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8/27/2016

PE4652 Teknologi Manufaktur


Latihan Pengecoran

1. Casting - Heating and Pouring


Example 1.1
A disk 40 cm in diameter and 5 cm thick is to be casted of pure aluminum in
an open mold operation.
The melting temperature of aluminum = 660C and the pouring
temperature will be 800C.
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 25C.
The heat of fusion of aluminum = 389.3 J/g. Other properties can be
obtained from Tables 4.1 and 4.2. Assume the specific heat has the same
value for solid and molten aluminum.
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Tabel 4.1

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Tabel 4.2

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Example 1.2
The downsprue leading into the runner of a certain mold has a length =
175 mm. The cross-sectional area at the base of the sprue is 400 mm2.
The mold cavity has a volume = 0.001 m3.
Determine:
(a) the velocity of the molten metal flowing through the base of the
downsprue
(b) the volume rate of flow
(c) the time required to fill the mold cavity.

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Example 1.3

The flow rate of liquid metal into the downsprue of a mold = 1


liter/sec.
The cross-sectional area at the top of the sprue = 800 mm2 and its
length = 175 mm.
What area should be used at the base of the sprue to avoid
aspiration of the molten metal?

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Casting - Shrinkage
Example 2.1

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.

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Solidification Contraction for Various Cast Metals


Metal or alloy

Volumetric solidification contraction (%)

Aluminum

6,6

Al4.5%Cu

6,3

Al12%Si

3,8

Carbon steel

2,5 - 3

1% carbon steel 4
Copper

4,9

70%Cu30%Zn

4,5

90%Cu10%Al

Gray iron

Expansion to 2,5

Magnesium

4,2

White iron

4 5,5

Zinc

6,5

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Example 2.2

Determine the scale of a "shrink rule" that is to be used by patternmakers for brass which is 70% copper and 30% zinc.
Express your answer in terms of millimeters of elongation per meter
of length compared to a standard rule.

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8/27/2016

Casting - Solidification Time and Riser Design


Example 3.1

A disk-shaped part is to be cast out of aluminum. The diameter of the


disk = 500 mm and its thickness = 20 mm.
If Cm = 2.0 sec/mm2 in Chvorinov's Rule, how long will it take the
casting to solidify?

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Example 3.2
A cylindrical riser is to be used for a sand casting mold. For a given cylinder volume,
determine the diameter-to- length ratio that will maximize the time to solidify.

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Example 3.3
A riser in the shape of a sphere is to be designed for a sand casting
mold. The casting is a rectangular plate, with length = 200 mm, width
= 100 mm, and thickness = 18 mm.
If the total solidification time of the casting itself is known to be 3.5
min, determine the diameter of the riser so that it will take 25% longer
for the riser to solidify.
Solution : for Home work

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