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Fluid Flow Degree of Superheat Part Geometry Material Properties (viscosity) Die Properties Continuity Equation A0v0 = A1v1 Bernoulli Equation Max Flow without turbulence Reynolds Number
Re r .v .D m
Microsegregation
Microsegregation or coring
Macrosegregation
Fluidity
Fluidity is used to characterize the mold filling ability, sometimes castability. Superheat = (Tmelt TL)/TL
Sand Casting
Pattern for shape Pack sand around pattern Remove Pattern Put Cope and Drag together Pour - gravity fed Take part out of sand - recycle sand.
Casting Terminology
Investment Casting
Create Wax Pattern Assemble Wax Tree Coat with Ceramic Melt out wax Pour in molten metal Break off ceramic
Mold removed, not destroyed Uses gravity to fill mold Metal flow is slow Mold is steel - has comparatively good thermal conductivity Machines smaller
Die Casting
Liquid metal injected into reusable steel mold, or die, very quickly with high pressures Reusable steel tooling and injection of liquid metal with high pressures differentiates die casting from other metal casting processes
Casting Defects
Porosity Impurities - oxides Cold Shut Hot Tearing Dimensional tolerance and part geometry Warping Shrinkage
Fill completely with metal Solidify quickly without defects Eject readily from the die
Intersections of walls, ribs and gussets should blend with transitions and generous radii
Generous radii and transitions promote metal flow and internal integrity. Radii and fillets enhance structural integrity. Fillets reduce heat concentration in both the die and castings.
Avoid undercuts
May require machining operations or additional die components, such as retractable core slides
Dimensions with critical tolerances should relate to only one die member
Precision is reduced for relationships across the parting line or to moving components
vDr Re = h
Bernoullis Theorem
Under steady well-developed flow conditions, the total energy of a unit volume of material must be a constant at every part of the system.
2 rv0 rv12 p0 + + rgh0 = p1 + + rgh1 + f 2 2
where p is the pressure, v is the velocity, h is the height above a reference plane, f is the energy losses due to friction, and r is the density.
Heat Extraction
The solidification time is a function of the volume of the casting and its surface area (Chvorinovs rule)