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Sand Casting Design and Calculations

This document provides specifications for producing a tail stock casting using sand casting of cast iron material. It includes drawings of the casting and pattern, suitable molding sand, and calculations for the gating system, risers, and pouring cup. The gating system is designed with ingate, runner, and pouring basin dimensions based on the casting weight of 18kg. Risers of 33mm and 50mm are calculated to have volumes of 54.66cm3 and 202.68cm3 respectively to compensate for shrinkage. The total casting weight including risers is estimated to be 35.84kg.

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Mohamed Elsemary
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59 views6 pages

Sand Casting Design and Calculations

This document provides specifications for producing a tail stock casting using sand casting of cast iron material. It includes drawings of the casting and pattern, suitable molding sand, and calculations for the gating system, risers, and pouring cup. The gating system is designed with ingate, runner, and pouring basin dimensions based on the casting weight of 18kg. Risers of 33mm and 50mm are calculated to have volumes of 54.66cm3 and 202.68cm3 respectively to compensate for shrinkage. The total casting weight including risers is estimated to be 35.84kg.

Uploaded by

Mohamed Elsemary
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

1.

It is required to produce the given tail stock by sand casting process from cast iron
material (GG20).
 Draw the casting drawing.
 Draw the pattern drawing.
 Draw the core only if it is required.
 Draw the assembly of the flask to illustrate the gating system and the
location of riser if it is required.
 State the suitable molding sand.
 Calculate the gating system if S=2.3, W casting=18 Kg, and µ=0.6.
 Pattern material:
- Assume Q < 500 Pieces Using wooden pattern (Split Pattern)

 Pattern Allowances:
- Machining allowance
1) At Z1= 52 & S1= 90 ( up= 5 ) , ( down=3.5 ≈ 5 )
2) At Z2,3= 52 & S2,3= 90 ( up= 5 ) , ( down=3.5 )
3) At Z4,5 (The slot width < 20 mm so it will be machined after casting)
4) At Z6= 25 & S6= 240 ( up= 5 ) , ( down=3.5 )
5) At Z7= 50 & S7= 60 ( up= 4.5 ) , ( down=3 ≈ 4.5 )

- Shrinkage allowance
For GG20 Pearlite C.I (Disabled shrinkage allowance = 0.9)

- Draft allowance
1) At H1=45 α =1° 30ʹ a = 1 mm
2) At H2,3=50 α =1° 30ʹ a = 1 mm
3) At H1=35 α =1° 30ʹ a = 1 mm

 Core Print dimension


- First we must add the machining allowance to main dimension
d1 =41 (L2=45 a1=1 a2=1.5 α =4)
d2 =180 (L2=90 a1=1.5 a2=2 α =4)
 Riser Calculations

𝜋
(Vfl) 1, 3= 4 ∗ 152 ∗ (30 + 10) + 70 ∗ 30 ∗ (30 + 10) = 91.1 𝑐𝑚3
100 s 100 6
(VR) 1, 3= (Vfl)1,3 ∗ ∗ 100 = 91.1 ∗ ∗ 100 = 54.66 𝑐𝑚3
c 10
2 𝜋 3 𝜋
(VR) 1, 3= 54.66 = 4 D1,3 ∗ 𝑙 = 2 D1,3 l = 2D
3 2∗54.66
D 1, 3= √ =3.3 cm=33 mm
𝜋 D D1 D2 V B r
From table (2-20) At D 1, 3=35 35 45 65 175 25 6
𝜋 𝜋
(VR) 1, 3 Standard = 4 D12 ∗ 𝑣 = 4 ∗ 4.52 ∗ 17.5=278.3 𝑐𝑚3

𝜋
(Vfl) 2= 4 (902 − 412 )(62 + 5) = 337.8 𝑐𝑚3
100 s 100 6
(VR) 2= (Vfl)1,3 ∗ ∗ 100 = 91.1 ∗ ∗ 100 = 54.66 𝑐𝑚3
c 10
𝜋 𝜋
(VR) 2= 202.68 = 4 D22 ∗ 𝑙 = 2 D32 l = 2D
3 2∗202.68
D 2= √ =5 cm=50 mm D D1 D2 V B r
𝜋
From table (2-20) At D 2=50 50 60 80 175 25 6
𝜋 𝜋
(VR) 2 Standard = 4 D12 ∗ 𝑣 = 4 ∗ 62 ∗ 17.5=494.8 𝑐𝑚3

G Riser = [2 ∗ V 𝑅 1,3 Standard + V 𝑅 2 Standard ] ∗ 𝜌 = [2 ∗ 278.3 + 494.8] ∗ 7.25 = 7.6 𝑘𝑔

 Total Casting Weight Calculations


G Gross = (1.15 − 1.4)(GRiser + GCasting ) = (1.4)(7.6 + 18) = 35.84 𝑘𝑔
From table (2-9) At G Gross =35.84 kg
a b c d e f
2∗70+100 70 70 50 50 60 90
H= = 120 𝑚𝑚
2
W = 87 + 45 + 90 + 100 = 322 𝑚𝑚
L = 100 + 50 + 240 = 390 𝑚𝑚

From table (2-10) H standard = 125


W standard = 350
L standard = 400
 Gating System Calculations

- Cast iron is pressurized system so (Fz:Fr:Fs = 1:1.2:1.4) (F=Fz)


1000 𝐺𝑔𝑟𝑜𝑠𝑠
F=
τ.μ.γ.√2𝑔.ℎ𝑝
- Sprue time (τ)
τ = 𝑠√𝐺𝑔𝑟𝑜𝑠𝑠 = 2.3√35.84 = 13.7 𝑠𝑒𝑐 ≈ 14 sec
- Static Pressure Head (hp)
𝑃2 (50)2
hp =𝐻 − 2𝑐 = 125 − 2∗100 = 112.5 𝑚𝑚
1000∗35.84 𝐹𝑧 1.25
⸫ Fz = 14∗0.6∗7.25∗√2∗981∗112 = 1.25 𝑐𝑚3 ⸫ Fz/ingate = No. = = 0.625 𝑐𝑚3
of ingate 2
𝐹𝑟 1.50
& Fr =1.50 𝑐𝑚3 ⸫ Fr/runner = No. = = 0.75 𝑐𝑚3
of runner 2
⸫ Fs =1.75 𝑐𝑚3
From table (2-14)
Fz/ingate a b c Fr/runner a b c Fs d
0.63 14 9 5.5 0.80 16 10 6 1.80 15
Fs d L D1
Or From table (2-15)
2 16 200 20

 Pouring Cup
4 𝐺𝑔𝑟𝑜𝑠𝑠 5 4 35.84 5
- v = 400 √( ) = 400 √( ) = 1295.3 𝑐𝑚3
𝜏 14
From table (2-16)
v L b h r1 r2 r3
1300 180 110 100 55 44 33

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