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Solidificaton Time

The document discusses the casting process, focusing on solidification time and Chvorinov's rule, which relates the solidification time of a casting to its volume and surface area. It highlights the importance of solidification mechanisms in preventing defects and the influence of cooling rates on the resulting metallographic structure. Additionally, it covers the design considerations for risers to ensure effective feeding of molten metal to the casting during solidification.

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Sundaramali Govindaswamy G
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27 views17 pages

Solidificaton Time

The document discusses the casting process, focusing on solidification time and Chvorinov's rule, which relates the solidification time of a casting to its volume and surface area. It highlights the importance of solidification mechanisms in preventing defects and the influence of cooling rates on the resulting metallographic structure. Additionally, it covers the design considerations for risers to ensure effective feeding of molten metal to the casting during solidification.

Uploaded by

Sundaramali Govindaswamy G
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Solidification time and

Chvorinov’s rule.
The casting process basically involves:
(a) pouring molten metal into a mold patterned
after the part to be manufactured
(b) allowing it to solidify
(c) removing the part from the mold.
Casting and
 Important considerations in casting operations are
solidification…
as follows:
 Flow of the molten metal into the mold cavity
 Solidification and cooling of the metal in the mold
 Influence of the type of mold material
 Solidification is a phase change of matter that results in the
production of a solid..
 Solidification mechanism is essential for preventing defects
What is due to shrinkage.
Solidification  The mode of solidification affects the properties of the
and casting acquires a metallographic structure which is
determined during solidification.
Solidification  Solidification time is nothing but the time it takes for the
time? casting to solidify.
 Its different for Pure Metals and Alloys
Solidification
time of Pure
Metal

A pure metal solidifies at a constant temperature equal to its


freezing point(same as melting point)
Solidification
Time of alloy

Alloy solidification binary isomorphous.


 Slow cooling rates or long, local solidification times result
in coarse dendritic structures with large spacing between
dendrite arms.
 The structures developed and the resulting grain size
Solidification influence the properties of the casting.
time-  Lack of uniformity in grain size and grain distribution
results in castings with anisotropic properties.
Importance  When the casting is cooled very slowly, each dendrite
develops a uniform composition.
 However, under the normal (faster) cooling rates
encountered in practice, cored dendrites are formed.
 Solidification time
 During the early stages of solidification, a thin, solidified skin begins
to form at the cool mold walls, and as time passes, the thickness of
the skin increases.
What is  The Skin thickness increases with elapsed time, and the skin is
thinner at internal angles (at A).
Chvorinov’s
rule?

 The solidification time of a casting is a function of the volume of


a casting and its surface area (Chvorinov’s rule). Solidification time
of a casting is given by the formula:
 Volume: volume of casting.
 Surface area of casting.
 “n” is constant (generally taken as 2 )
 C: Mold constant C depends on:
 Mold material
 Thermal properties of casting metal
 Pouring temperature relative to melting point
 Here, the ratio of volume and surface area is also called as
modulus of casting.
 Casting with a higher volume‑to‑surface area ratio
cools and solidifies more slowly than one with a
lower ratio
 To feed molten metal to the main cavity, TTS for riser
What
must be greater than TTS for main casting
Chvorinov's
 Since mold constants of riser and casting will be
Rule Tells Us?
equal, design the riser to have a larger
volume‑to‑area ratio so that the main casting
solidifies first
 This minimizes the effects of shrinkage
Three metal pieces being cast have the same volume but different
shapes: One is a sphere, one a cube, and the other a cylinder with
its height equal to its diameter. Which piece will solidify the fastest,
and which one the slowest? Assume that n = 2.
Solution: Let us assume the volume to be 1 unit.
Solidification
times for
various shapes
 Chvorinov's rule can be used to ensure that the casting will solidify before
the riser. This is necessary if the liquid within the riser is to effectively feed
the casting to compensate for solidification shrinkage.
 “ Riser solidification time must be longer than casting solidification time ”
 Since mold constants of riser and casting will be equal so the shape of the
riser is the only thing which make the solidification time difference.
 Consider shapes : sphere, cube, cylinder.

Riser design…  Using Chvorinov’s rule we get:

 Here, ideal shape of riser should be sphere, but incorporating a spherical


riser inside the moulding boxes would be a tough task.
 So instead of spherical riser a cylindrical riser is used.
 By experiments say the further investigators found that the Modulus of the
riser is equal to 1.2 times the Modulus of the casting
 Chvorinov’s rule is applicable for only one
directional solidification.
Limitation of  The casting material used must be pure metal
Chvorinov’s or binary eutectic alloy.
rules……  The medium is isotropic and homogeneous.
 Only applicable to limited metals under ideal
conditions.
 Now a days software are used for the this time determination
purpose.
 Some of them are SOLIDcast & OPTIcast and SUTcast.
 These software stimulate the whole casting process and provide us
with in depth information about the probability of success of
casting.
New  These software are much more accurate and precise as compared
to the traditional methods.
technology in
determining
solidification
time.
MEE 2014 METAL CASTING TECHNOLOGY
Note: Choose a DA-1 (Date of submission:08-08-2020)
1. Selection of a part
part with i. Select suitable material for the casting (why justify)
configuration ii. Tabulate material properties needed for casting design
iii. Prepare casting drawing
which need all
2. Pattern making and Solidification
the allowances:
Shrinkage, i. Allowances calculation - Tabulate all allowance
ii. Pattern material (why justify)
machining, iii. Pattern diagram
draft iv. Find Solidification time. Predict the cast structure
v. Mould diagram
DA-2 (Date of submission:15-09-2020)
3. Casting Design
i. Moulding process selection – Give the reasons
Note: Choose a ii. Core making and assembly
part with iii. Gating and riser design – Show all the calculation, include necessary neat diagrams.
iv. Yield calculation.
configuration
4. Casting, Property improvement and Defect analysis
which need all i. Melting process and treatment of molten metal
the allowances: ii. Heat treatment process
iii. Possible casting defects and how to minimise defects in the casting method?
Shrinkage,
machining, draft 5. a. Cleaning, testing of casting, costing and energy conservation
i. Different inspection and testing methods to evaluate the casting.
ii. Costing estimation of casting
iii. Energy conservation method employed

b. Simulation
Simulate casting design, gate, runner and riser
 Isotropic: Properties of a material are
identical in all directions.
 Anisotropic: Properties of a material
depend on the direction; for example,
wood. In a piece of wood, you can see
lines going in one direction; this
Important direction is referred to as "with the
grain“
terms:
 Isomorphous In this systems the two
components have unlimited solubility,
which means that they are like water
and alcohol when they mix - they
always form a solid solution regardless
of the ratio of atoms/molecules.

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