IIT Guwahati

QUIZ 1 ME222 (Manufacturing Technology I) Duration: 60 mts

Total: 50 marks

NOTE: Part C should be answered in the question paper itself. Provide
figures wherever required. Data not given can be assumed.

Part A: Solve the following problems. (2 x 5 = 10 marks)
1. In casting experiments performed using a certain alloy and type of sand mold, it took 155
seconds for a cube-shaped casting to solidify. The cube was 50 mm on a side. (a)
Determine the value of the mold constant C
m
in Chvorinov's rule, (b) If the same alloy
and mold type were used, find the total solidification time for a cylindrical casting in
which the diameter = 30 mm and length = 50 mm.
(a) V/A = 125000/15000 = 8.33 mm; C
m
= 155/(8.33)
2
= 2.232 s/mm
2
.
(b) V = 35343 mm
3
; A = 6126 mm
2
; V/A = 5.77; t
s
= 2.232 (5.77)
2
= 74.3 sec.

2. The total solidification times of three casting shapes are to be compared: (1) a sphere with
diameter = 10 cm, (2) a cylinder with diameter and length both = 10 cm, and (3) a cube
with each side = 10 cm. The same casting alloy is used in the three cases. (a) Determine
the relative solidification times for each geometry. (b) Based on the results of part (a),
which geometric element would make the best riser? (c) If C
m
= 3.5 min/cm
2
in
Chvorinov's rule, compute the total solidification time for each casting.
(a) Sphere: V = 4/3r
3
; A = 4 r
2
;
V/A = 1.667 cm; t
s
= (1.667)
2
C
m
= 2.778 C
m
Cylinder: 2.778 C
m
; Cube: 2.778 C
m

(b) All three geometries are good for making risers
(c) t
s
(for all cases) = 2.778 x 3.5 = 9.723 min.

Part B: Answer the following. (4 x 6 = 24 marks)
3. Explain bedding-in method and false cope in making mold with their significance.
4. Explain the significance of, (i) core print, (ii) chaplets, and (iii) tins.
5. Explain vertical and bottom gating methods. Derive expression for filling time in bottom
gating method.
6. Write short notes on vacuum molding.

Part C: Answer the following in two or three lines clearly. (4 x 4 = 16 marks)

7. Identify the three sources of contraction in a metal casting after pouring.










8. What is significance of chill in casting?








9. What is runner in casting practice? What is its significance?











10. A mold cavity has the shape of a cube, 100 mm on a side. Determine the dimensions and
volume of the final cube after cooling to room temperature if the cast metal is copper.
Assume that the mold is full at the start of solidification and that shrinkage occurs
uniformly in all directions. For Cu, solidification shrinkage is 4.9%, solid contraction
during cooling is 7.5%.
Volume of cavity = V = 100
3
= 1000000 mm
3

volume of casting = a
3
= v = 1000000 (1-0.049) (1-0.075) = 879675 mm
3

dimensions of cube = a = 95.82 mm.