PROSMAN CHEAT SHEET - 13406123 Dc = dimension of cavity, mm; Dp =

1) Metal Casting molded part dimension, mm; S =

a) Total heat required shrinkage values (table)

3) Plastic Processes 4) Blow molding

H = total heat required to raise the
a) Swell ratio of parison diameter
temperature of the metal to the pouring
temperature, J; ρ = density; g/cm 3; Cs=
weight specific heat for the solid metal,
J/g-°C; Tm = melting temprature of the b) Swell ratio for the wall thickness
metal, °C; To = starting temprature; Hf
= heat of fusion, J/g; Cl = weight
specific heat of the liquid metal, J/g- c) Swelling of the wall thickness is
°C; Tp = pouring temperature; V = a) Die Swell propotional to the square of the
volume of metal, cm3. diameter swelling
b) Velocity of the flowing metal at
the base of sprue rs = swell ratio, Dx = diameter of the
extruded cross-section, mm; Dd =
c) Flow rate diemeter of the die orifice, mm.
b) Flight angle
d) Time required to fill mold cavity
P = pitch of screw; D = barrel
diamater, mm.
d) Max allowable tensile stress and
e) Chvorinov’s rule c) Volume drag flow rate
pressure during inflation
v = velocity of the moving plate, m/s; d
TST = total solidification time, min; V = distance separating the two plates, m
= volume of the casting, cm3; A = ; w = width of the plates , m.
surface are of the casting, cm2; n = d) Velocity of moving plate
p = air pressure used, Pa; σ =
exponent (usually n=2) ; Cm = mold
maximum allowable tensile stress, Pa.
constant.
5) Rolling
f) Archimedes’ core lift force
a) Draft and reduction
(if wf <<)
Fb = buoyancy force, Wm = weight of
molten metal displaced, Wc = weight of D = screw flight diameter, m; N =
core. screw rotational speed, rps; dc = screw
g) Casting alloys data. channel depth, m; wc = screw channel d = draft, mm; to = starting thickness,
Material Density Solid. Solid. width, m; A = flight angle; wf = flight mm; tf = final thickness, mm; R = roll
(g/cm3) Shrink Therm land width, m. radius, mm; r = reduction.
(%) al (%) e) Back pressure flow b) Spreading
Aluminium 2.7 7 5.6
Alum-Silver 2.6 7 5
alloy Qb = back pressure flow, m3/s; η = Lo = starting length, mm; L f = final
Alum- 2.81 7 5 viscosity, N-s/m2, Pas; dp/dl = the length
Copper pressure gradient, MPa/m. c) Forward slip
alloy f) Magnitude of the melt flow
Brass 8.62 n/a n/a
Gray cast 7.16 1.8 3 s = forward slip; vf = final (exiting)
iron work velocity; vr = roll speed.
Copper 8.73 4.5 7.5 d) True strain
g) Maximum flow and pressure
Lead 11.30 n/a n/a
Steel 7.82 n/a n/a
LowC n/a 3 7.2
caststeel
h) Shape factor (circular opening) Yf = average flow stress.
2) Centrifugal casting
a) G-Factor e) Force and torque

Dd = die opening diameter, m; η = melt

viscosity, N-s/m2; Ld = die opening f) Contact length
N = rotational speed, rpm; R = inside length, m.
radius of the mold, m; optimal GF = i) Die characteristic eq.
60-80. g) Power
b) Rotational speed j) Extruder characteristic eq.
P = power; N = rotational speed; F =
rolling force; L = contact length.
6) Forging
k) Dimension of cavity in injection
R = inside diameter of the mold, m. a) True strain
molding to reduce shrinkage
c) Vertical centrifugal casting

b) Shape factor
 Alum alloy, all tempers. 0.045
Alum alloy;brass;soft cold 0.060
μ = coefficient of friction; D = rolled stell;soft stainless steel.
workpart diameter, mm; h = workpart Cold rolled steel,half 0.075
height, mm.
hard;stainless steel.
c) Force
a = allowance; t = thickness, mm.
b) Diameters
7) Extrusion
---figure 20.6---
a) Extrusion/reduction ratio
Blanking punch Ø = Db – 2c
Blanking die Ø = Db
Hole punch Ø = Dh
b) True strain Hole die diameter = Dh + 2c
c) Cutting force

c) Pressure
S = shear strength; t = stock thickness;
L = length of the cut edge; TS =
ultimate tensile strength.
d) Extrusion strain 10) Sheet-metal bending
a) Bend allowance
a,b = empirical constant.
e) Ram pressure (indirect extrusion)
BA = bend allowance, mm; A = angle,
f) Ram pressure (direct extrusion) degree; R = radius, mm; t = stock
thickness, mm; Kba = constant; Kba =
0.33, R<2t; Kba = 0.5, R ≥ 2t.
g) Ram force b) Springback

h) Power
A’ = included angle of sheet metal; A’b
i) Die shape factor = included angle of bending tool.
c) Maximum force

Cx = perimeter of extruded x-section, F = bending force; TS = tensile

mm; Cc = perimeter of cicle of the same strength; w = width of part in the
area as the extruded shape. direction of bend axis; t = stock
8) Wire and bar drawing thickness; D = die opening dimension.
a) Reduction area 11) Sheet-metal drawing
a) Clearance

b) Draft 12) Stretch forming

a) Stretch force
c) True strain and stress
13) Shear spinning
a) Final thickness
---figure 20.43---

d) Draw stress b) Spinning reduction

σd = draw stress, MPa; μ = friction

coefficient; α = die angle; D = average
diameter of work during drawing; Lc =
contact length, mm.
e) Draw force

f) Power

v = exit velocity.
9) Sheet-metal cutting
a) Clearance
Metal group a