Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Textbook Question
Chapter 10, Problem 10RQ
What is a sprue? What shape should a sprue have if a mold has no other choking means?
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For pouring the part, whose perspective pictures are given below, into sand mold,model design, core design if necessary, all molding steps andFinally, draw the mold in the best way to pour and shape all the mold elements.Name it by pointing on it (Note: The hole shown in the figure is a through hole.)
4) List the passageway (gating system) elements in sand casting moulds and show
them with drawing?
Draw the stress-strain curve and gives the stress and strain equations for both
Engineering and True stress-strain
Calculate mould dimension for sprue runner and in-gate, the material using fluorothermoplastic
and using injection molding.
Question:
1. explain the steps for making a mold
2. If possible, use a simulation of the position where the defect will occur
3. Calculate to make mold male and female, the shape is near net shape product and
determine material for dies, the liquid materials is 167°C
Guidelines
Sprue Gate Guidelines
L
50% W1
A1
2-3°
W1
20- 100% of W2
R1
> 1.5 mm
T2
75-100% T1 (part thickness)
D1
125-400% T1 (part thickness)
D1
100-300% T1 (part thickness)
Part Thickness
1.6 mm
R
> 1 mm (0.040")
% Shrinkage Parallel to Flow
4.0-4.5
% Shrinkage Perpendicular to Flow 4.3-4.8
T3
100-200 % (part thickness)
Chapter 10 Solutions
Manufacturing Engineering & Technology
Ch. 10 - Explain why casting is an important manufacturing...Ch. 10 - Why do most metals shrink when they are cast?Ch. 10 - What are the differences between the...Ch. 10 - What are dendrites? Why are they called so?Ch. 10 - Describe the difference between short and long...Ch. 10 - What is superheat? Is it important? What are the...Ch. 10 - Define shrinkage and porosity. How can you tell...Ch. 10 - What is the function of chills? What are they made...Ch. 10 - Why is the Reynolds number important in casting?Ch. 10 - What is a sprue? What shape should a sprue have if...
Ch. 10 - How is fluidity defined? Why is it important?Ch. 10 - Explain the reasons for hot tearing in castings.Ch. 10 - Why is it important to remove dross or slag during...Ch. 10 - Why is Bernoullis equation important in casting?Ch. 10 - Describe thixocasting and rheocasting.Ch. 10 - What is Chvorinovs Rule?Ch. 10 - How is a blister related to a scab?Ch. 10 - Is there porosity in a chocolate bar? In an ice...Ch. 10 - Describe the stages involved in the contraction of...Ch. 10 - Explain the effects of mold materials on fluid...Ch. 10 - It is known that pouring metal at a high rate into...Ch. 10 - Describe the events depicted in Fig. 10.5.Ch. 10 - Would you be concerned about the fact that...Ch. 10 - Review Fig. 10.8 and make a summary, explaining...Ch. 10 - Make a sketch of volume vs. temperature for a...Ch. 10 - What practical demonstrations can you suggest to...Ch. 10 - Explain why a casting may have to be subjected to...Ch. 10 - List and explain the reasons why porosity can...Ch. 10 - Why does porosity have detrimental effects on the...Ch. 10 - A spoked handwheel is to be cast in gray iron. In...Ch. 10 - Which of the following considerations are...Ch. 10 - Explain why the constant C in Eq. (10.7) depends...Ch. 10 - Are external chills as effective as internal...Ch. 10 - Explain why, as shown in Table 10.1, gray cast...Ch. 10 - Referring to Fig. 10.11, explain why internal...Ch. 10 - Note the shape of the two risers shown in Fig....Ch. 10 - Is there any difference in the tendency for...Ch. 10 - What is the influence of the cross-sectional area...Ch. 10 - It has long been observed that (a) low pouring...Ch. 10 - In casting metal alloys, what would you expect to...Ch. 10 - If you inspect a typical cube of ice, you are...Ch. 10 - How can you tell whether cavities in a casting are...Ch. 10 - Describe the drawbacks to having a riser that is...Ch. 10 - Reproduce Fig. 10.2 for a casting that is...Ch. 10 - List the process variables that affect the...Ch. 10 - Assume that you have a method of measuring...Ch. 10 - A round casting is 0.2 m (7.9 in.) in diameter and...Ch. 10 - A cylinder with a diameter of 2.0 in. and a height...Ch. 10 - The constant C in Chvorinovs rule is given as 2.5...Ch. 10 - Pure copper is poured into a sand mold. The metal...Ch. 10 - For the sprue described in Problem 10.58, what...Ch. 10 - When designing patterns for casting, pattern...Ch. 10 - Can you devise fluidity tests other than that...Ch. 10 - Figure P10.55 indicates various defects and...Ch. 10 - The fluidity test shown in Fig. 10.9 illustrates...Ch. 10 - Utilizing the equipment and materials available in...Ch. 10 - One method of relieving stress concentrations in a...Ch. 10 - Describe the effects on mold design, including the...Ch. 10 - Small amounts of slag often persist after skimming...Ch. 10 - Design an experiment to measure the constants C...
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- Explain in detail different components of a gating system in sand mold castingarrow_forward2. A mold sprue is 180 mm long, the cross-sectional area at its base is 2.4 cm?. The sprue feeds a horizontal runner leading into a mold cavity whose volume is 1600 cm3. Determine, volume rate of flow and time to fill the mold.arrow_forward3. (Slow or Fast, which one? – Circle one) cooling rates results in coarse dendritic structures. 4. The higher the viscosity of the melt, the . its fluidity? 5. Name 3 defects in casting: 6. Internal or external are an effective means of reducing shrinkage porosity during solidification. 7. Is green-sand molding expensive? 8. .... are inserts placed in the molds to form the hollow regions in casting. 9. The method of casting turbine blades: Sample A 10. Which one has higher stiffness? Sample A or Sample B Sample B 11. Which one has higher toughness? Sample A or Sample B 12. Which one has higher strength? Sample A or Sample B 13. Which one has higher ductility? Sample A or Sample 14. Higher ......... means more rigidity. Strain 15. Before the no-slip point, the velocity is (higher or lower, which one? - Circle one) 16. In flat-rolling process, using smaller diameter rolls (increases or decreases, which one? - Circle one) the roll force. 17. Balls for ball bearings can be made by rolling…arrow_forward
- 6. The part of gating system which regulates the rate of pouring of molten metal in the mold is called 7. High refractoriness of a material refers to its. b. Chemical strength towards other material d. Ability to get dissolved in molten metal a. Slipperiness of the material c. Strength to withstand high temperature e. None of the above Your answer is: . 8. Usually weaker constituent of a composite is called . 9. Which polymer is the most important commercially: a. thermoplastics c. elastomers b. thermosets d. all of the above e. None of the above Your answer is: 10. Which of the following casting processes are expendable mold operations: a. centrifugal casting c. investment casting e. sand casting b. die casting d. low pressure casting f. None of the above Your answer is:arrow_forwardSketch a simple part that can be green sand or injection molded. Sketch at least one view of the part. Draw the part in casting orientation. Choose the parting line and label it. Decide if cores are necessary and label them.arrow_forwardHighlighting the positive pattern making allowances, explain in detail with a neat sketch and labelling the same, the 2-box molding procedure for the following component considering it as a split pattern. Through Hole (a)arrow_forward
- amswer with respect to solidworks software need it correctlyarrow_forward5. Name the various additives used in moulding sand and explain how they affect its properties and Differentiate between binding and non-binding additives.arrow_forwardFor the casting of the part whose perspective pictures are given below, take into account the section surface (model design), (core design if necessary), all molding stages and finally (the mold in the most suitable form for casting) and name all mold elements by showing them on the figure (Note: The hole seen in the figure is a full hole.)arrow_forward
- In sand moulding and casting process, which of the following is the purpose of a chill? a. To increase the rate of heat extraction from the casting b. To reduce the possibility of blow holes O c. To increase the surface finishing of the casting d. To decrease the solidification timearrow_forwardI need the answer as soon as possiblearrow_forwardConverging passage is used for feeding the liquid molten metal into the mould to (a) increase the rate of feeding (b) quickly break off the protruding portion of the casting (c) decrease wastage of cast metal (d) avoid aspiration of airarrow_forward
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