ms Term paper
Casting Processes
Sand Casting http://www.youtube.com/watch?v=rgL2Jn5mk1A http://www.youtube.com/watch?v=dlQ54WATvzA
Investment Casting http://www.youtube.com/watch?v=tyrXq_u1OH0 http://www.youtube.com/watch?v=dOw624I9FDQ
Die Casting http://www.youtube.com/watch?v=LH8B3i6e8d4 http://www.youtube.com/watch?v=1AgDGLNE6Es
Continous Casting http://www.youtube.com/watch?v=d-72gc6I-_E Centrifugal Casting http://www.youtube.com/watch?v=3qKGx_AxHp0 Process Physics
1
A1
V1
2
V2
A2
1
h1
2
Flow characteristics
•
•
•
•
•
rD
Reynold’s number
Re
r : density (kg/m3) v : velocity of the fluid (m/s)
D : diameter of the channel (m)
Viscosity (η) is a measure of a fluid’s resistance to flow :
• If Re < 2000: laminar flow
If 2000< Re < 20000: laminar+turbulent (mixed)
If 20000 < Re: turbulent flow (cavitation)
Laminar Flow
Turbulent Flow
Ns
m2
• What is the casting yield of process described below?
10 Kg
5 Kg
Exercise-1
A certain mold is used to cast a cylindrical part. The cylinder diameter and height is 10 mm and 30 mm respectively. 3000 mm3 liquid is poured into the mold in 10 sec. The horizontal runner has a square cross-section with dimension of 2 mm.
Determine;
a) The casting yield
b) The volumetric flow rate of molten metal
c) The velocity of the liquid at the runner
Exercise-2
In a die casting application the molten metal is fed to a vacuumed die cavity at the same height, i.e. the inlet gate to the cavity and the molten metal outside are at the same height. The outside supply is open to the atmosphere. The density is 8000 kg/m3 and the supply velocity can be assumed
to be negligible. (Atmospheric pressure is 100 kPa.) What is the inlet velocity of the metal into the cavity (m/s)?
Exercise-3
A sphere with radius 300mm will be cast in a die with a vacuum casting process as shown below. The molten metal (ρ=7800kg/m3) passes through the pouring
Sand Casting http://www.youtube.com/watch?v=rgL2Jn5mk1A http://www.youtube.com/watch?v=dlQ54WATvzA
Investment Casting http://www.youtube.com/watch?v=tyrXq_u1OH0 http://www.youtube.com/watch?v=dOw624I9FDQ
Die Casting http://www.youtube.com/watch?v=LH8B3i6e8d4 http://www.youtube.com/watch?v=1AgDGLNE6Es
Continous Casting http://www.youtube.com/watch?v=d-72gc6I-_E Centrifugal Casting http://www.youtube.com/watch?v=3qKGx_AxHp0 Process Physics
1
A1
V1
2
V2
A2
1
h1
2
Flow characteristics
•
•
•
•
•
rD
Reynold’s number
Re
r : density (kg/m3) v : velocity of the fluid (m/s)
D : diameter of the channel (m)
Viscosity (η) is a measure of a fluid’s resistance to flow :
• If Re < 2000: laminar flow
If 2000< Re < 20000: laminar+turbulent (mixed)
If 20000 < Re: turbulent flow (cavitation)
Laminar Flow
Turbulent Flow
Ns
m2
• What is the casting yield of process described below?
10 Kg
5 Kg
Exercise-1
A certain mold is used to cast a cylindrical part. The cylinder diameter and height is 10 mm and 30 mm respectively. 3000 mm3 liquid is poured into the mold in 10 sec. The horizontal runner has a square cross-section with dimension of 2 mm.
Determine;
a) The casting yield
b) The volumetric flow rate of molten metal
c) The velocity of the liquid at the runner
Exercise-2
In a die casting application the molten metal is fed to a vacuumed die cavity at the same height, i.e. the inlet gate to the cavity and the molten metal outside are at the same height. The outside supply is open to the atmosphere. The density is 8000 kg/m3 and the supply velocity can be assumed
to be negligible. (Atmospheric pressure is 100 kPa.) What is the inlet velocity of the metal into the cavity (m/s)?
Exercise-3
A sphere with radius 300mm will be cast in a die with a vacuum casting process as shown below. The molten metal (ρ=7800kg/m3) passes through the pouring