Problem $1$: Design a Casting Mold

An aluminum workpiece shown below is to be manufactured by sand casting $($can assume part to be a box$).$ Casting is done by pouring the liquid metal into the pouring cup of a sand mold. It was found that the liquid metal is flowing from the pouring cup into the downsprue with a flow rate of $2,000c\frac{m^3}{sec}.$ The crosssectional area of the sprue is round. The downsprue is $50$ cm long, mold constant of $3\mathrm{.}5mi\frac{n}{c}{m}^2,$ riser is assumed to have $D=H,$ also assume a pouring cup height.

ion Unit: cm

Determine the following:

Material Properties Used

a$.$ Density $(k\frac{g}{m}{m}^3)=q,$

b$.$ Melt Temperature $(C)T_m=q,$

c$.$ Thermal Capacitance for Solid Material $(\frac{J}{k}\frac{g}{C})C_s=.$

d$.$ Thermal Capacitance for Liquid Material $($J$/$kg$/$C$)$ CL$=$

e$.$ Assumed Initial Temperature $(C)TO=$

f$.$ Viscosity $($kg$/$mm$-$s$),=$

g$.$ Heat of Fusion $($J$/$kg$),$ Hfusion$=$

h$.$ Pouring temperature $($make necessary assumptions$)T_p=$

Sand Used $\_$

Part oversize to allow for shrinkage or part pattern, Volume, $V_{\text{p}\text{a}\text{r}\text{t}}$ and Surface Area, $A_{\text{p}\text{a}\text{r}\text{t}\text{.}}($show calculations$)$

Solidification time for Part, $t_{\text{p}\text{a}\text{r}\text{t}}$ with mold constant, $C_m=1\frac{s}{m}m2,$ and exponent $n=2t_{\text{p}\text{a}\text{r}\text{t}}=$

Riser Dimensions, Volume, $V_{\text{r}\text{i}\text{s}\text{e}\text{r}}$ and Surface Area, $A_{\text{r}\text{i}\text{s}\text{e}\text{r}}$

D$=$

$H=$

$V_{\text{r}\text{i}\text{s}\text{e}\text{r}}=$

Ariser:

$6.$ Expected solidification time of riser, triser. $($show calculations$)$

triser $=$

$7.$ Dimensions of downsprue and gate. Design for no turbulence.

Sprue entrance diameter, $D_1=$

Sprue Exit, $D_2=$

$8.$ Total molten metal volume $($show calculations$)$

$V_{\text{m}\text{e}\text{t}\text{a}\text{l}}=$

$9.$ Mold Fill time $t_f=.$

$10.$ Selected furnace to melt the aluminum with calculation of proper Heat required, H$.($show calculations$)$ H $=$

$11.$ Draw and Label Steps for Sand Casting and show mold design sketch with all parts labeled $($where is the Parting Line?$)$:

Problem $1$: Design a Casting Mold

An aluminum workpiece shown below is to be manufactured by sand casting $($can assume part to be a box$).$ Casting is done by pouring the liquid metal into the pouring cup of a sand mold. It was found that the liquid metal is flowing from the pouring cup into the downsprue with a flow rate of $2,000c\frac{m^3}{sec}.$ The crosssectional area of the sprue is round. The downsprue is $50$ cm long, mold constant of $3\mathrm{.}5mi\frac{n}{c}{m}^2,$ riser is assumed to have $D=H,$ also assume a pouring cup height.

ion Unit: cm