8

Casting of Metals

Dr. Talaat A. El-Benawy
1433/1432

Forces acting on the

mould
the mould fills
it becomes exposed

As
to
high metallostatic pressures which tend to
displace or distort the mould sections and
cores. These forces can be accurately
predicted
and
contained
by
foundry
measures.
The first need is for a dense, rigid mould,
since the pressure tends to expand the
mould cavity, especially in greensand
practice. Rigidity of the mould parts can be
increased by using box bars or cover plates
to reinforce the sand mass; these measures
become increasingly necessary with moulds
of large area.

Assuming a rigid mould, the next concern

is with the force tending to separate the
mould parts. The upward force acting on a
flat mould surface is
equal to 9.81 h A [N],
where = density of the metal
[kg/m3]
h = head of metal, m
A = superficial area, m2
A completely flat mould surface gives rise
to the maximum lifting force: calculations
for other shapes can thus be safely based
upon their projected areas. The force is
resisted
by
using
box
clamps
and
arrangements of plates and tie-bars to
hold the mould parts together and by

Cores too are exposed to an upthrust,

equivalent in this case to the weight of
metal displaced; the net upward force is
thus considerable except in the casting of
light alloys. The force is countered by
high mechanical strength and rigidity in
core
construction,
enhanced
by
reinforcing grids and irons.
Cores must be firmly supported against
movement in the mould. A core relying
upon a single coreprint in the mould
bottom, for example, tends to float out of
position and must be anchored with wires
or sprigs. Cores of large dimensions may
require several points of support: if these
cannot all be provided in the form of

Example 1:
It is required to cast the cast iron part shown in the figure. If
the flask dimensions is 300 300 200 mm3, the density of
steel is 7.8 g/cm3 and the density of sand is 1.67 g/cm3,
calculate the required weight that should be used to prevent
the buoyancy force from lifting the upper flask.

Example 2:
It is required to cast the cast iron tube shown in the figure.
If the flask dimensions is 800 600 300 mm3, the density
of steel is 7.8 g/cm3 and the density of sand is 1.67 g/cm3,
calculate:
1. the required weight that should be used to prevent the
buoyancy force from lifting the upper flask and
2. the force
acting
on the core
of the
replacement
molten metal F =
Weight
B1

Weigh of the core

Resultant Force = 590 N
If the core is printed at its two sides, then the
bending moment at the middle of core can be
calculated according
FB2 =7.8 (hef 400 400) 10-6 9.81
Hef = 300 - hcg where hcg= 125 mm
Hef = 175 mm
FB2 = 1978 N
Total FB = 1978 + 590 2600 N by neglecting sand
weight, this will equal the required weight to
prevent the flask from lifting up.