Part 2: Problems

Solidification Time and Riser Design:

1. In the casting of steel under certain mold conditions, the mold constant in Chvorinov's Rule is
known to be 4.0 min/cm2 based on previous experience. The casting is a flat plate whose length =
30 cm, width = 10 cm, and thickness = 20 mm. Determine how long it will take for the casting to
solidify.
Solution:
Given that:

Mold Constant = 4.0min/cm2

Length = 30cm
Width = 10cm
Thickness = 20mm = 2cm

Area = 2(Length * Thickness) +2(Length * Width) +2(Width * Thinkness)

=2(30*2) +2(30*10) +2(10*2) =2(60) +2(300) +2(20)
=120+600+40
=760cm2

Volume = Length *Height* Width

=30cm*2cm*10cm
=600cm3

Chvorinov's Rule
Total Soldification Time = Cm (V/A)n
=4.0min/cm2 * (600cm*3/760cm*2)2
=4.0min/cm2 *0.623cm2
=2.49min

2. A disk-shaped part is to be cast out of aluminum. The diameter of the disk = 500 mm and its
thickness = 20 mm. If the mold constant = 2.0 sec/mm 2 in Chvorinov's Rule, how long will it take the
casting to solidify?
Solution:
Given That:
Diameter = 500mm
Thickness = 20mm
Cm=2.0sec/mm2
Area = 2 + 2 + 2
=2 2+2
2
=2 ( 2 ) + 2( 2 ) h=2 2 +

= (500)2 + (500)(20)
2
=392500mm2+314000 2
=423900mm2

Volume = 2
=3.14 62500 20
=3925000mm3

3925000^3
Total Solidification Time = 2.0sec/mm2 ( 423900^2 ) 2
=2.18573 sec/mm
=171.46sec
=2.86min

3. In casting experiments performed using a certain alloy and type of sand mold, it took 155 sec for a
cube-shaped casting to solidify. The cube was 50 mm on a side
Solution:
Given That:
Total Solidification Time = 155sec
Width = 50mm

(a) Determine the value of the mold constant in Chvorinov's Rule.

Area = 6 2

= 6 (50)2

=15,000mm2

Volume = (side)^3
= (50)3
= 125,000 mm3

(V/A) = 125,000/15,000 = 8.333 mm Cm

Cm= TTS /(V/A)2

= 155/(8.333)2
 = 2.232 s/mm2

(b) If the same alloy and mold type were used, find the total solidification time for a cylindrical casting in
which the diameter = 30 mm and length = 50 mm.

Diameter = 30 mm
Length = 50 mm.

Volume = D2 L/4
= (30)2 (50)/4
= 35,343 mm3

Area = 2D2 /4 + DL
= (30)2 /2 + (30)(50)
= 6126 mm

V/A = 35,343/6126
= 5.77

Total Solidification Time = 2.232 (5.77)2

= 74.3 s
= 1.24 min.

4. The total solidification times of three casting shapes are to be compared: (1) a sphere with diameter = 10
cm, (2) a cylinder with diameter and length both = 10 cm, and (3) a cube with each side = 10 cm. The same
casting alloy is used in the three cases. (a) Determine the relative solidification times for each geometry.
(b) Based on the results of part (a), which geometric element would make the best riser? (c) If the mold
constant = 3.5 min/cm 2 in Chvorinov's Rule, compute the total solidification time for each casting.
Solution:
Given That:
For ease of computation, make the substitution 10 cm = 1 decimeter (1 dm).
Thus 1000 cm3 = 1.0 dm3

Sphere:
Volume = D 3 /6
= 1.0 dm3.
Diameter = 6/
= 1.910 dm3.
= (1.910) 0.333
= 1.241 dm

Sphere Area = D2
= (1.241)2
 = 4.836 dm2

V/A = 1.0/4.836
= 0.2067 dm

Total Solidification Time = (0.2067)2Cm

= 0.0428Cm

Cylinder:
Volume = D 2 H/4
= D 3 /4
= 1.0 dm3.

D3 = 4/
= 1.273 dm3

Therefore, D = H = (1.273) 0.333

= 1.084 dm

Area = 2D 2 /4 + DL
= 2 (1.084) 2 /4 + (1.084) (1.084)
= 5.536 dm2

V/A = 1.0/5.536
= 0.1806 dm

Total Solidification Time = (0.1806)2 Cm

= 0.0326Cm

Cube:
Volume = L3 =1.0 dm3.
Length = 1.0 dm.

Area = 6L2
= 6(1)2
= 6.0 dm2

V/A = 1.0/6.0
= 0.1667 dm

Total Solidification Time = (0.1667) 2 Cm

= 0.02778Cm
Which geometric element would make the best riser?
Sphere would be the best riser, since V/A ratio is greatest.

If the mold constant = 3.5 min/cm 2 in Chvorinov's Rule, compute the total solidification time for each casting.
Given that Cm = 3.5 min/cm 2
= 350 min/dm3

Sphere: TTS = 0.0428(350)

= 14.98 min
Cylinder: TTS = 0.0326(350)
= 11.41 min
Cube: TTS = 0.02778(350)
= 9.72 min

5. A cylindrical riser is to be designed for a sand casting mold. The length of the cylinder is to be
1.25 times its diameter. The casting is a square plate, each side = 10 in and thickness = 0.75 inch.
If the metal is cast iron, and the mold constant = 16.0 min/in 2 in Chvorinov's Rule, determine the
dimensions of the riser so that it will take 30% longer for the riser to solidify. The finished casting
is what fraction of the combined weight of the riser and casting?
Solution:
Given That:
Volume = t.L2
= 0.75(10.0)2
= 75 in3

Area = 2L2 + 4Lt

= 2(10.0)2 + 4(10.0) (0.75)
= 230.0 in2

V/A = 75/230
= 0.3261

Casting TTS = 16(0.3261)2

= 1.70 min

Riser TTS = 1.30(1.70)

= 2.21 min

Volume = D 2 H/4
= 0.25D 2 (1.25D)
= 0.3125D3

Area = 2D 2 /4 + DH
= 0.5D 2 + 1.25D2
 = 1.75D2

V/A = 0.3125D3 /1.75D2

= 0.1786D

Riser TTS = 16.0(0.1786D)2

= 16.0(0.03189)D2
= 0.5102D2
= 2.21 min D2
= 2.21/0.5102
= 4.3316

D = (4.3316) 0.5
= 2.081 in H
= 1.25(2.081)
= 2.602 in.

6. A cylindrical riser with diameter-to-length ratio = 1.0 is to be designed for a sand casting mold. The
casting geometry is illustrated in figure, in which the units are inches. If the mold constant = 19.5
min/in2 in Chvorinov's Rule, determine the dimensions of the riser so that the riser will take 0.5
minute longer to freeze than the casting itself.
Solution:
Given That:

Volume = V(5 in x 10 in rectangular plate) +V(5 in. half disk) +V(upright tube) -V(3 in x 6 in rectangular
cutout).V(5 in x 10 in rectangular plate)
= 5 x 12.5 x 1.0
= 62.5 in3

V (5 in. half disk) = 0.5(5)2(1)/4 = 9.817 in 3V(upright tube)

= 3.0(2.5)2/4 - 4(1.5)2/4)
= 7.657 in3

V (3 in x 6 in rectangular cutout)
=3x6x1
= 18.0 in3

Total Volume = 62.5 + 9.817 + 7.657 - 18.0 = 61.974 in3

Total Area= 1 x 5 + 1(12.5 + 2.5+ 12.5) + 2(6+3) + 2(5 x 12.5 - 3 x 6) + 2(.5(5)2/4) - 2(1.5)2/4 +2.5(3) + 1.5(3+1)
= 203.36 in2

V/A = 61.974/203.36
= 0.305

Casting TTS = 19.5(0.305)2

= 1.81 min

Riser design 1.81 + 0.5

= 2.31 min
Riser volume V =D2L/4
=D3/4
= 0.25D3

Riser Area= DL+ 2D2/4

=D2+ 0.5D2
= 1.5D2

V/A= 0.25D3/1.5D2
=D/6TTS=Cm(V/A)22.31
= 19.5(D/6)2
= 0.5417D2D2
= 2.31/0.5417
= 4.266 in2

D= 2.065 in and L= 2.065 in

Pouring:
1. The downsprue leading into the runner of a certain mold has a length = 175 mm. The crosssectional
area at the base of the sprue is 400 mm 2 . The mold cavity has a volume = 0.001 m 3 . Determine (a) the
velocity of the molten metal flowing through the base of the downsprue, (b) the volume rate of flow, and
(c) the time required to fill the mold cavity.
Solution:
Given That:
Length = 175mm
Area = 400mm2
Volume = 0.001m3
vb =?
T=?

Volume = 2gh
=29.8175
=3430
=58.56mms-1

As,
Q=VA
Q=58.56mms-1400mm2
=23424mm3s-1
 TMF = V/A = 0.001 m3/23424mm3 s-1

2. The volume rate of flow of molten metal into the downsprue from the pouring cup is 50 in 3 /sec. At the top
where the pouring cup leads into the downsprue, the cross-sectional area = 1.0 in 2 . Determine what the area
should be at the bottom of the sprue if its length = 8.0 in. It is desired to maintain a constant flow rate, top and
bottom, in order to avoid aspiration of the liquid metal.
Solution:
Given That:

Q=50in^3/sec
At=1.0in^2
L=8.0in

Vb=2
= 2 9.8 8.0
= 12.5 1

And

Q = VA,
Vt=Q/A
=50/1.0
=50in/sec

VtAt = VbAb ,50.0 1.0 = 12.5 , = 42

3. Molten metal can be poured into the pouring cup of a sand mold at a steady rate of 1000 cm 3 /s. The molten
metal overflows the pouring cup and flows into the downsprue. The cross-section of the sprue is round, with a
diameter at the top = 3.4 cm. If the sprue is 25 cm long, determine the proper diameter at its base so as to maintain
the same volume flow rate.
Solution:
Given That:

Q=1000cm^3/s
Dt=3.4cm
L=25cm
Db=?

A1V1=A2V2
A= 2
2
= ( 2 )
=9.07cm2
Q=A1V1
V1=110.25cm/s

Q=A2V2
1000cm^3/s
2
= ( 2 )
2 = 3.6772
= 1.9176