Manufacturing Engineering & Technology
7th Edition
ISBN: 9780133559897
Author: KALPAKJIAN
Publisher: PEARSON
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Textbook Question
Chapter 10, Problem 37QLP
Is there any difference in the tendency for shrinkage void formation in metals with short and long freezing ranges, respectively? Explain.
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On the continuous growth, Calculate the interfacial undercooling if the melting temperature is 600 K and the latent heat of melting is given as 30 kJ/kg? (Assume the driving force for solidification as 45 kJ/kg?
When designing patterns for casting, patternmakers use special rulers that automatically incorporate solid shrinkage allowances into their designs. For example, a 12-in. patternmaker’s ruler is longer than 1 foot. How long should a patternmaker’s ruler be for making patterns for (a) aluminum castings and (b) high-manganese steel?
A slab of 1500 mm x 750 mm x 500 mm is required to be cast using a sand casting process. It was observed previously that the total solidification time (T) for this casting = 1.6 min. Find out the cylindrical riser dimensions (diameter to height ratio = 1) for a solidification time T = 5 min.
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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- Which ingot has greater mechanical resistance? Why? Explain in detail what occurred during solidification.arrow_forwardWith a solidification factor of 0.97 x 106 s/m², the solidification time (in seconds) for a spherical casting of 200 mm diameter is...arrow_forwardA 5 cm cube solidifies in 4.6 min. Assume n=2. Calculate (a) the mold constant in Chvorinov’s rule and (b) the solidification time for a 1.25 cm X 12.5 cm X 15 cm bar cast under the same conditionsarrow_forward
- It's important to explain the fundamentals of strain hardening. Is this technique still reliable in hot conditions? Explainarrow_forwardIs it possible to manufacture a propeller of a commercial-scale heavy-duty ship using the Investment Casting Process? Briefly support your explanation with reasoning if it is not possible.arrow_forwardIn sand casting of hollow part of lead, a cylindrical core of diameter 120 mm and height 180 mm is placed inside the mould cavity. The densities of core material and lead are 1600 kg/m³ and 11300 kg/m³ respectively. The net force (in N) that tends to lift he core during pouring of molten metal will be. . . . .arrow_forward
- A riser in the shape of a sphere is to be designed for a sand casting mould at Simon Castings. The casting is a rectangular plate, with length = 400 mm, width = 250 mm, and thickness = 15 mm. If the total solidification time of the casting itself is known to be 7 min, determine the diameter of the riser so that it will take 30% longer for the riser to solidify.arrow_forwardWhen casting a 4x10x20 in. Part, which has a top overflow with a H / D = 1.5 ratio, you want to determine the height and diameter of the overflow to prevent shrinkage in the part to be cast. Note: Remember that to achieve this, the overflow has to solidify some time after the piece has solidified, since in this case the overflow acts as a riser.arrow_forwardA compound thin cylinder has a common diameter of 100 mm, and the inner cylinder has a thickness of 2.5 mm. The radial pressure between the two cylinders is 200 KPa and the difference between the two common diameters before shrinkage was 0,004305 mm. E=200GPaarrow_forward
- 80 kg of aluminum is to be heated to a pouring temperature of 750°C. The unit melting and pouring energy of the metal = 1035 J/g. Thermal efficiency of the furnace = 65%. How much time is required to heat the metal from 25°C to the pouring temperature if the electric induction furnace generates 100 kW?arrow_forwardQ: what is the differance between casting and forging processs ? Explain the three stages in casting process and its application.arrow_forwardA aluminium alloy casting has a cylindrical geometry with 100mm in diameter and weighs 3200 gram. This casting takes 7.5 min to completely solidify. Another smaller and lighter cylindrical-shaped casting with the same diameterto-length ratio weighs 1800 gram. This casting is made of the same aluminium alloy and the same conditions of mold and pouring were used. Determinea) The mold constant in Chvorinov’s Rule,b) The dimensions of the lighter castingc) The total soldification time of the lighter casting. The density of aluminium alloy= 2.7 gram/cm3and n=2arrow_forward
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Explanation of Solidification of Metals & Alloys | Manufacturing Processes; Author: Magic Marks;https://www.youtube.com/watch?v=G5z9KknF_s8;License: Standard Youtube License