Figure 1: Digital manufacturing. Freepik.

com

Guidelines
Solve the following problems in your regular workgroup. The first group of problems is
intended to develop problem-solving skills. The second group, challenge problems,
entails a slightly greater difficulty and must be integrated with other skills previously
acquired in the race. The last problem represents a complete design. Here it is hoped that
you can go over every aspect seen in the foundry problem. Its resolution will also add ten
extra points for the partial.
A forum has been set up to discuss the resolution of this issue. They can discuss all the
problems, even the challenge problem. If you have doubts, I can also intervene to clarify
for your better resolution.

Problem 1:

Aluminum is initially melted at room temperature, 50 ° C above its melting temperature. Once
this temperature is reached, it is poured into an open mold to form an ingot and allowed to
cool in the environment until reaching a temperature equal to 50 ° C above room
temperature. Determine:
• The mathematical expression that describes the heat exchange in each of the stages
of this process.
• If we assume that 𝑐_\ {𝑝_𝑙} = c_ {p_s}, and neglect the volumetric changes of the
part, determine how much heat was exchanged in J during this process, if the final
part has the following dimensions: 20 cm × 10 × cm × 100 cm.
• Draw the T vs t diagram for this process.
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 • How would this diagram change if instead of aluminum, an aluminum alloy were used
as the metal?
• Describe what the formation of grains would be like if it is a sand mold.
• The mathematical expression to find the solidification time if it is a metal mold. What
factors influence the change between a sand mold and a metal mold?

Problem 2:

One cubic meter of a particular eutectic alloy is heated in a crucible from room temperature
to 100ºC above its melting point to melt it. The density of the alloy is 7.5 g cm-3, the melting
point is 800 ºC, specific heat of 0.33 J g-1 ° C-1 in the solid-state and 0.29J g-1 ° C -1 in
liquid state; and the heat of fusion is 160 J g-1. How much heat energy must be added to
complete heating, assuming no losses? R /. 3 335 MJ

Problem 3:
A pure aluminum disc 40 cm in diameter and 5 cm thick is to be cast in an open mold casting
operation. The melting temperature of aluminum is 660ºC, and the pouring temperature is
800ºC. Assume that the amount of aluminum to be heated will be 5% more than what is
needed to fill the mold's cavity. Calculate the amount of heat that must be added to the metal
to bring it to pour temperature, starting at room temperature 25 ° C. The heat of fusion of
aluminum is 389.3 J g-1. Other properties can be obtained from tables. Assume that the
specific heat has the same value for solid and molten aluminum. R. / 19 MJ

Problem 4:
A mold has a sprue of 6.0 inch long. The cross-sectional area at the bottom of the sprue is
0.5 in2. The sprue leads to a horizontal drain that feeds the mold cavity; whose volume is
75 in3. Determine
• the velocity of the molten metal flowing through the base of the sprue (V = 68.1 in s-
1),
• the volumetric flow rate (34 in3 s-1), and
• the time required to fill the mold cavity (2.2 s).
Problem 5:
Molten metal is to be poured into the funnel of a sand mold, at a stable rate of 1 000 cm3 s-
1. Molten metal bypasses the funnel and flows into the sprue. The cross section of the sprue
is round, with a top diameter of 3.4 cm. If the sprue is 25 cm long, determine the appropriate

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diameter at its base to maintain the same flow rate. R. / D = 2.39 cm.

Problem 6:
The final dimensions of a low carbon steel disc cast are diameter = 12.0 in., And thickness
= 0.75 in. Determine the dimensions of the mold cavity so that shrinkage is taken into
account. Assume that the contraction occurs uniformly in all directions. Use the shrinkage
values listed in the table

Challenge:

Problem 7:
Find the dimensions of a cylindrical riser used to cast a cube of pure aluminum with a side 20 cm.
Remember that the shrinkage of aluminum during solidification is 6.5%.

Problem 8:
Design a sprue that allows cast iron (\ rho_\ {Fe} = 7800 kg m-3) to be delivered through the gate at
a rate of 10 kg s-1.

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Problem 9:

Determine the time it would take to fill the mold to the Y-Y cut line depicted in the figure with
cast iron. Assume there are no losses due to friction in this system. Will these dimensions
meet the minimum parameters to avoid significant bubble formation?

Problem 10:

This problem has a value of 10 extra points for the test

Design a mold and riser for the part depicted in the figure. It would help if you considered finding
the necessary geometry for the mold that achieves an adequate filling and solidification time.
For this, consider the following:

• The metal used to make this piece is cast iron.

• The solidification time of the riser must be greater than the solidification time of the piece.
To do this, assume a sand mold coefficient value.
• Suggestion: Use a vertical mold. You are free to select the measures of the sprue,
channels, diameters, as long as the filling times achieved are small and the amount of
bubble formed does not exceed the minimum established (remember to use the
Reynolds number).

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 • Determine the weight to place on the top layer of this mold if no buoyancy problems are
expected.
• In this case, how would you consider the contraction of the metal as it cools down?
• Theoretical question: What defects could the piece have as a final result?

All dimensions are in mm.