Tutorial Questions: ME3101D Manufacturing Sciences

1. Three metal pieces being cast have the same volume, but different shapes: one is a
sphere, one a cube and other a cylinder with its height equal to its diameter. Which
piece will solidify the fastest and which one the slowest?
[Ans: tsphere= 0.043, tcube= 0.028, tcylinder=0.033]
2. A cylinder riser of 6cm diameter and 6cm height has to be designed for a sand casting
mould for producing a steel rectangular plate casting of 7cmx10cmx2cm dimensions
having the total solidification time of 1.36min. What will be the total solidification
time(in minute)of the riser?
[Ans: 3.002min]
3. An Aluminium alloy(density 2600kg/m3) casting is to be produced. A cylindrical hole
of 100mm diameter and 100mm length is made in the casting using sand core(density
1600kg/m3). What will be the net buoyancy force(in Newton) acting on the core?
[Ans: 7.70N]
4. The dimensions of a cylindrical side riser (height=dia.) for a 25cmx15cmx5cm steel
casting are to be determined. For the tabulated shape factor values given below,
determine the diameter of the riser(in cm).
Shape Factor Riser vol./Casting Vol
2 1
4 0.70
6 0.55
8 0.50
10 0.40
12 0.35
[Ans: 10.5 -10.7cm]
5. Grey Cast Iron blocks of size 100mmx50mmx10mm with a central spherical cavity of
diameter 4mm are sand cast. The shrinkage allowance for the pattern is 3%. What will
be the ratio of the volume of pattern to volume of casting?
[Ans: 1.0928]
6. A cylindrical job with diameter of 200mm and height of 100mm is to be cast using
modulus method of riser design. Assume that the bottom surface of cylindrical riser
does not contribute as cooling surface. If the diameter of the riser equal to its height,
then what will be the height of the riser(in mm)?
[Ans: d=150mm]
7. A sprue in a sand mould has a top diameter of 20mm and height of 200mm. The velocity
of the molten metal at the entry of the sprue is 0.5m/s. Assume acceleration due to
gravity as 9.8m/s2 and neglect all losses. If the mould is well ventilated, what will be
the velocity up to 3 decimal points accuracy of the molten metal at the bottom of the
sprue?
[Ans: V=2.09m/s]
8. Two castings of the same metal have the same surface area. One casting is in the form
of a sphere and the other is a cube. What is the ratio of the solidification time for the
sphere to that of the cube?[Ans: 6/π)
9. A cube and a sphere made of cast iron (each of volume 1000cm3) were cast under
identical conditions. The time taken for solidifying the cube was 4s. What will be the
solidification time of sphere?
[Ans: 20]
10. What will be the ratio of solidification time of a cylindrical casting (h=d) to that of a
cubic casting of side 2times the height of cylindrical cavity?
[Ans: 0.5625]
11. A cube shaped casting solidifies in 5min.What will be the solidification time in min.
for a cube of the same material, which is 8times heavier than the original casting?
[Ans: 20]
12. Two castings, a cube and a slab of the same material solidify under identical mould
conditions. The volumes of castings are equal but the slab dimensions are in the ratio
of 1:2:4. Find the ratio of the solidification time of the cube to that of the slab.
[Ans: 192.9]
13. The height of the down sprue is 175mm and its cross-sectional area at the base is
200mm2. The cross -sectional area of the horizontal runner is also 200mm2. Assuming
no losses, what is the correct choice for the time (in seconds) required to fill a mould
cavity of volume 106 mm3?
[Ans: 2.67]
14. Compare the solidification time of two optimum risers of the same volume when one
has a cylindrical shape and the other is of the form of a rectangular parallelopiped.
[Ans: tcyl= 1.084tpar]
15. Determine the dimensions of an optimum cylindrical riser attached to the side of a steel
plate casting having the dimensions 25cmx12.5cmx5cm by
i) Using Caine’s relationship
ii) Using N R L(modified Caine’s relationship)
iii) Assuming that the volume shrinkage on solidification is 3% for steel and the volume
of the riser is three times that dictated by the shrinkage consideration alone.
[Ans: i) 10.89cm ii) 9.98cm iii)5.64cm]
16. Consider riser of a steel plate of dimensions 25cmx25cmx0.25cm. Design the riser
[Ans: Minimum Volume=4.69cm3]
17. Determine dimensions of a cylindrical riser to be used for casting as aluminium cube
of side 15cm. The volume shrinkage of aluminium during solidification is 6.5%.
[Ans: d≥ 15 𝑓𝑜𝑟 𝑠𝑖𝑑𝑒 𝑟𝑖𝑠𝑒𝑟, 𝑑 ≥ 18 𝑓𝑜𝑟 𝑡𝑜𝑝 𝑟𝑖𝑠𝑒𝑟]
18. Determine the solidification time of the following two iron castings when superheats,
into sand moulds at the initial temperature 28oC
i) A slab-shaped casting 10cm thick
ii) A sphere 10cm in diameter
Data for iron: Tf = 1540oC; L= 272 kJ/kg; ρm = 7850kg/m3
Data for sand: c= 1.17kJ/kg-K; k= 0.8655W/m-K; ρ = 1600kg/m3
[Ans: i) ts= 0.675hr. ii) ts = 0.055hr.]
19. The fig.1 shows a mould along with the riser for casting a plate 20cmx20cmx5cm.
Determine the area Ag such that the mould and the riser get filled up within 10sec. after
the down sprue has been filled. It should be noted that A3 ≫ 𝐴𝑔 since below the down
sprue a flat gate is attached to the casting. Neglect the frictional and orifice effects.
[Ans: 4.45cm2]
 Fig.1
Linked Questions
A steel slab casting (25cmx25cmx5cm) with a side riser casting poured horizontally into the
mould. For steel a=0.10, b=0.03, c=1. Determine:
20. The diameter of the cylinder riser
a) 13cm b)19cm c)23cm d)25cm
21. Using Caine’s relationship, Find out the value of freezing ratio
a) 0.3 b)0.6 c)0.9 d)1.2
[Ans: 13cm & 1.2]
A plate like steel casting with length 300mm, width 200mm and thickness 25mm, using N.
R.L method. Given from the graph VR/VC=0.26.
22. Determine the diameter of the cylindrical riser with h/d=1
a) 40cm b)60cm c)75cm d)80cm
23. The height of cylindrical riser with h/d=1
a) 80mm b)100mm c)120mm d)150mm
[Ans: d=80mm, h=80mm]
An Aluminium cube of 10cm side has to be cast along with a cylindrical riser of height equal
to its diameter. The riser is not insulated on any surface. If the volume shrinkage of Aluminium
during solidification is 6%. Calculate
24. Shrinkage volume of cube on solidification
a) 30cm3 b)45cm3 c)60cm3 d)90cm3
25. Minimum volume of the riser
a) 130cm3 b)140cm3 c)160cm3 d)180cm3
[Ans: 60cm3 & 180cm3]
In a particular mould design, the down sprue has an area of cross section of 6.45cm2 where the
pouring basin leads into the sprue. The sprue is 20cm long. The required metal flow rate at the
top section of the sprue is 820cm3/s
26. The pouring height necessary above the sprue top will be
a) 4.5cm b) 6.5cm c) 7.5cm d) 8.5cm
27. Find the area of cross section of the sprue at its bottom to avoid aspiration of liquid
metal
 a) 2.5cm2 b) 3.5cm2 c) 4.5cm2 d)6.5cm2
[Ans: 6.5cm & 3.5cm2]
For casting Aluminium cube of sided 15cm. The volume shrinkage of Aluminium during
solidification is 6.5%. The cylindrical top riser is used
28. What will be the diameter of cylindrical riser
a) 18cm b) 21cm c)25cm d)24cm
29. What will be the height of cylindrical riser
a) 6cm b) 9cm c)12cm d)16cm
[Ans: 18cm & 9cm]