Assignment 4

A. Choose the correct answer(s):

1. Sand casting is which of the following types? (a) expendable mold, or (b) permanent mold.
Answer. (a)

2. The upper half of a sand casting mold is called which of the following? (a) cope, or (b) drag.
Answer. (a)

3. In casting, a flask is which one of the following? (a) beverage bottle for foundrymen, (b) box
which holds the cope and drag, (c) container for holding liquid metal, or (d) metal which
extrudes between the mold halves.
Answer. (b)

4. In foundry work, a runner is which one of the following? (a) channel in the mold leading
from the downsprue to the main mold cavity, (b) foundryman who moves the molten metal to
the mold, or (c) vertical channel into which molten metal is poured into the mold.
Answer. (a)

5. Total solidification time is defined as which one of the following? (a) time between pouring
and complete solidification, (b) time between pouring and cooling to room temperature, (c)
time between solidification and cooling to room temperature, or (d) time to give up the heat
of fusion.
Answer. (a)

6. During solidification of an alloy when a mixture of solid and liquid metals are present, the
solid-liquid mixture is referred to as whic h one of the following? (a) eutectic composition,
(b) ingot segregation, (c) liquidus, (d) mushy zone, or (e) solidus.
Answer. (d)

7. In a sand casting mold, the V/A ratio of the riser should be which one of the following
relative to the V/A ratio of the casting itself? (a) equal, (b) greater, or (c) smaller.
Answer. (b)

8. A riser that is completely enclosed within the sand mold and connected to the main cavity by
a channel to feed the molten metal is called which of the following (may be more than one)?
(a) blind riser, (b) open riser, (c) side riser, and (d) top riser.
Answer. (a) and (c).
B. Solve the following problems:
1. In the casting of steel under certain mold conditions, the mold constant in Chvorinov's
Rule is known to be Cm = 4.0 min/cm2, based on previous experience. The casting is a flat
plate whose length = 30 cm, width = 10 cm, and thickness = 20 mm. Determine how long
it will take for the casting to solidify.
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Solution: Volume V = 30 x 10 x 2 = 600 cm3
Area A = 2(30 x 10 + 30 x 2 + 10 x 2) = 760 cm2
Chvorinov’s Rule: TST = Cm (V/A)2 = 4(600/760)2 = 2.49 min

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 Cm 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
Cm = TST/(V/A)2 = 155/(8.333)2 = 2.232 s/mm2
(b) Cylindrical casting with D = 30 mm and L = 50 mm.
Volume V = D2L/4 = (30)2(50)/4 = 35,343 mm3
Area A = 2D2/4 + DL = (30)2/2 + (30)(50) = 6126 mm2
V/A = 35,343/6126 = 5.77
TST = 2.232 (5.77)2 = 74.3 s = 1.24 min.

3. A cylindrical riser is to be used for a sand-casting mold. For a given cylinder volume,
determine the diameter-to- length ratio that will maximize the time to solidify.
Solution: To maximize TST, the V/A ratio must be maximized.
Cylinder volume V = D2L/4. L = 4V/D2
Cylinder area A = 2D2/4 + DL
Substitute the expression for L from the volume equation in the area equation:
A = D2/2 + DL = D2/2 + D(4V/D2) = D2/2 + 4V/D
Differentiate the area equation with respect to D:
dA/dD = D - 4V/D2 = 0 Rearranging, D = 4V/D2
D3 = 4V/
D = (4V/)0.333
From the previous expression for L, substituting in the equation for D that we have developed,
L = 4V/D2 = 4V/(4V/)0.667 = (4V/)0.333
Thus, optimal values are D = L = (4V/)0.333, and therefore the optimal D/L ratio = 1.0

4. 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 inch. If the metal is cast iron, and Cm = 16.0 min/in2 in Chvorinov's Rule,
determine the dimensions of the riser so that it will take 30% longer for the riser to
solidify.
Solution: Casting volume V = tL2 = 0.75(10.0)2 = 75 in3
Casting area A = 2L2 + 4Lt = 2(10.0)2 + 4(10.0)(0.75) = 230.0 in2
V/A = 75/230 = 0.3261 Casting TST = 16(0.3261)2 = 1.70 min
Riser TST = 1.30(1.70) = 2.21 min
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Fall 2023 / 2024 Manufacturing Technology
Riser volume V = D2H/4 = 0.25D2(1.25D) = 0.3125D3
Riser area A = 2D2/4 + DH = 0.5D2 + 1.25D2 = 1.75D2
V/A = 0.3125D3/1.75D2 = 0.1786D
Riser TST = 16.0(0.1786D)2 = 16.0(0.03189)D2 = 0.5102D2 = 2.21 min
D2 = 2.21/0.5102 = 4.3316
D = (4.3316)0.5 = 2.081 in
H = 1.25(2.081) = 2.602 in.

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