Suez Canal University

Faculty of Engineering
Mechanical Engineering Department

Manufacturing Engineering
(Fall 2015)
Quiz 1 (Answer Key)
Time Allowed: 45 mins
Attempt to solve all question on the same paper
Question 1: We know that pouring molten metal at a high rate into a mold has certain
disadvantages. Are there any disadvantages to pouring it very slowly? (Answer in no
more than 10 words) any answer of the three would be considered correct
Answer 1: liquid metal may solidify before filling the mold.
Answer 2: incomplete castings can be resulted.
Answer 3: Longer pouring time adds more cost to the casting.
Question2: In a sand casting operation, what factors determine the time at which you
should remove the casting from the mold? (Check the correct answers only)
( ) A. Thermal conductivity of mold-material
( ) B. Thermal conductivity of cast metal
( ) C. Thermal conductivity of the pattern
( ) D. Diameter of the sprue
( ) E. Thickness and the overall size of the casting
( ) F. Temperature at which the metal being poured
( ) G. Area of the pouring cup
( ) H. Overall size of the casting of the top riser
( ) I. Reynolds number
Question 3: A sufficient amount of pure Aluminum is to be heated for casting a disk of
30 cm in diameter and 9 cm in thickness in an open mold operation.
(a) Compute the amount of heat that must be added to the metal to heat it to a
temperature of 800C for pouring, starting from a room temperature of 26C. Assume
that the amount of metal heated will be 10% more than needed to fill the mold cavity.
Properties of the metal are: density = 2.7/3, melting point = 660C, specific heat
of the metal C = 0.88 J/g-C ; and heat of fusion = 389.3 J/g. Assume the specific heat has
the same value for solid and molten aluminum.

Suez Canal University

Faculty of Engineering
Mechanical Engineering Department

(b) If every Joule needs 2.8*10^-8 KWh of electricity and the cost per 1 KWh is 12
piasters. Calculate the daily cost needed for this manufacturing process if the daily
production of this part needs 50 minutes to be accomplished and the manufacturing site
works for 8 hr-shift for 2 shifts.
Solution:
(a) Volume=4 2 = (4)302 (9) = 6361.725 3
Volume of aluminum to be heated = 6361.725(1.1) = 6997.898 3
Heat required = 2.70(6997.898){0.88(660-26) + 389.3 + 0.88(800-660)}= 20,224,862 J
(b) Electricity required per part= 2.8*10^-8 (KWh) * 20,224,862 (J) = 0.5663 KWh
Cost/ part= 0.5663 (KWh) *0.12 (EGP/KWh) = 0.06796 EGP
Working time/day = 8 (hours/shift) * 2 (shifts/day) * 60 (min/hour) = 960 min/day
Parts produced/day = 960 (min/day) / 50 (min/part) = 19 parts/day
Daily cost = 19 (parts/day) * 0.06796 (EGP/part) = 1.29 EGP
Question 4: Match
Complete the tables by matching the phrases on the left with the headings on the right.
Select the appropriate answer choices and drag them to the type to which they refer.
FOUR of the answer choices will NOT be used.
Answer Choices

Formed due to equal cooling throughout cast

Takes into account for mold shrinkage
Could be solved using inverse reflection
Depends on the size of sprue
Depends on the material distortion
Used with patterns containing holes
For external surfaces, allowance is negative
Provide safe removal of pattern from mold
Allows metal cools to room temperature

Shrinkage allowance
Allows metal cools to room temperature
Machining allowance
Depends on the material distortion
Draft allowance
Provide safe removal of pattern from mold
Core and core prints
Used with patterns containing holes
Distortion allowance
Formed due to equal cooling throughout cast

Based on the seen videos of casting types, select the best product to the casting type
Answer Choices

PET bottles
Metallic Pipes
Disc Brake
Tin cans
Carburetor
Turbine blades

Centrifugal casting
Metallic Pipes
Die casting
Carburetor
Investment casting
Turbine blades
Full mold casting

Suez Canal University

Faculty of Engineering
Mechanical Engineering Department

Plastic bags
Cylinder block
Gears

Disc Brake
Permanent mold casting
Cylinder block

Question5: The part shown in the accompanied figure is to be sand cast out of pure
Aluminum. Make a sketch of the wooden pattern for this part. Include all necessary
allowances for shrinkage, machining, and draft.

Suez Canal University

Faculty of Engineering
Mechanical Engineering Department

Solution:

Convert all given dimensions to inches for the ease of calculations: 1 mm

=0.0394 inch, 1 feet= 12 inch.
It is an Aluminum (non-Ferrous) metal, giving allowances for machining of 0.09
inch for all given dimensions (as they are all less than 8 inches)
Shrinkage allowance for Aluminum in less than 4 feet of 0.155 inch/ft (for all
given dimensions)
Shrinkage Allowance

Dim. Dim.
Dim.
(mm) (inch) (feet)
Category
38 1.4972 0.1247667 up to 4 ft
28 1.1032 0.0919333 up to 4 ft
56 2.2064 0.1838667 up to 4 ft
102 4.0188
0.3349 up to 4 ft
16 0.6304 0.0525333 up to 4 ft

Shrink. All. Shrink.

type
(inch/ft)
Dim.
type
positive
0.155 1.516539 positive
positive
0.155 1.11745 positive
positive
0.155 2.234899 positive
positive
0.155 4.07071 positive
negative
0.155 0.622257 negative

Machining Allowance
Draft Allowance
Machin.
all
Mach. Height of the given Draft Dim.
Category
(inch)
Dim.
surface (inch)
Angle (mm)
up to 8 inch
0.09 1.60654
1 to 2
1.5
38
up to 8 inch
0.09 1.20745
1 to 2
1.5
28
up to 8 inch
0.09 2.3249
2 to 4
1
56
up to 8 inch
0.09 4.16071
4 to 8
0.75
102
up to 8 inch
0.09 0.53226
1
3
16

Using the final dimensions and angles obtained provide a free hand sketch for
the wooden pattern.

Question6: Pure aluminum is poured into a sand mold. The metal level in the pouring basin is
100 mm above the metal level in the mold, and the runner is circular with a 20-mm diameter.
What are the velocity and rate of the flow of the metal into the mold? Is the flow turbulent or
laminar? what runner diameter is needed to ensure a Reynolds number of 1900? How long will a
200 3 casting take to fill with such a runner?
Use the following rules to solve the problem:
=

= 4 2

Suez Canal University

Faculty of Engineering
Mechanical Engineering Department

Solution:
Assuming the pressure does not change appreciably in the channel and that there is no friction
in the sprue, the flow is

Where the subscript 1 indicates the top of the sprue and 2 the bottom. If we assume that the
velocity at the top of the sprue is very low (as would occur with the normal case of a pouring
basin on top of the sprue with a large cross sectional area), then 1 = 0. The velocity at the
bottom of the sprue is
22 = 2(1 2 ) or
2 = 2 = 2(9.81 2 )(100 )(103 /) = 1.4007

= 1400.714 mm/s

If the opening is 20-mm in diameter, the area is

=

2
= (20)2 = 314.16 2 = 0.000314 2
4
4

Therefore, the flow rate is

= 2 = (1.4007)(0.000314) = 0.00044 3 = 440047.31 3 /
Pure aluminum has a density of 2700 /3 and a viscosity of around 0.0015 /2 around
700C. The Reynolds number is then (using v = 1.4007 m/s and D = 0.02 m),

3
(1.4007 )(0.02)(2700 )
=
=
= 50425.71

0.0015 /2
This situation would represent turbulence, and the velocity and/or diameter should be
decreased to bring Re below 20,000 or so.

A Reynolds number of 1900 can be achieved by reducing the channel diameter, so that
= 1900 =

(1.4007)(2700)
=

0.0015

; , = 0.00075 = 0.75358

For this diameter, the initial flow rate would be

2 2
3
3
2
7
(1.4007)(0.00075)
= 2 =
=
= 6.2 10
= 0.6247
4
4

This means that a 200 3 casting would take 320.13 s (about 5.3355 min) to fill and only if the
initial flow rate could be maintained.