Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 10, Problem 55SDP
Figure P10.55 indicates various defects and discontinuities in cast products. Review each defect and offer solutions to prevent it.
FIGURE P10.55
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A flat plate is to be cast in an open mold whose bottom has a square shape of 12.5 cm by 12.5 cm. The
mold is 7.0 cm deep. A total of 350 cm³ of molten aluminum is poured into the mold. Solidification
shrinkage is known to be 6.25%, which is a volumetric contraction, not a linear contraction. Table 7.1
lists the linear shrinkage due to thermal contraction after solidification. If the availability of molten
metal in the mold allows the square shape of the cast plate to maintain its square dimension until
solidification is completed, determine the final dimensions (width and height) of the plate.
Parvinbhai
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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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- As quick as possible. Describe some common casting faults, and suggest steps that may be taken to minimize the risk of such faults occurring.arrow_forwardA riser in the shape of a sphere is to be designed for a sand casting mold. The casting is a rectangular plate, with length = 100 mm, width = 50 mm, and thickness = 10 mm. If the total solidification time of the casting itself is known to be 2.5 min, determine the diameter of the riser so that it will take 20% longer for the riser to solidify. %3D %3!arrow_forwardEX.3//A cylindrical riser must be designed for a sand-casting mold. The casting itself is a steel rectangular plate with dimensions 7.5 cm x 12.5 cm x 2.0 cm. Previous observations have indicated that the total solidification time (TTs) for this casting =1.6 min. The cylinder for the riser will have a diameter-to-height ratio=1.0. Determine the dimensions of the riser so that its TTS = 2.0 min.arrow_forward
- A disk-shaped part is to be cast out of aluminum. The diameter of the disk 500 mm and its thickness = 20 mm. If the mold constant 2.0 sec/mm2 in %3D Chvorinov's rule, how long will it take the casting to solidify?arrow_forwardDescribe the die casting process in detail. Use neat sketches for clarity. Differentiate clearly between hot-chamber die casting and cold-chamber die casting processes. What is the difference between true centrifugal and semi-centrifugal casting? Describe the centrifugal casting process in detail. Use neat sketches to elaborate your description.arrow_forwardQuestion 3 3.1 Briefly explain the Casting and Molding processes and define their basic requirements. 3.2 If a manufacturer was asked to produce a set of plastic bottles, which method would you suggest? Justify your answer. 3.3 What is the Forging process? Explain the process including two forged products. 3.4 Briefly explain the heat treatment processing techniques using a phase diagram.arrow_forward
- A flat plate is to be cast in an open mold whose bottom has a square shape that is 200 mm by 200 mm. The mold is 40 mm deep. A total of 106 mm3 of molten aluminum is poured into the mold. Solidification shrinkage is known to be 6.0%. The linear shrinkage due to thermal contraction after solidification is 1.3%. If the availability of molten metal in the mold allows the square shape of the cast plate to maintain its 200 mm by 200 mm dimensions until solidification is completed, determine the final dimensions of the plate.arrow_forwardA disk-shaped part is cast out of aluminium with a diameter of 630 mm and a thickness of 16 mm. If the mold constant is 2.2 sec/mm2 in Chvorinov's rule, how long will it take the casting to solidify?arrow_forwardSolve fast plzzzzarrow_forward
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