ADVANCED CASTING TECHNIQUES ASSIGNMENT

Ans 1.a)
Sand casting and die casting are both the manufacturing process to produce cast parts by
pouring molten liquid metal into the Permanent Mold, which contains a empty cavity of the
desired design, and then allowed to solidify. The main difference between sand casting and
Permanent Mold die casting is in the mold.

The sand casting is a cast part produced by shaping a mold from a sand mixture and pouring
molten liquid metal into the cavity in the mold. The mold is then cooled until the metal has
solidified.It is expendable mold casting.

Die casting is the process of forcing molten metal under high pressure into mold cavities (which
are machined into dies). Most die castings are made from nonferrous metals, specifically zinc,
copper, and aluminum based alloys, but ferrous metal die castings are possible. It is non-
expendable mold casting.

Non-expendable mold casting differs from expendable processes in that the mold is not required
to be reformed after each production cycle.

The sand casting is one of the most well-liked and simplest types of casting that has been used
for centuries. Sand casting allows for miniscule batches to be made compared to permanent
mold casting and at a very tolerable cost. Not only does this method allow manufacturers to
create products at a low cost, but there are other benefits to sand casting, such as very small
size operations.

The die casting method is especially suited for applications where many small to medium sized
parts are needed with good detail, a fine surface quality and dimensional consistency. In recent
years, injection-molded plastic parts have been substituted for some die castings because they
are cheaper and lighter. Plastic parts are a practical alternative if hardness is not required and
little strength is needed.

Ans3a

1. Velocity v=(2*9810*200)0.5=1981 mm/s

2. Volume flow rate q=va=1981*400=792,400 mm3/s

3. Time to fill cavity tmf=v/q=1,200,000/792,400=1.515s

Ans 3b)
2  2  3
Casting volume V = tL = 0.75(10.0) = 75 in
2  2  2 
Casting area A = 2L + 4Lt = 2(10.0) + 4(10.0)(0.75) = 230.0 in V/A =
2 
75/230 = 0.3261 Casting TTS = 16(0.3261) = 1.70 min
Riser TTS = 1.30(1.70) = 2.21 min
2 2 3
Riser volume V = D H/4 = 0.25D (1.25D) = 0.3125D
2 2  2  2
Riser area A = 2D /4 + DH = 0.5D + 1.25D = 1.75D
3 2 
V/A = 0.3125D /1.75D = 0.1786D
2  2  2 
Riser TTS = 16.0(0.1786D) = 16.0(0.03189)D = 0.5102D = 2.21 min 

2 
D = 2.21/0.5102 = 4.3316
0.5 
D = (4.3316) = 2.081 in
H = 1.25(2.081) = 2.602 in.