) © MPGroover 2010
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D = 2.39 cm
9.8 During pouring into a sand mold, the molten metal can be poured into the downsprue at a constant
flow rate during the time it takes to fill the mold. At the end of pouring the sprue is filled and there is
negligible metal in the pouring cup. The downsprue is 15 cm long. Its cross-sectional area at the top =
5 cm2 and at the base = 3.75 cm2. The cross-sectional area of the runner leading from the sprue also =
3.75 cm2, and it is 20 cm long before leading into the mold cavity, whose volume = 1015 cm3. The
volume of the riser located along the runner near the mold cavity = 390 cm3. It takes a total of 3.0 sec
to fill the entire mold (including cavity, riser, runner, and sprue. This is more than the theoretical time
required, indicating a loss of velocity due to friction in the sprue and runner. Find (a) the theoretical
velocity and flow rate at the base of the downsprue; (b) the total volume of the mold; (c) the actual
velocity and flow rate at the base of the sprue; and (d) the loss of head in the gating system due to
friction.
Solution: (a) Velocity v = (2 × 9.8 × 100 × 15)0.5 = 171.5 cm/sec
Flow rate Q = 171.5 × 3.75 = 643.1 cm3/sec
(b) Total V = 1015 + 390 + 0.5 (5 + 3.75)(15) + (3.75)(20) = 1545.6 cm3
(c) Actual flow rate Q = 1545.6/3 = 515.2 cm3/sec
Actual velocity v = 515.2/3.75 = 137.4 cm/sec
(d) v = (2 × 9.8 × 100 × h)0.5 = 44.3 h0.5 = 137.4 cm/sec
h0.5 = 137.4/44.3 = 3.102
h = 3.1022 = 9.622 cm
Head loss = 15 − 9.622 = 5.378 cm
Shrinkage
9.9 Determine the shrink rule to be used by pattern makers for white cast iron. Using the shrinkage value
in Table 9.1, express your answer in terms of centimeters of elongation per meter of length compared
to a standard one-meter scale.
Solution: For white cast iron, shrinkage 2.1% from Table 9.1.
Thus, linear contraction = 1.0 – 0.021 = 0.979.
Shrink rule elongation = (0.979)-1 = 1.02145
For a 100-cm rule, L = 1.02145(100) = 102.145 cm
Elongation per meter of length = 2.145 cm
9.10 Determine the shrink rule to be used by mold makers for die casting of zinc. Using the shrinkage
value in Table 9.1, express your answer in terms of decimal mm of elongation per 300 mm of length
compared to a standard 300-mm scale.
Solution: For zinc, shrinkage 2.6% from Table 9.1.
Thus, linear contraction = 1.0 – 0.026 = 0.974.
Shrink rule elongation = (0.974)-1 = 1.0267
For a 300-mm rule, L = 1.0267(300) = 308.008 mm
Elongation per 300 mm of length = 8.008 mm
9.11 A flat plate is to be cast in an open mold whose bottom has a square shape that is 200 mm by 200
mm. The mold is 40 mm deep. A total of 1,000,000 mm3 of molten aluminum is poured into the
mold. Solidification shrinkage is known to be 6.0%. Table 9.1 lists the linear shrinkage due to
thermal contraction after solidification to be 1.3%. If the availability of molten metal in the mold
allows the square shape of the cast plate to maintain its 200 mm by 200 mm dimensions until
solidification is completed, determine the final dimensions of the plate.

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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) © MPGroover 2010
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Solution: The initial volume of liquid metal = 1,000,000 mm3. When poured into the mold it takes
the shape of the open mold, which is 200 mm by 200 mm square, or 40,000 mm2. The starting height
of the molten metal is 1,000,000 / 40,000 = 25 mm.
Volumetric solidification shrinkage is 6%, so when the aluminum has solidified its volume =
1,000,000(0.94) = 940,000 mm3. Because its base still measures 200 mm by 200 mm due to the flow
of liquid metal before solidification, its height has been reduced to 940,000 / 40,000 = 23.5 mm.
Thermal contraction causes a further shrinkage of 1.6%. Thus the final dimensions of the plate are
200(0.984) by 200(0.984) by 23.5(0.984) = 196.8 mm by 196.8 mm by 23.124 mm.
Solidification Time and Riser Design
9.12 In the casting of steel under certain mold conditions, the mold constant in Chvorinov's rule is known
to be 4.0 min/cm2, based on previous experience. The casting is a flat plate whose length = 30 cm,
width = 10 cm, and thickness = 20 mm. Determine how long it will take for the casting to solidify.
Solution: Volume V = 30 x 10 x 2 = 600 cm3
Area A = 2(30 x 10 + 30 x 2 + 10 x 2) = 760 cm2
Chvorinov’s rule: TTS = Cm (V/A)2 = 4(600/760)2 = 2.49 min
9.13 Solve for total solidification time in the previous problem only using an exponent value of 1.9 in
Chvorinov's rule instead of 2.0. What adjustment must be made in the units of the mold constant?
Solution: Chvorinov’s rule: TTS = Cm (V/A)1.9 = 4(600/760)1.9 = 2.55 min
The units for Cm become min/cm1.9 - strange units but consistent with Chvorinov’s empirical rule.
9.14 A disk-shaped part is to be cast out of aluminum. The diameter of the disk = 500 mm and its
thickness = 20 mm. If the mold constant = 2.0 sec/mm2 in Chvorinov's rule, how long will it take the
casting to solidify?
Solution: Volume V = πD2t/4 = π(500)2(20)/4 = 3,926,991 mm3
Area A = 2πD2/4 + πDt = π(500)2/2 + π(500)(20) = 424,115 mm2
Chvorinov’s rule: TTS = Cm (V/A)2 = 2.0(3,926,991/424,115)2 = 171.5 s = 2.86 min
9.15 In casting experiments performed using a certain alloy and type of sand mold, it took 155 sec for a
cube-shaped casting to solidify. The cube was 50 mm on a side. (a) Determine the value of the mold
constant in Chvorinov's rule. (b) If the same alloy and mold type were used, find the total
solidification time for a cylindrical casting in which the diameter = 30 mm and length = 50 mm.
Solution: (a) Volume V = (50)3 = 125,000 mm3
Area A = 6 x (50)2 = 15,000 mm2
(V/A) = 125,000/15,000 = 8.333 mm
Cm = TTS /(V/A)2 = 155/(8.333)2 = 2.232 s/mm2
(b) Cylindrical casting with D = 30 mm and L = 50 mm.
Volume V = πD2L/4 = π(30)2(50)/4 = 35,343 mm3
Area A = 2πD2/4 + πDL = π(30)2/2 + π(30)(50) = 6126 mm2
V/A = 35,343/6126 = 5.77
TTS = 2.232 (5.77)2 = 74.3 s = 1.24 min.
9.16 A steel casting has a cylindrical geometry with 10 cm diameter and weighs 9 kg. This casting takes
6.0 min to completely solidify. Another cylindrical-shaped casting with the same diameter-to-length
ratio weighs 5.4 kg. This casting is made of the same steel, and the same conditions of mold and
pouring were used. Determine: (a) the mold constant in Chvorinov's rule, (b) the dimensions, and (c)
the total solidification time of the lighter casting. The density of steel = 7850 kg/m3.
Solution: (a) For steel, ρ = 7850 kg/m3 = 0.00785 kg/cm3
Weight W = ρV, V = W/ρ = 9/0.00785 = 1146.5 cm3
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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) © MPGroover 2010
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Volume V = πD2L/4 = π(10)2L/4 = 25πL = 1146.5 cm3
Length L = 1146.5/25π = 14.6 cm
Area A = 2πD2/4 + πDL = 2π(10)2/4 + π(10)(14.6) = 615.75 cm2
(V/A) = 1146.5/615.75 = 1.862 cm
Cm = 6.0/(1.862)2 = 1.731 min/cm2
(b) Find dimensions of smaller cylindrical casting with same D/L ratio and w = 5.4 kg.
Weight is proportional to volume: V = (5.4/9)(1146.5) = 687.9 cm3
D/L ratio = 10/14.6 = 0.685; thus L = 1.4599D
Volume V = πD2L/4 = π(D)2(1.4599D)/4 = 1.1466D3
D3 = (687.9 cm3)/1.1466 = 599.95 cm3
D = (599.95)0.333 = 8.416 cm
L = 1.4599(8.416) = 12.287 cm
(c) V = πD2L/4 = π(8.416)2(12.287)/4 = 683.5 cm3
A = 2πD2/4 + πDL = 0.5π(8.416)2 + π(8.416)(12.287) = 436.12 cm2
V/A = 683.5/436.12 = 1.567 cm
TTS = 1.731(1.567)2 = 4.25 min.
9.17 The total solidification times of three casting shapes are to be compared: (1) a sphere with diameter
= 10 cm, (2) a cylinder with diameter and length both = 10 cm, and (3) a cube with each side = 10
cm. The same casting alloy is used in the three cases. (a) Determine the relative solidification times
for each geometry. (b) Based on the results of part (a), which geometric element would make the
best riser? (c) If the mold constant = 3.5 min/cm2 in Chvorinov's rule, compute the total
solidification time for each casting.
Solution: For ease of computation, make the substitution 10 cm = 1 decimeter (1 dm)
(a) Chvorinov’s rule: TTS = Cm(V/A)2
(1) Sphere volume V = πD3/6 = π(1)3/6 = π/6 dm3
Sphere surface area A = πD2 = π(1)2 = π dm2
V/A = (π/6)/π = 1/6 = 0.1667 dm
Chvorinov’s rule TTS = (0.1667)2Cm = 0.02778Cm
(2) Cylinder volume V = πD2H/4 = π(1)2(1)/4 = π/4 = 0.25π dm3
Cylinder area A = 2πD2/4 + πDL = 2π(1)2/4 + π(1)(1) = π/2 + π = 1.5π dm2
V/A = 0.25π/1.5π = 0.1667 dm
Chvorinov’s rule TTS = (0.1667)2Cm = 0.02778Cm
(3) Cube: V = L3 = (1)3 = 1.0 dm3
Cube area = 6L2 = 6(1)2 = 6.0 dm2
V/A = 1.0/6.0 = 0.1667 dm
Chvorinov’s rule TTS = (0.1667)2Cm = 0.02778Cm
(b) All three shapes are equivalent as risers.
(c) If Cm = 3.5 min/cm2 = 350 min/dm2, then TTS = 0.02778(350) = 9.723 min. Note, however, that
the volumes of the three geometries are different: (1) sphere V = 0.524 dm3 = 524 cm3, cylinder V
= 0.25π = 0.7854 dm3 = 785.4 cm3, and (3) cube V = 1.0 dm3 = 1000cm3. Accordingly, we might
revise our answer to part (b) and choose the sphere on the basis that it wastes less metal than the
other shapes.
9.18 The total solidification times of three casting shapes are to be compared: (1) a sphere, (2) a cylinder,
in which the length-to-diameter ratio = 1.0, and (3) a cube. For all three geometries, the volume =
1000 cm3. The same casting alloy is used in the three cases. (a) Determine the relative solidification
times for each geometry. (b) Based on the results of part (a), which geometric element would make
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Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) © MPGroover 2010
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the best riser? (c) If the mold constant = 3.5 min/cm2 in Chvorinov's rule, compute the total
solidification time for each casting.
Solution: For ease of computation, make the substitution 10 cm = 1 decimeter (1 dm). Thus 1000
cm3 = 1.0 dm3.
(1) Sphere volume V = πD3/6 = 1.0 dm3. D3 = 6/π = 1.910 dm3. D = (1.910)0.333 = 1.241 dm
Sphere area A = πD2 = π(1.241)2 = 4.836 dm2
V/A = 1.0/4.836 = 0.2067 dm
Chvorinov’s rule TTS = (0.2067)2Cm = 0.0428Cm
(2) Cylinder volume V = πD2H/4 = πD3/4 = 1.0 dm3. D3 = 4/π = 1.273 dm3
Therefore, D = H = (1.273)0.333 = 1.084 dm
Cylinder area A = 2πD2/4 + πDL = 2π(1.084)2/4 + π(1.084)(1.084) = 5.536 dm2
V/A = 1.0/5.536 = 0.1806 dm
Chvorinov’s rule TTS = (0.1806)2Cm = 0.0326Cm
(3) Cube: V = L3 =1.0 dm3. L = 1.0 dm
Cube area = 6L2 = 6(1)2 = 6.0 dm2
V/A = 1.0/6.0 = 0.1667 dm
Chvorinov’s rule TTS = (0.1667)2Cm = 0.02778Cm
(b) Sphere would be the best riser, since V/A ratio is greatest.
(c) Given that Cm = 3.5 min/cm2 = 350 min/dm3
Sphere: TTS = 0.0428(350) = 14.98 min
Cylinder: TTS = 0.0326(350) = 11.41 min
Cube: TTS = 0.02778(350) = 9.72 min
9.19 A cylindrical riser is to be used for a sand-casting mold. For a given cylinder volume, determine the
diameter-to-length ratio that will maximize the time to solidify.
Solution: To maximize TTS, the V/A ratio must be maximized.
Cylinder volume V = πD2L/4. L = 4V/πD2
Cylinder area A = 2πD2/4 + πDL
Substitute the expression for L from the volume equation in the area equation:
A = πD2/2 + πDL = πD2/2 + πD(4V/πD2) = πD2/2 + 4 V/D
Differentiate the area equation with respect to D:
dA/dD = πD – 4 V/D2 = 0 Rearranging, πD = 4V/D2
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D = 4 V/π
D = (4 V/π)0.333
From the previous expression for L, substituting in the equation for D that we have developed,
L = 4V/πD2 = 4V/π(4V/π)0.667 = (4V/π)0.333
Thus, optimal values are D = L = (4V/π)0.333, and therefore the optimal D/L ratio = 1.0
9.20 A riser in the shape of a sphere is to be designed for a sand casting mold. The casting is a rectangular
plate, with length = 200 mm, width = 100 mm, and thickness = 18 mm. If the total solidification time
of the casting itself is known to be 3.5 min, determine the diameter of the riser so that it will take
25% longer for the riser to solidify.
Solution: Casting volume V = LWt = 200(100)(18) = 360,000 mm3
Casting area A = 2(200 x 100 + 200 x 18 + 100 x 18) = 50,800 mm2
V/A = 360,000/50,800 = 7.0866
Casting TTS = Cm(7.0866)2 = 3.50 min
Cm = 3.5/(7.0866)2 = 0.0697 min/mm2
Riser volume V = πD3/6 = 0.5236D3
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8
Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) © MPGroover 2010
03-12-09, 03-13-09
Riser area A = πD2 = 3.1416D2
V/A = 0.5236D3/3.1416D2 = 0.1667D
TTS = 1.25(3.5) = 4.375 min = 0.0697(0.1667D)2 = 0.001936D2
D2 = 4.375/0.001936 = 2259.7 mm2
D = 47.5 mm
9.21 A cylindrical riser is to be designed for a sand casting mold. The length of the cylinder is to be 1.25
times its diameter. The casting is a square plate, each side = 25 cm and thickness = 1.875 cm. If the
metal is cast iron, and the mold constant = 2.56 min/cm2 in Chvorinov's rule, determine the
dimensions of the riser so that it will take 30% longer for the riser to solidify.
Solution: Casting volume V = tL2 = 1.875(25)2 = 1171.875 cm3
Casting area A = 2L2 + 4Lt = 2(25)2 + 4(25)(1.875) = 1437.5 cm2
V/A = 1171.875/1437.5 = 0.8152 cm Casting TTS = 2.56(0.8152)2 = 1.70 min
Riser TTS = 1.30(1.70) = 2.21 min
Riser volume V = πD2H/4 = 0.25πD2(1.25D) = 0.3125πD3
Riser area A = 2πD2/4 + πDH = 0.5πD2 + 1.25πD2 = 1.75πD2
V/A = 0.3125πD3/1.75πD2 = 0.1786D
Riser TTS = 16.0(0.1786D)2 = 2.56(0.03189)D2 = 0.0816D2 = 2.21 min
D2 = 2.21/0.0816 = 27.08
D = (27.08)0.5 = 5.2 cm
H = 1.25(5.2) = 6.5 cm
9.22 A cylindrical riser with diameter-to-length ratio = 1.0 is to be designed for a sand casting mold. The
casting geometry is illustrated in Figure P10.25, in which the units are centimeters. If the mold
constant in Chvorinov's rule = 3.12 min/cm2, determine the dimensions of the riser so that the riser
will take 0.5 min longer to freeze than the casting itself.
Solution: Casting volume V = V(12.5 cm × 25 cm rectangular plate) + V(12.5 cm half disk) +
V(upright tube) - V(7.5 cm × 15 cm rectangular cutout).
V(5 in × 10 in rectangular plate) = 12.5 × 31.25 × 2.5 = 976.56 cm3
V(5 in. half disk) = 0.5π(12.5)2(2.5)/4 = 153.4 cm3
V(upright tube) = 7.5π(6.25)2/4 − 10π(3.75)2/4) = 119.7 cm3
V(3 in × 6 in rectangular cutout) = 7.5 × 15 × 2.5 = 281.25 cm3
Total V = 976.56 + 153.4 + 119.7 − 281.25 = 968.41 cm3
Total A = 2.5 × 12.5 + 2.5(31.25 + 6.25π + 31.25) + 5(15 + 7.5) + 2(12.5 × 31.25 − 7.5 × 15) +
2(0.5π(12.5)2/4) − 2(3.75)2π/4 + 6.25π(7.5) + 3.75π(7.5 + 2.5) = 1271.06 cm2
V/A = 968.41/1271.06 = 0.762 cm
Casting TTS = 3.12(0.762)2 = 1.81 min
Riser design: specified TTS = 1.81 + 0.5 = 2.31 min
Riser volume V = πD2L/4 = πD3/4 = 0.25πD3
Riser area A = πDL + 2πD2/4 = πD2 + 0.5πD2 = 1.5πD2
V/A = 0.25πD3/1.5πD2 = D/6
TTS = Cm(V/A)2
2.31 = 3.12(D/6)2 = 0.0867D2
D2 = 2.31/0.0867 = 26.644 cm2 D = 5.162 cm and L = 5.162 cm

Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes only to
students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work beyond that permitted
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9