MANUFACTURING PROCESSES - 2

ASSIGNMENT 2 (CASTING)

1. Define casting. Explain steps involved in preparation of sand casting. Further, discuss
advantages and disadvantages of casting.

2. (a) what is pattern? Explain different pattern materials with their relative advantages,
disadvantages and applications.
(b) Explain various allowances need to be considered while designing a pattern.
(c) Discuss different types of patterns used in casting.

3. (a) What is a gating system and explain the need of it in casting? Explain its parts and their
importance.
(b) What is a gating ratio? What is the importance of pressurized and unpressurized gating
systems?
(c) Explain sequence of steps involved in designing a sprue, runner and ingates.

4. (a) What is a riser? Explain different types of rises along with their advantages and limitations.
(b) Explain all design consideration and steps involved in designing of a riser.
(c) Explain the importance of controlling direction of solidification in casting. Explain how one
can evaluate the total time of solidification.

5. Write short notes on following:

(i) Shell moulding.
(ii) Die casting and its categories.
(iii) True centrifugal casting, semi centrifugal casting and centrifuge.
(iv) Investment casting.

6. (a) What is a core and explain the importance of core prints.

(b) What are chaplets in casting.

7. (a) Explain all methods of melting (Crucible melting, cupola melting etc.)
(b) Explain various casting defects.

8.

(a) Three metal pieces being cast have the same volume but different shapes. One is sphere and
other is cube and another is cylinder. They all have height equal to diameter. Evaluate, which
piece will solidify first and which solidifies in the last.
(b) Determine the solidification time for a spherical casting of 400 mm diameter with a
solidification factor of 0.95106 s/m2.

(c) A molten drop of liquid metal in the form of spherical shape with 2 mm diameter will solidify
in 20 seconds. Same molten liquid of double in diameter solidified in the same moulding sand,
how much time it will take to solidify?

(d) A cylindrical job with diameter of 200 mm and height of 100 mm 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 is equal to its height, then the height of the riser (in
mm) is?

(e) A round casting is 0.1 m in diameter and 0.5 m in length. Another casting of the same metal
is elliptical in cross-section, with a major-to-minor axis ratio of 2, and has the same length and
cross-sectional area as the round casting. Both pieces are cast under the same conditions. What is
the difference in the solidification times of the two castings?

(f) A mould having dimensions 1009020 mm3 is filled with molten material through a height
of gate h and CSA of A. The flow rate of liquid metal into the down sprue of a mold = 1 liter/sec.
The cross sectional area at the top of the sprue = 800 mm2 and its length = 175 mm. What area
should be used at the base of the sprue to avoid aspiration of the molten metal?

(g) Molten metal can be poured into the pouring cup of a sand mold at a steady rate of 1000
cm3/s. The molten metal overflows the pouring cup and flows into the down sprue. The cross-
section of the sprue is round, with a diameter at the top = 3.4 cm. If the sprue is 25 cm long,
determine the proper diameter at its base so as to maintain the same volume flow rate.

(h) A cylindrical riser is to be designed for a sand casting mold. The length of the cylinder is to
be 1.25times its diameter. The casting is a square plate, each side = 10 in and thickness = 0.75
inch. If the metal is cast iron, and the mold constant = 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.

(I) A 100-mm (4-in.) thick square plate and a right circular cylinder with a radius of 100 mm (4
in.) and a height of 50 mm each have the same volume. If each is to be cast using a cylindrical
riser, will each part require the same size riser to ensure proper feeding? Explain.