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1. (a) Compare no bake moulding process and sodium silicate moulding process
in metal casting. 3
1. (b) Develop a relation between the diameter and the height of a cylindrical
top riser. 3
𝜋𝜋
Soln. Volume of riser = v = 4 𝑑𝑑 2 ℎ where d/ h = diameter/height of riser
4𝑣𝑣
𝜋𝜋ℎ = 2
𝑑𝑑
Radiation is through curved surface and only top surface of the top riser.
𝜋𝜋 4𝑣𝑣
Surface area = A = 4 𝑑𝑑 2 + 𝑑𝑑 𝑑𝑑 21
𝑑𝑑𝑑𝑑 π 4𝑣𝑣
𝑑𝑑𝑑𝑑
= 2 d − 𝑑𝑑 2 = 0
π
Or, 2 d − 𝜋𝜋ℎ = 0
𝑑𝑑 = 2ℎ; h = d/2
1. (c) Design a top riser for 1.2 m x 1.0 m x 0.8 m mould cavity. The material of
the casting is aluminium with coefficient of linear solid shrinkage 2% and
coefficient of linear liquid shrinkage 2.5%. Compare the solidification time of
the molten metal in the top riser and molten metal in the mould cavity.
Modify the dimension of the riser if required. 4
Volume of riser = v = 3 x v s =
Solidification time:
𝑣𝑣 𝑛𝑛
𝑡𝑡 = 𝑘𝑘 � �
𝐴𝐴
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𝜋𝜋 2 2
𝑑𝑑 ℎ𝑣𝑣
𝑡𝑡𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 = � 4
𝜋𝜋 2 � if k = 1 & n = 2
𝑑𝑑 +𝜋𝜋𝜋𝜋 ℎ
4
𝜋𝜋 2 𝑑𝑑 2
𝑑𝑑 ( )𝑣𝑣 𝑑𝑑
=� 4
𝜋𝜋 2
2
𝑑𝑑 � = 6 = 0.04
𝑑𝑑 +𝜋𝜋𝜋𝜋 ( )
4 2
Soln. Assuming the height of the sprue equal to the height of riser and let 1.2 x 1.0
be the top surface of the cavity, the buoyancy force acting on the cope is
1.2 x 1.0 (x 0.12)x 0.265 x 106= 38.16 kN
2. (a) Discuss the use of lubricant in forging operation. Give examples. 3
Soln.
Page 2 of 7
2. (a) Derive a relation to show that friction affects the rolling process. Relate
the radius of roll and the draft. 4
Draft = ∆h = ho – hf
= 2 (R – R cos α)
= 2R (1 - cos α)
=Rα2
Where
1-cos α = 2 sin2 (α /2)
And, α ≈ 0
2. (c) Compute the number of passes required to roll 20 mm thick 1112
annealed steel to 2.4 mm thick without applying any axial force.
Assume roll diameter = 200 mm and coefficient of friction between the roll 3
material & the steel = 0.2
Soln. During rolling the sheet splits into two or more number of layers. The is
known as alligatoring. It results from inhomogeneous deformation of the
material during rolling or from defective cast ingot (such as piping).
OR
2’. (a) Derive the magnitude of the maximum reduction per pass while drawing a
cylindrical metal specimen. 3
Soln. During drawing the drawing stress can’t exceed tensile stress of the material.
𝐴𝐴𝑖𝑖
𝜎𝜎𝑑𝑑 = 𝑌𝑌𝑌𝑌𝑌𝑌 � � = 𝑌𝑌
𝐴𝐴𝑓𝑓
𝐴𝐴𝑖𝑖
𝑙𝑙𝑙𝑙 � �=1
𝐴𝐴𝑓𝑓
𝐴𝐴𝑖𝑖
= 𝑒𝑒
𝐴𝐴𝑓𝑓
𝐴𝐴𝑖𝑖 −𝐴𝐴𝑓𝑓 1
Maximum reduction/pass = =1− = 0.63 = 63%
𝐴𝐴𝑓𝑓 𝑒𝑒
Soln. 𝐴𝐴 𝑖𝑖 𝑑𝑑 𝑖𝑖2
Dimension after 1st pass = = = 𝑒𝑒
𝐴𝐴 𝑓𝑓 𝑑𝑑 12
𝑑𝑑𝑖𝑖 25
𝑑𝑑1 = = = 15.16 𝑚𝑚𝑚𝑚
√𝑒𝑒 √2.72
15.16
Dimension after 2nd pass = = 9.12 mm
√𝑒𝑒
9.12
Dimension after 3rd pass = = 5.57 mm
√𝑒𝑒
Minimum 3 passes.
Alternate solution:
𝐴𝐴𝑖𝑖 𝑑𝑑𝑖𝑖2 𝑑𝑑12
= 𝑥𝑥 𝑥𝑥 … . = 𝑒𝑒 𝑛𝑛
𝐴𝐴𝑓𝑓 𝑑𝑑12 𝑑𝑑22
Page 4 of 7
𝐴𝐴 𝑑𝑑 2 25 2
𝑛𝑛 ≥ 𝑙𝑙𝑙𝑙 �𝐴𝐴 𝑖𝑖 �= 𝑙𝑙𝑙𝑙 �𝑑𝑑 𝑖𝑖2 � = 𝑙𝑙𝑙𝑙 � 82 � = 2.3
𝑓𝑓 𝑓𝑓
Minimum 3 passes
2’. (c) Compute the force required to draw the above specimen in the first and
the last pass. For computing flow stress, assume K and n from the Table 1
given below. 4
252
𝜀𝜀1 = 𝑙𝑙𝑙𝑙 � �=1
15.162
𝐾𝐾𝜀𝜀 𝑛𝑛 205𝑥𝑥10.2
Ȳ= = = 170.83𝑃𝑃𝑃𝑃
𝑛𝑛 + 1 0.2 + 1
𝐴𝐴𝑖𝑖 𝜋𝜋
𝐹𝐹 = Ȳ𝐴𝐴𝑓𝑓 𝑙𝑙𝑙𝑙 � � = 170.83𝑥𝑥 𝑥𝑥15.162 x1 = 30835.6 MN
𝐴𝐴𝑓𝑓 4
Soln. In direct extrusion direction of extrusion force and the direction of extruded
part is same. Moreover, the whole specimen in the extrusion chamber
moves. Energy if required to overcome thus the friction force.
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Table 1. Values for K and n at room temperature.
Page 7 of 7