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Tutorial 4

This document contains 4 questions and solutions regarding metal casting design calculations using Chvorinov's rule. Question 1 calculates the solidification time of an aluminum disk casting using its diameter, thickness, and a given mold constant. Question 2 determines the mold constant from experimental data on a cube casting, and then uses it to calculate the solidification time of a cylindrical casting. Question 3 asks for the dimensions of a riser casting that will take 30% longer to solidify than the main casting. Question 4 involves calculating the mold constant, dimensions, and solidification time of a lighter cylindrical casting based on data from a heavier casting of the same material.

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138 views

Tutorial 4

This document contains 4 questions and solutions regarding metal casting design calculations using Chvorinov's rule. Question 1 calculates the solidification time of an aluminum disk casting using its diameter, thickness, and a given mold constant. Question 2 determines the mold constant from experimental data on a cube casting, and then uses it to calculate the solidification time of a cylindrical casting. Question 3 asks for the dimensions of a riser casting that will take 30% longer to solidify than the main casting. Question 4 involves calculating the mold constant, dimensions, and solidification time of a lighter cylindrical casting based on data from a heavier casting of the same material.

Uploaded by

omar salah
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Engineering Production

Tutorial 4
Metal Casting Design Calculations
Question 1
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?
Question 1
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

π π
• Volume V = t = × (500)2 × (20) = 3,926,991 mm3
D2
4 4
π 2 π
• Area A = 2 × ( D ) + πDt = 2× ( × 5002) + π(500)(20) = 424,115 mm2
4 4
• Chvorinov’s rule: TTS= Cm (𝑉/𝐴)2= 2.0(3,926,991/424,115)2 = 171.5 s =
2.86 min
Question 2
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.
Question 2
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
TTS 155
• Cm= 2 = 2 = 2.232 s/mm2
(V/A) (8.333)
Question 2
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
(b) Cylindrical casting with D = 30 mm and L = 50 mm.
π 2 π
• Volume V = D L = × (30)2 × (50) π(30)2(50)/4 = 35,343 mm3
4 4
π 2 π
• Area A = 2 × ( D ) + πDL = 2× ( × 302) + π(30)(50) = 6126 mm2
4 4
• V/A = 35,343/6126 = 5.77
• TTS = 2.232 (5.77)2= 74.3 s = 1.24 min.
Question 3
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 = 10 in and thickness = 0.75 in. If the metal is cast iron, and the
mold constant = 16 min/in2. Determine the dimensions of the riser so that it
will take 30% longer for the riser to solidify.
Question 3
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 = 10 in and thickness = 0.75 in. If the metal is cast iron, and the
mold constant = 16 min/in2. Determine the dimensions of the riser so that it
will take 30% longer for the riser to solidify.
Solution
Question 4
A steel casting has a cylindrical geometry with 4.0 in diameter and weighs
20 lb. This casting takes 6.0 min to completely solidify. Another cylindrical-
shaped casting with the same diameter-to-length ratio weighs 12 lb. This
casting is made of the same steel, and the same conditions of mold and
pouring were used. Knowing that the density of steel = 0.2836 lb/in3,
Determine:
(a) The mold constant in Chvorinov's rule.
(b) The dimensions of the smaller cylindrical casting.
(c) The total solidification time of the lighter casting.
Solution

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