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.
1.50 in.
4.58 in.
3 (typical)
11.46 Repeat Problem 11.45, but assume that the aluminum spool is to be cast by
expendable-pattern casting. Explain the important dierences between the two
patterns.
A sketch for a typical expandable-pattern casting is shown below. A cross-sectional view
is also provided to clearly show the dierences between green-sand (from Problem 11.45)
and evaporative-casting patterns. There may be some variation in the patterns produced by
students depending on which dimensions are assigned a machining allowance. The important
elements of this pattern are as follows (dimensions in inches.):
(a) One-piece pattern, made of polystyrene.
(b) Shrinkage allowance = 5/32 in./ft
(c) Machining allowance = 1/16 in.
(d) No draft angles are necessary.
0.56 in.
0.52 in.
3
.
0
4
i
n
.
4
.0
5
in
.
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Metal Casting Processes 137
11.47 In sand casting, it is important that the cope-mold half be weighted down with
sucient force to keep it from oating when the molten metal is poured in.
For the casting shown in Fig. P11.47, calculate the minimum amount of weight
necessary to keep the cope from oating up as the molten metal is poured in.
(Hint: The buoyancy force exerted by the molten metal on the cope is dependent
on the eective height of the metal head above the cope.)
A A
Section A-A
3.00
2.00
2.50
1.00
0.50
2.00
1.00
1.00
2.50
4.00
5.00
R = 0.75
Material: Low-carbon steel
Density: 0.26 lb/in
3
All dimensions in inches
2.00
The cope mold half must be heavy enough or be weighted suciently to keep it from oating
when the molten metal is poured into the mold. The buoyancy force, F, on the cope is exerted
by the metallostatic pressure (caused by the metal in the cope above the parting line) and
can be calculated using the formula
F = pA
where p is the pressure at the parting line and A is the projected area of the mold cavity.
The pressure is
p = wh = (0.26 lb/in
3
)(2.00 in.) = 0.52 psi
The projected mold-cavity area can be calculated from the dimensions given on the right
gure in the problem, and is found to be 10.63 in
2
. Thus the force F is
F = (0.52)(10.63) = 5.52 lb
11.48 If an acceleration of 100 g is necessary to produce a part in true centrifugal
casting and the part has an inner diameter of 8 in., a mean outer diameter of 14
in., and a length of 20 ft, what rotational speed is needed?
The angular acceleration is given by =
2
r. Recognizing that the largest force is experienced
at the outside radius, this value for r is used in the calculation:
=
2
r = 100 g = 3220 ft/s
2
Therefore, solving for ,
=
/r =
3220 ft/s
2
4
d
2
L = 24
4
(0.125 in.)
2
1
2
4r
3
3
5r
3
3