Lecture 4-Metal Casting

Production Technology
Dr. Mohamed Fahmy
Chapter 4
FUNDAMENTAL DESIGN CALCULATIONS IN
METAL CASTING
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
FUNDAMENTAL DESIGN
CALCULATIONS IN METAL CASTING
1.Overview of Casting Technology
2.Heating and Pouring
3.Solidification and Cooling
FUNDAMENTAL DESIGN
Sand Casting Mold
‫اناء الصب‬
‫القناة السفلى‬
‫قارورة‬
Figure 10.2 (b) Sand casting mold.

Gating System
Channel through which molten metal flows into cavity from

outside of mold
▪Consists of a downsprue, through which metal enters a runner

leading to the main cavity
▪At the top of downsprue, a pouring cup is often used to minimize

splash and turbulence as the metal flows into downsprue
FUNDAMENTAL DESIGN CALCULATIONS
IN METAL CASTING
Heating the Metal
▪Heating furnaces are used to heat the metal to molten

temperature sufficient for casting
▪The heat required is the sum of:
1.Heat to raise temperature to melting point
2.Heat of fusion to convert from solid to liquid
3.Heat to raise molten metal to desired temperature for
pouring ‫للصب‬
Heating furnaces of various kinds are used to heat the
metal to a molten temperature sufficient for casting. The
heat energy required is the sum of
(1) the heat to raise the temperature to the melting point,
(2) the heat of fusion to convert it from solid to liquid,
(3) the heat to raise the molten metal to the desired
temperature for pouring.
This can be expressed:
H= ρV{Cs[Tm -To]+ Hf+ Cl(Tp-Tm)}
Where H= total heat required to raise the temperature of the metal to the pouring temperature, J
ρ=Density g/cm3
V= Volume of metal Heated cm3
Hf= Heat of Fusion J/g
Cs= weight specific heat for the solid metal, J/g°C
Cl= weight specific heat of the liquid metal, J/g°C
Tp= Pouring Temperature °C
Tm=Melting Temperature of metal °C
To= starting temperature-usually ambient-°C
EX1
One cubic meter of a certain eutectic alloy is heated in a crucible
from room temperature to 100°C above its melting point for
casting. The alloy’s density = 7.5 g/cm3, melting point = 800°C,
specific heat=0.33 J/g°C in the solid state and 0.29 J/g°C in the
liquid state; and heat of fusion= 160 J/g. How much heat energy
must be added to accomplish the heating, assuming no losses?
solution
Cs = 0.33 J/g°C
H= ρ*V*{Cs[Tm -To]+ Hf+ Cl(Tp-Tm)} Cl= 0.29 J/g°C
To = = 25°C
Tm = = 800°C
heat of fusion= Hf = 160 J/g Tp-Tm = 100°C
An open mold casting operation is to be used to cast a disk 35 cm in diameter and 8
cm height made of pure zinc (Melting temperature =420 Cº). The pouring
temperature will be 150 Cº over its melting temperature and the amount of zinc
heated will be 8 % more than what is needed to fill the mold cavity.
Determine, the amount of heat that must be added to the metal to heat it to the
pouring temperature, starting from room temperature of 25 Cº.
Data: Heat of fusion of Zn= 113 J/g ; Specific Heat = 0.388 J/g. Cº ; density= 7.14
g/cm³. Assuming the specific heat has the same value for solid and liquid zinc
An open mold casting operation is to be used to cast a disk 35 cm in diameter and 8 cm height made of pure zinc (Melting temperature =420 Cº). The
pouring temperature will be 150 Cº over its melting temperature and the amount of zinc heated will be 8 % more than what is needed to fill the mold
cavity.
Determine, the amount of heat that must be added to the metal to heat it to the pouring temperature, starting from room temperature of 25 Cº.
Data: Heat of fusion of Zn= 113 J/g ; Specific Heat = 0.388 J/g. Cº ; density= 7.14 g/cm³
Assuming the specific heat has the same value for solid and liquid zinc
density= 7.14 g/cm³
Diameter=35 cm
H= ρ*V*{Cs[Tm -To]+ Hf+ Cl(Tp-Tm)}
Hight h=8 cm
Cs = Cl=0.388 J/g°C
Tm = =420 °C
=
H= 7.14*8321.7*[0.388*(420-25)+113+0.388*(570-420)] =19 J
To = = 25°C
heat of fusion= Hf = 113 J/g

Pouring ‫ صب‬the Molten Metal
▪For this step to be successful, metal must flow into all regions
of the mold, most importantly the main cavity, before
solidifying
▪Factors that determine success
▪Pouring temperature
▪Pouring rate
▪Turbulence ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Mold Filling (Pouring) Time
h = elevation
Bernoulli’s theorem p = pressure at elevation
▪ Based on v = velocity of the liquid
- principle of conservation of energy ρ = density of the fluid
- frictional losses in a fluid system
2
p v
h+ + = Constant 0 0 0 0
g 2g
▪ Conservation of energy requires that, 2 2 0
p1 v p2 v
h+ + = h2 +
1
+ +f 2
g 2 g g 2 g
Sprue profile Q=v1 A1 =v2A2=continuity
▪ Relationship between height and cross-sectional area at any point in the sprue is given by
A1 h2
=
A2 h1 1 V1=0
▪ Velocity of the molten metal leaving the gate is
v = c 2 gh h1
▪ When liquid level reached height x, gate velocity is

2 h2=0
v=c 2g h−x
Mass continuity
▪ States that for an incompressible liquid the rate of flow is constant.

Q = volumetric rate of flow
A = cross-sectional area of the liquid stream
Q = A1v1 = A2v2 v = velocity of the liquid
▪ Subscripts 1 and 2 pertain to two different locations in the system.

The volume flow rate of metal into a mold is 0.01 m3/min. The top
of the sprue has a diameter of 20 mm, and its length is 200 mm.
What diameter should be specified at the bottom of the sprue to
prevent aspiration?
What is the resultant velocity at the bottom of the sprue if the
metal being cast is aluminum `
Lets use the subscripts 1 for the top and 2 for the bottom of sprue.
Since d1= 20 mm = 0.02 m,
h1 + v 2 / 2g = h2 + v 2 / 2g →
0.2 m + (0.531 m/s)2 2(9.81 m/s2 ) = 0 + v 2 2 2(9.81 m/s2 )
or v2 = 1.45 m/s.
To prevent aspiration, the sprue opening should be the same as that required by
flow continuity,
or Q = A2v2 = 1.667 × 10−4 m3 /s = A2(1.45 m/s) → A2 = 1.150 × 10−4 m2 hence
d = 12 mm
A mold sprue is 20 cm long, and the cross-sectional area at its
base is 2.5 cm2. The sprue
feeds a horizontal runner leading into a mold cavity whose
volume is 1560 cm3.
Determine: (a) velocity of the molten metal at the base of the
sprue, (b) volume rate of flow,
and (c) time to fill the mold.
:
FUNDAMENTAL DESIGN

Solidification of Metals
Transformation of molten metal back into solid state
▪Solidification differs depending on whether the metal is
▪A pure element or
▪An alloy
Cooling Curve for a Pure Metal
▪A pure metal solidifies at a constant temperature equal to its freezing
point (same as melting point)
Cooling curve for a pure metal during casting.

Solidification of Alloys
▪Most alloys freeze over a temperature range rather than at a single
temperature
(a) Phase diagram for a copper-nickel alloy system and (b) associated cooling
curve for a 50%Ni-50%Cu composition during casting.
Solidification Time
Mold Constant in Chvorinov's Rule
▪Mold constant Cm depends on:
▪Mold material
▪Thermal properties of casting metal
▪Pouring temperature relative to melting point
▪Value of Cm for a given casting operation can be based on
experimental data from previous operations carried out using same
mold material, metal, and pouring temperature, even though the
shape of the part may be quite different
What Chvorinov's Rule Tells Us
▪A casting with a higher volume-to-surface area ratio cools and solidifies

more slowly than one with a lower ratio
▪To feed molten metal to main cavity, TST for riser must greater than TST
for main casting
▪Since mold constants of riser and casting will be equal, design the riser to
have a larger volume-to-area ratio so that the main casting solidifies first
▪This minimizes the effects of shrinkage
Shrinkage in Solidification and Cooling
Figure 10.8 Shrinkage of a cylindrical casting during solidification and cooling: (0)
starting level of molten metal immediately after pouring; (1) reduction in level caused by
liquid contraction during cooling (dimensional reductions are exaggerated for clarity).
Shrinkage in Solidification and Cooling
Figure 10.8 (2) reduction in height and formation of shrinkage cavity caused by
solidification shrinkage; (3) further reduction in height and diameter due to
thermal contraction during cooling of solid metal (dimensional reductions are
exaggerated for clarity). ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Solidification Shrinkage
▪Occurs in nearly all metals because the solid phase
has a higher density than the liquid phase
▪Thus, solidification causes a reduction in volume per
unit weight of metal
▪Exception: cast iron with high C content
▪Graphitization during final stages of freezing causes
expansion that counteracts volumetric decrease
associated with phase change
Shrinkage Allowance
▪Patternmakers account for solidification shrinkage and thermal

contraction by making mold cavity oversized
▪Amount by which mold is made larger relative to final casting size is
called pattern shrinkage allowance
▪Casting dimensions are expressed linearly, so allowances are applied
accordingly ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Riser
Reservoir in the mold which is a source of liquid metal to
compensate ‫ تعويض‬for shrinkage of the part during
solidification
▪The riser must be designed to freeze ‫يتصلب‬after the main
casting in order to satisfy its function
Riser Design
▪Riser is excess metal (waste) that is separated from the casting and
remelted to make more castings
▪To minimize waste in the unit operation, it is desirable for the

volume of metal in the riser to be a minimum
▪Since the geometry of the riser is normally selected to maximize

the V/A ratio, this allows riser volume to be reduced to the
minimum possible value
Core in Mold
(a) Core held in place in the mold cavity by chaplets, (b) possible chaplet
design, (c) casting with internal cavity.
Buoyancy ‫ الطفو‬in Sand Casting Operation
▪During pouring, buoyancy of the molten metal tends to displace the core, which can
cause casting to be defective
▪Force tending to lift core = weight of displaced liquid less the weight of core itself
Fb = Wm - Wc
where Fb = buoyancy force; Wm = weight of molten metal displaced; and Wc = weight
of core
A sufficient amount of pure copper is to be heated for casting a large plate in an open
mold. The plate has dimensions: length = 20 in, width =10 in, and thickness = 3 in.
Compute the amount of heat that must be added to the metal to heat it to a temperature
of 2150F for pouring. Assume that the amount of metal heated will be 10% more than
what is needed to fill the mold cavity. Properties of the metal are: density=0.324
lbm/in3, melting point = 1981F, specific heat of the metal=0.093 Btu/lbm-F in the
solid state and 0.090 Btu/lbm-F in the liquid state, and heat of fusion = 80 Btu/lbm.

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Production Technology

Dr. Mohamed Fahmy

FUNDAMENTAL DESIGN CALCULATIONS IN

1.Overview of Casting Technology

2.Heating and Pouring

3.Solidification and Cooling

1.Overview of Casting Technology

Figure 10.2 (b) Sand casting mold.

Channel through which molten metal flows into cavity from

▪Consists of a downsprue, through which metal enters a runner

▪At the top of downsprue, a pouring cup is often used to minimize

1.Overview of Casting Technology

2.Heating and Pouring

3.Solidification and Cooling

▪Heating furnaces are used to heat the metal to molten

heat of fusion= Hf = 113 J/g

▪ Velocity of the molten metal leaving the gate is

▪ When liquid level reached height x, gate velocity is

▪ States that for an incompressible liquid the rate of flow is constant.

▪ Subscripts 1 and 2 pertain to two different locations in the system.

1.Overview of Casting Technology

2.Heating and Pouring

3.Solidification and Cooling

Transformation of molten metal back into solid state

▪Solidification differs depending on whether the metal is

Cooling curve for a pure metal during casting.

▪A casting with a higher volume-to-surface area ratio cools and solidifies

▪Patternmakers account for solidification shrinkage and thermal

▪To minimize waste in the unit operation, it is desirable for the

▪Since the geometry of the riser is normally selected to maximize

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