Volume of base: V1 = 18 x 75 x 56 32 x 6 x 75 (2 x x 122 x 12) / 4 = 58485.67 mm3 Surface Area of base: A1 = 18 x 75 x 2 + 56 x 6 x 2 + 4 x 12 x 6 + 32 x 75 + 6 x 75 x 2 + 56 x 31.5 x 2 + x 12 x 6 x 2 = 10940.38 mm2 Modulus of base: M1 = V1 / A1 = 58485.

485.67 / 10940.38 = 5.35 mm.

Volume of Cylindrical part: V2 = ( x 362 x 25) / 4 ( x 222 x 25) / 4 = 15943.58 mm3 Surface Area of Cylindrical part: A2 = x 36 x 25 + x 22 x 25 + 2( x 362 x 222) / 4 25 x 12 = 5530.80 mm2 Modulus of Cylindrical part: M2 = V2 / A2 = 15943.58 / 5530.80 = 2.88 mm.

Volume of Rib portion: V3 = 27050 mm3 Surface Area of Rib portion: A3 = 5812 mm2 Modulus of Rib portion: M3 = V3 / A3 = 27050 / 5812 = 4.65 mm.

58485.67 15943.58 27050 101479.25

10940.38 5530.8 5812 22283.18

5.35 * 2.88 4.65

Core Design: Let, Core Diameter = Dc Core body Length = Lc Core print Diameter = Dp Core print Length = Lp Self weight of core body = W c For silica sand, W c = ( x Dc 2 x L c x c ) / 4 = ( x 222 x 25 x 1600 x 10-9 ) / 4 = 0.015 Kgs. Self weight of core print = W p Wp = ( x 222 x Lp x 1600 x 10-9 ) / 4 = 12.16 x 10-4 x Lp Now, 0.015 = 12.16 x 10-4 x Lp Lp = 12.33 mm 13 mm Weight of core print = 12.16 x 10-4 x 13 = 0.0158 Kgs. Total weight = W c + Wp = 0.0308 Kgs = 0.31 N

Now, Upward buoyancy force = Volume displaced x Density of liquid metal = ( x Dc2 x Lc x metal x 9.81) / 4 = ( x 222 x 13 x 7820 x 10-9 x 9.81) / 4 = 0.38 N

Net upward buoyancy force = 0.38 0.31 = 0.07 N

Compressive Stress in mould under two core prints, = ( 0.5 x 0.07 ) / ( Lp x Dp ) = ( 0.5 x 0.07 ) / ( 22 x 13 ) = 1.22 x 10-4 N / mm2

Green Strength of sand = 0.05 N / mm2 > 1.22 x 10-4 N / mm2 Hence, Core & Core print design is safe.

Solidification Time: By using Chvorinovs Equation,

cast = Density of liquid metal = 7820 kg / m3 L = Latent heat of metal = 272 KJ / Kg Ccast = Specific heat of cast metal = 795 J/ Kg.k Tpour = Pouring temperature = 1650 0C Tsol = Solidus temperature = 1540 0C Tamb = Ambient temperature = 40 0C Tint = Interface temperature = 0.9 x Tsol = 0.9 x 1540 = 1390 0C mould = Density of mould material = 1600 kg / m3 Kmould = Thermal conductivity of mould 0.61 J / mks Cmould = Specific heat of mould material = 1130 J / Kg.K

Feeder Design: Let, Diameter of feeder = Df Height of feeder = Hf = 1.5Df Volume of feeder Vf = ( x Df2 x Hf ) / 4 = 0.375 x Df3 Surface Area of feeder Af = ( x Df x Hf ) + ( x Df2 ) = 1.75 x x Df2 Modulus of feeder = Vf /Hf = 0.214Df Taking modulus of feeder = 1.2 x modulus of last freezing area = 1.2 x 5.35 = 6.42 mm 0.214 Df = 6.42 Df = 30 mm Hf = 45 mm Volume of last freezing area = 58485.67 mm3 Modified Surface area of last freezing region = 10940.38 ( x 302 ) / 4 = 10233.52 mm2 Modified modulus of last freezing region = 58485.67 / 10233.52 = 5.72 mm Modified modulus of feeder = 1.2 x 5.72 = 6.86 mm = 0.214 Df Modified Diameter of feeder = Df = 32 mm Modified Height of feeder = Hf = 32 x 1.5 = 48 mm

Neck Design: Let, Neck Diameter = DN Neck Height = HN = 10 mm.given Volume of neck = VN = ( x DN2 x HN) / 4 Surface area of neck = AN = x DN x HN Modulus of neck = VN / AN = DN / 4 Also, Modulus of neck = 1.1 x modulus of last freezing area = 1.1 X 5.72 = 6.3 mm DN = 25.2 mm 26 mm

Feeder Yield:

Vc = Casting volume Vf = Volume of feeder including neck = ( x 322 x 48 ) / 4 + ( x 262 x 10 ) / 4 = 43913.18 mm3

Feeder Efficiency:

Optimal filling time:

K0 = Overall coefficient = 1.0 Kf = Fluidity coefficient = 1.0 Ks = Size coefficient = 1.1 Kt = Thickness coefficient = 1.4 Kw = Weight coefficient = 1.0 P = Weight power = 0.4 Lf =Fluidity length = 400 mm t = Average wall thickness = 20 mm

Casting weight ( without feeder and gating )= 0.8 kg Feeder weight = 43913.18 x 1600 x 10-9 = 0.08 kg Assuming, Gating ratio = 10% of total casting W = ( 0.08 + 0.8 ) / 0.9 = 0.98 1.0 Kg

Tf =1.32 sec Average pouring rate = 1 / 1.32 = 0.76 kg/s

Assuming Gating ratio of

1.0 : 2.0 : 1.5

Metallostatic pressure = H = Mould height + Pouring height = 300 + 50 = 350 mm Sprue velocity = Vsprue = Cf = Friction factor = 0.8 Vsprue = = 2.09 m/s

The gating ratio 1.0 : 2.0 : 1.5 implies a choke at sprue exit. Using continuity equation, AgVg = AsVs Velocity at ingate = 2.09/1.5 = 1.39 m/s The ingate velocity is higher than recommended i.e. 1 m/s Hence, modified gating ratio would be 1.0 : 2.0 : 2.09 Hence, Velocity at ingate = 2.09/2.09 = 1.0 m/s Sprue design Choke area = Ac = Where, W = Total casting weight = 1 kg

c = Metal density = 7870 gm/cm3 Tf = Total filling time = 1.32 sec Vc = Choke velocity = 2.09 m/s 46.05 mm2 Now, A1V1 = A2V2 Sprue top area = A1 = A2V2/V1 = Diameter of sprue at top = 12.45 mm Diameter of sprue at bottom = 7.65 mm 121.83 mm2

Runner design: Assuming Rectangular cross-section, For runner dimensions, Height / Width = 1.5 For Ingate dimensions, Height / Width = 0.5 For the modified gating ratio 1.0 : 2.0 : 2.09 Area of runner = 46.05 x 2 = 92.1 mm2 Cross-sectional area of runner = Height x Width

= 1.5 x Width x Width 92.1 = 1.5 Width2 Width of runner c/s = 7.83 mm Height of runner c/s = 11.75 mm

Area of Ingate = 46.05 x 2.09 = 96.24 mm 2 Cross-sectional area of ingate = Height x Width

= 0.5 x Width x Width 96.24 = 0.5 Width2 Width of ingate c/s = 13.87 mm Height of ingate c/s = 6.93 mm Reynolds number = Re = Vd/ = Density of liquid metal = 7020 kg/m3 = Viscosity = 5.5 x 10-3 N-s/m2 V = Velocity of liquid = 2.09 m/s d = Sprue exit diameter = 7.65 mm Re = 7020 x 2.09 x 7.65 x 10-3 / 5.5 x 10-3 Re = 20407