Castanal 1

ME 6222: Manufacturing Processes and Systems
Prof. J.S. Colton GIT 2011

1
Casting Analysis - 1

Melting and Pouring
ver. 1
2
Overview
Processes
Analysis
Melting
Pouring
Solidification and cooling
Surface tension
Gas solubility and porosity
Defects
Design rules
Economics
3
Casting Steps
quick route from raw material to finished
product
Melt metals
Pour / force liquid into hollow cavity
(mold)
Cool / Solidify
Remove
Finish
4
Temperature vs. Time
Temperature
time
initial
melting solidification
pouring
removal
5
Melting
Raw material (charge)
scrap, alloying materials
Atmosphere
Air (oxygen), vacuum, inert gas (argon)
Heating
External - electric, gas, oil
Internal - induction, mix fuel with charge
steel making in blast furnace -mix coke with steel
Furnace material - refractory
high melting point metals, ceramics
Heat
Raw materials
Furnace
Atmosphere
6
Heat to melt
H = heat [J]
= density
V = volume
c = specific heat (s = solid, l = liquid)
H
f
= heat of fusion
( ) ( ) | |
melt pour l f initial melt s
T T c H T T c V H + + =
Melting Time
Estimate by

Take into account oven efficiency
7
Power
Energy
time =
8
Melting Ex. 1-1
Calculate the time required to raise the
temperature of a 120 kg aluminum billet
from 20
o
C to 50
o
C above its melting
point using a 20 kW furnace that is 75%
efficient.

9
Melting Ex. 1-2
density = 2700 kg/m
3
melting point = 660
o
C
heat of fusion = 396 kJ/kg
specific heat of liquid = 1.05 kJ/kg-K
specific heat of solid = 0.9 kJ/kg-K

H = 120 * [0.9 * (660-20)
+ 396 + 1.05 * (710 660)]
= 123 MJ = 1.17 x 10
5
BTU
Melting Ex. 1-3
time = 123 MJ / (20 kW * 75%)
time = 2.3 hours

Should probably buy a bigger furnace
10
11
Pouring - Fluid Flow
Reynolds number
Bernoullis equation
Continuity
12
Reynolds number (Re)
ratio of momentum (inertia) to viscosity
( ) ( ) ( )
( ) viscosity
diameter velocity density
Re
- -
=
=
Vd
13
Critical Reynolds number
Re < 2,000
viscosity dominated, laminar flow
Re > 20,000
inertia dominated, turbulent flow
Controlled through gate and runner
design
14
Bernoullis Equation
Used to calculate flow velocities
Assumptions: steady state, incompressible, inviscid
flow

P = pressure g = gravity
= density h = height
v = velocity f = losses due to friction

f gh
v
P gh
v
P
o
o
o
+ + + = + +
1
2
1
1
2
2 2


15
Continuity
Q
0
= Q
1
A
0
v
0
= A
1
v
1

where:
Q = volumetric flow rate
A = area
v = velocity

Assumption: incompressible flow
16
Pouring Ex. 2-1
Determine the geometry of the sprue, so that
there is no air aspiration (the pressure never
is less than atmospheric).

hc
ht
1
2
3
1 = free surface of metal
2 = spue top
3 = sprue bottom
pouring basin
sprue
17
Casting Ex. 2-2
Assuming
entire mold is at atmospheric pressure (no
point below atmospheric)
metal in the pouring basin is at zero
velocity (reservoir assumption)
3
2
3
3 1
2
1
1
2 2
gh
v
P gh
v
P
+ + = + +
t
gh v 2
3
=
18
Casting Ex. 2-3
Similarly
2
2
2
2 1
2
1
1
2 2
gh
v
P gh
v
P
+ + = + +
c
gh v 2
2
=
19
Casting Ex. 2-4
By continuity
A
2
v
2
= A
3
v
3
Hence
t
c
h
h
v
v
A
A
= =
3
2
2
3
20
Mold Filling Time Estimate
Using continuity
Q = A
g
v
g
=A
3
v
3
Assuming A
g
= A
3

Hence
t 3 gate
2gh v v = =
gate gate
v A
mold of Volume
time filling Mold =
21
Pouring Ex. 3-1
Given
height of sprue (h
t
) = 20 cm
area of sprue (A
3
) = 2.5 cm
2
volume of mold cavity (V) = 1560 cm
3
Find
v
sprue
Flow rate (Q)
Mold filling time
22
Pouring Ex. 3-2
Q = v
base of sprue
*A
3

= 198.1 * 2.5 = 495 cm
3
/s

Mold filling time = V/Q =1560 / 495 = 3.2 s

cm/s 1 . 198 20 * 981 * 2 2 v
sprue of base
= = =
t
gh
23
Bottom Gated Systems
Air forced up and out of mold
Reduced splashing and oxidation
As metal is poured into the system,
effective head is reduced.
h
h
m h
t
A
m
= mold cross-sectional area
A
g
= gate cross-sectional area
24
In time dt,
height of metal in mold increases dh
flow rate in mold, Q
m
= A
m
dh/dt
flow rate of metal delivered by gate to mold,
Q
g
= A
g
v
g
, where

( ) h h g v
t g
= 2
25
Equating Q
m
= Q
g
,

If t
f
= filling time,
( )dt h h g A dh A
t g m
= 2
( )
m t t
g
m
f
t
m
g
h
t
h h h
g A
A
t
dt
A
A
h h
dh
g
f
m
=
=
} }
2
2
2
1
0 0
26
Pouring - Ex. 4-1
You are pouring liquid iron into a mold.
The mold has a sprue height of 2 inches.
The bottom of the sprue has a diameter
of 0.2 in.

Cope
Drag
Casting
Parting Line
Sprue
Risers
Gate
27
Pouring - Ex. 4-2
You wish to pour the metal so that you do
not entrain air.

What should the diameter of the gate
(d
gate
) be?

28
Pouring - Ex. 4-3
Here we need to use:
Reynolds number
Values below 20,000 are OK in casting
To prevent entrainment of air resulting from
turbulence
Bernoullis equation
Continuity
29
Pouring - Ex. 4-4
Iron data:
density () = 7860 kg/m
3

viscosity at pouring temp () = 2.25 cp
= 2.25 x 10
-3
N*s/m
2

h
0
= 2 in. = 0.051 m
h
1
= 0 m
g = 9.8 m/s
2
A
1
= tr
2
= 3.14 * 0.00254
2
=
2.03 x 10
-5
m
2

30
Pouring - Ex. 4-5
Now we need to determine the
velocity at the bottom of the sprue
(v
1
) using Bernoullis equation.
31
Pouring - Ex. 4-6
We can assume that the velocity
at the top of the mold (v
o
) is zero,
if there is a pouring basin, which is
typical.

32
Pouring - Ex. 4-7
Ignore friction effects (f=0).
Assume the mold is open to
atmospheric pressure
(P
0
=P
1
=P
atm
).
Ignore the effect of the height of
the metal in the mold.
33
Pouring - Ex. 4-8
Substituting into Bernoullis equation:
f gh
v
P gh
v
P
o
o
o
+ + + = + +
1
2
1
1
2
2 2

0 0 8 . 9 7860
2
7860
051 . 0 8 . 9 7860
2
0 7860
2
1
2
+ - - +
-
+
= - - +
-
+
v
P
P
atm
atm
34
Pouring - Ex. 4-9
And solving:

v
1
= 1 m/s

Checking Reynolds number

Re = 7860*1*0.00508/2.25x10
-3
=17,746 < 20,000
35
Pouring - Ex. 4-10
Now using continuity:

A
1
v
1
= A
gate
v
gate
=

2.03 x 10
-5
* 1 = A
gate
v
gate

and A
gate
= tr
gate
2
36
Pouring - Ex. 4-11
Now, Reynolds number < 20,000

Solving gives:
v
gate
*d
gate
= 5.72 x 10
-3
m
2
/s

000 , 20
10 2.25
7860
Re
3 -
=
-
- -
= =
gate gate
d v
Vd

37
Pouring - Ex. 4-12
Combining the following equations:

2.03 x 10
-5
* 1 = A
gate
v
gate

A
gate
= tr
gate
2

v
gate
*d
gate
= 5.72 x 10
-3
m
2
/s

38
Pouring - Ex. 4-13
And solving gives:

d
gate
= 4.5 mm = 0.18 in.

A not unreasonable answer, given
the sprue is 5 mm in diameter.
Data for Solid Materials
Room Temperature
39
Material Specific heat
(kJ/kg-
o
C)
Density
(kg/m
3
)
Thermal
conductivity
(W/m-
o
C)
Sand 1.16 1500 0.60
Aluminum 0.90 2700 222
Nickel 0.44 8910 92.1
Magnesium 1.03 1740 154
Copper 0.38 8960 394
Iron 0.46 7860 75.4
Steel 0.434 7832 59
Data for Liquid Metals
40
Material Melting
point (
o
C)
Density
(kg/m
3
)
Latent heat
of
solidification
(fusion)
(kJ/kg)
Thermal
conductivity
(W/m-
o
C)
Specific
heat
(kJ/kg-
o
C)
Viscosity
(mPa-s)
Aluminum 660 2390 396 94 1.05 4.5
Nickel 1453 7900 297 0.73 4.1
Magnesium 650 1585 384 139 1.38 1.24
Copper 1083 7960 220 49.4 0.52 3.36
Iron 1537 7150 211 0.34 2.2
41
Summary
Analysis
Melting
Pouring
Solidification and cooling
Surface tension
Gas solubility and porosity
42

Castanal 1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Castanal 1

Uploaded by

Copyright:

Available Formats

ME 6222: Manufacturing Processes and Systems

Prof. J.S. Colton GIT 2011

ME 6222: Manufacturing Processes and Systems

ME 6222: Manufacturing Processes and Systems

You might also like