Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133128741
Author: Serope Kalpakjian, Steven Schmid
Publisher: Prentice Hall
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Chapter 11, Problem 53SDP
Sketch and describe a casting line consisting of machinery, conveyors, robots, sensors, etc., that automatically could perform the expendable-pattern casting process.
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Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. You are given a task to fabricate an engine block. In your own words, explain how to fabricate it using any suitable four types of processes which can be used and discuss the benefits of each processes
For casting the part, whose perspective pictures are given below, into sand mold,model design, core design if necessary, all molding stages andFinally, draw the mold in the most suitable form for casting and shape all the mold elements.Name it by showing on it (Note: The hole shown in the figure is a full hole.)
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Chapter 11 Solutions
Manufacturing Engineering & Technology
Ch. 11 - Describe the differences between expendable and...Ch. 11 - Name the important factors in selecting sand for...Ch. 11 - What are the major types of sand molds? What are...Ch. 11 - List important considerations when selecting...Ch. 11 - What is the function of a core?Ch. 11 - What is the difference between sand-mold and...Ch. 11 - What are composite molds? Why are they used?Ch. 11 - Describe the features of plaster-mold casting.Ch. 11 - Name the type of materials typically used for...Ch. 11 - What are the advantages of pressure casting over...
Ch. 11 - List the advantages and limitations of die...Ch. 11 - What is the purpose of a riser? What is a blind...Ch. 11 - Explain the purpose of a vent and a runner in a...Ch. 11 - How are shell molds produced?Ch. 11 - What keeps the mold together in vacuum casting?Ch. 11 - What is squeeze casting? What are its advantages?Ch. 11 - What are the advantages of the lost-foam casting...Ch. 11 - Prob. 18RQCh. 11 - What are the reasons for the large variety of...Ch. 11 - Why are risers not as useful in die casting as...Ch. 11 - Describe the drawbacks to having a riser that is...Ch. 11 - Why can blind risers be smaller than open-top...Ch. 11 - Why does die casting produce the smallest cast...Ch. 11 - Why is the investment-casting process capable of...Ch. 11 - What differences, if any, would you expect in the...Ch. 11 - Recently, cores for sand casting have been...Ch. 11 - Would you recommend preheating the molds used in...Ch. 11 - Give reasons for, and examples of, using die...Ch. 11 - Referring to Fig. 11.3, do you think it is...Ch. 11 - Explain why squeeze casting produces parts with...Ch. 11 - How are the individual wax patterns attached on a...Ch. 11 - Describe the measures that you would take to...Ch. 11 - You have seen that, even though die casting...Ch. 11 - How are hollow parts with various cavities made by...Ch. 11 - It was stated that the strength-to-weight ratio of...Ch. 11 - How are risers and sprues placed in sand molds?...Ch. 11 - In shell-mold casting, the curing process is...Ch. 11 - Why does the die-casting machine shown in Fig....Ch. 11 - Prob. 39QLPCh. 11 - What are the benefits to heating the mold in...Ch. 11 - The slushy state of alloys refers to that state...Ch. 11 - Can a chaplet also act as a chill? Explain.Ch. 11 - Rank the casting processes described in this...Ch. 11 - Estimate the clamping force for a die-casting...Ch. 11 - In sand casting, it is important that the...Ch. 11 - If an acceleration of 100 g is necessary to...Ch. 11 - A jeweler wishes to produce 24 gold rings in one...Ch. 11 - Describe the procedures that would be involved in...Ch. 11 - The optimum shape of a riser is spherical to...Ch. 11 - Sketch and describe a casting line consisting of...Ch. 11 - Outline the casting processes that would be most...Ch. 11 - Make a list of the mold and die materials used in...Ch. 11 - Write a brief paper on the permeability of molds...Ch. 11 - Light metals commonly are cast in vulcanized...Ch. 11 - It sometimes is desirable to cool metals more...Ch. 11 - The part shown in Fig. P11.59 is a hemispherical...Ch. 11 - Porosity that has developed in the boss of a...Ch. 11 - In Fig. II.1b the gemstones have been cast in...
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- Describe the detailed processes about the Investment casting. Please use numbered list to show each step and process.arrow_forwardIn turbine blade casting, how is a single-crystal structure achieved? Select one or more: a. By using a curving coil-like channel in the casting mould b. By removing grain boundaries by hot working and recrystallisation c. By careful control of the temperatures of the mould d. By introducing impurities into the molten alloy in the mouldarrow_forwardSolve fast plzzzzarrow_forward
- Describe 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_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_forward2. Assignment You are tasked to investigate the following and to compile your findings in a technical report: 2.1 What is the benefit of using investment casting for the production of a turbine rotor compared to other casting processes? 2.2 Which AM materials and processes (according to the ISO/ASTM 52900 standard) is mostly used during the manufacturing of patterns for the investment casting process? List the advantages and disadvantages of each of the AM processes. 2.3 What are the advantages and disadvantages of using AM techniques to produce patterns for the investment casting process, compared to conventional methods? 2.4 Show with a sketch, how the build orientation of the processes listed in Question 2.2 can have an influence on the accuracy and surface quality of a pattern. 2.5 Which manufacturing process (listed in Question 2.2) will be most suitable to produce a pattern for the turbine rotor? Provide reasons for your selection. 2.6 The use of additive manufactured patterns…arrow_forward
- Q1.Write down your answer briefly. i) Why is the permeability of shell mold higher as compared to sand mold? ii)What type of die casting process is mostly preferable for higher production rate? Justify your answer. iii) Bauschinger effect can be reduced by the stress aging process. Justify your answer. iv) Why is the sand for foundry practice called green sand? Can it be used for the core making process? v) What is moldability? How do you determine moldability of molding sand? vi) Which casting process is usually preferred for producing long tubular objects? Is it possible to manufacture a solid and parallelepiped object having different dimensions in a centrifugal casting process? Justify your answer. vii) What is directional solidification? How does a riser promote directional solidification?arrow_forwardcompute the diameter of the sphere (mm) that will freeze in the same time in same casting process with a 62.5mm x 150mm x 225mm plate. Assume that constant mold for this casting is 55 mm^2/sarrow_forwardPlease show all of your work; thank youarrow_forward
- 25. A riser in the shape of a sphere is to be designed for a sand casting mold. The casting is a rectangular plate, with length = 200 mm, width = 100 mm, and thickness = 22 mm. If the total solidification time of the casting itself is known to be 3.5 min, determine the diameter of the riser so that it will take 25% longer for the riser to solidify.arrow_forwardFor the sand casting of the part whose perspective pictures are given below, take into account the surface of the section, the model design, if necessary, the core design, all the molding stages and and finally draw the most suitable form mold for casting, and name all the mold elements by showing them on the figure (Note: The hole shown in the figure, full hole.)arrow_forwardmanufacturing methodsarrow_forward
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