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Riser Design and Solidification Calculations

The document contains multiple examples related to casting design and process calculations. Example 1 calculates solidification time for a steel plate casting using Chvorinov's rule. Example 2 calculates dimensions and solidification time for a cylindrical steel casting using information from a similar casting. Example 3 calculates the heat required to heat an aluminum casting from room temperature to pouring temperature.

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Caleb Quaynor
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27 views13 pages

Riser Design and Solidification Calculations

The document contains multiple examples related to casting design and process calculations. Example 1 calculates solidification time for a steel plate casting using Chvorinov's rule. Example 2 calculates dimensions and solidification time for a cylindrical steel casting using information from a similar casting. Example 3 calculates the heat required to heat an aluminum casting from room temperature to pouring temperature.

Uploaded by

Caleb Quaynor
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

Example 1 – Riser Design

• In the casting of steel under certain mold conditions, the mold


constant in Chvorinov's Rule is known to be Cm = 4.0 min/cm2, based
on previous experience. The casting is a flat plate whose length = 30
cm, width = 10 cm, and thickness = 20 mm. Determine how long it
will take for the casting to solidify.
Solution
Solution – Continuation

Surface Area of casting = L W

Total Solidification Tst =Cm (V/A)n

n = 2 for non permanent mold casting.

Volume of plate V= L×W×t = 30×10×0.2 = 60cm3

Surface Area A = L×W = 30×10 = 300cm2

Tst = 4(60/300)2 = 0.16 minutes


Example 2 – Riser Design
• A steel casting has a cylindrical geometry with 4.0 in diameter and
weighs 20 lb. This casting takes 6.0 min to completely solidify.
Another cylindrical-shaped casting with the same diameter-to-length
ratio weighs 12 lb. This casting is made of the same steel and the same
conditions of mold and pouring were used. Determine: (a) the mold
constant in Chvorinov's Rule; and (b) the dimensions, and (c) the total
solidification time of the lighter casting. Note: The density of steel =
490 lb/ft.
Solution
Solution continuation
Solution continuation
Solution continuation
Example 1 – Heating
A disk 40cm in diameter and 5cm thick is to be casted of pure
aluminum in an open mold operation. The melting temperature of
aluminum is 660oC and the pouring temperature will be 800oC.
Assume that the amount of aluminum heated will be 5% more than
needed to fill the mold cavity. Compute the amount of heat that
must be added to the metal to heat it to the pouring temperature,
starting from a room temperature of 25oC. The heat of fusion of
aluminum is 389.3J/g.
Take specific heat of solid Cs = 0.21Cal/g-OC, specific heat of liquid
Cl = 0.21Cal/g-OC, and density of aluminum ρ = 2.70g/cm3
Solution – Continuation
Data:
Temperatures: Tp = 800oC, Tm = 660oC To = 25oC
Specific heat of solid cs = 0.21Cal/g-OC
Specific heat of liquid cl = 0.21Cal/g-OC
Density of aluminum ρ = 2.70g/cm3
Disk diameter, D = 40cm, Thickness, t = 5cm
Pure Aluminum; Latent heat, hf = 389.3 J/kg
1 Cal = 4.2 J
Solution – Continuation

Amount of heat that must be added to the metal = Total heat


required H= Hs + Hf + Hl
Solution – Continuation

Hs = mcsT = mcs(Tm - To)


Volume of Casting, V = (πD2/4)t = (π×402/4)×5 = 6283 cm3
Heated Volume, VH = 1.05V = 1.05(62 83) cm3 = 6597cm3
Heated mass m = ρVH = 2.70×(6597) = 17813g
Hs = 17813(0.21×4.2)×(660 - 25)
Hs = 9.97MJ
Solution – Continuation

Latent heat, Hf = mhf = 17813×389.3 = 6.93MJ


Hf = 6.93MJ
Hl = mclT = mcl(Tp – Tm) = 17813×(0.21×4.2)×(800-660)
Hl = 2.19MJ
Total heat required H = 9.97 + 6.93 + 2.19 = 19.09MJ

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