You manage production in a company possessing equipment for the following processes: 1. Sand casting (green...

Transcribed Image Text:

You manage production in a company possessing equipment for the following processes: 1. Sand casting (green sand) 2. Investment casting 3. Sand casting (sodium silicate sand) 4. Single crystal casting 5. Die casting 6. Drilling 7. Milling 8. Boring 9. Turning 10. Grinding 11. Threading Problem You have as start material new 9mmx6mmx4mm pieces of white iron as well as scrap of the same material. You need to manufacture the component shown on the next page. 20,000 pieces with no surface finish requirement are needed. a) Select a casting process for the manufacture of the component. (2 pt) b) Discuss and justify each point of your casting design procedure including (do all necessary calculations! If you use any core, consider that the cooling effect of the core is identical to that of the mold! Make sketches to illustrate your casting process!) 1) The material you use for the mold (1 pt) 2) The material you use for pattern and core, respectively, if applicable (2 pt) 3) The geometry of your sprue-cup assembly (2 pt) 4) The configuration of mold, mold cavity, and core if any (1 pt) 5) How you position cup, risers and vents, if needed (7 pt) 6) Any applicable approach as substitute for risers, if needed (1 pt) 7) 3 casting defects that may occur during casting, and what you have included in your design in order to avoid them (3x1 pt) 8) Compared to the final parts, how much larger you would design the pattern or die cavity (1 pt) 50 mm 120 mm 70 mm 50 mm 120 mm 50 mm R= 35 mm 100 mm 100 mm 40 mm You manage production in a company possessing equipment for the following processes: 1. Sand casting (green sand) 2. Investment casting 3. Sand casting (sodium silicate sand) 4. Single crystal casting 5. Die casting 6. Drilling 7. Milling 8. Boring 9. Turning 10. Grinding 11. Threading Problem You have as start material new 9mmx6mmx4mm pieces of white iron as well as scrap of the same material. You need to manufacture the component shown on the next page. 20,000 pieces with no surface finish requirement are needed. a) Select a casting process for the manufacture of the component. (2 pt) b) Discuss and justify each point of your casting design procedure including (do all necessary calculations! If you use any core, consider that the cooling effect of the core is identical to that of the mold! Make sketches to illustrate your casting process!) 1) The material you use for the mold (1 pt) 2) The material you use for pattern and core, respectively, if applicable (2 pt) 3) The geometry of your sprue-cup assembly (2 pt) 4) The configuration of mold, mold cavity, and core if any (1 pt) 5) How you position cup, risers and vents, if needed (7 pt) 6) Any applicable approach as substitute for risers, if needed (1 pt) 7) 3 casting defects that may occur during casting, and what you have included in your design in order to avoid them (3x1 pt) 8) Compared to the final parts, how much larger you would design the pattern or die cavity (1 pt) 50 mm 120 mm 70 mm 50 mm 120 mm 50 mm R= 35 mm 100 mm 100 mm 40 mm