Manufacturing Processes

PROBLEM BASED LEARNING

Submitted to:
Sir Ghulam Moeen-ud-Din

Submitted by:
Rohan
Elahi
2020-ME-161

Mechanics of Materials I
 University of Engineering and Technology, Lahore
(Question 01)
A cylindrical riser with diameter-to-length ratio = 1.0 is to be designed for a sand-casting mold. The casting
geometry is illustrated in Figure below; the units are inches. If the mold constant in Chvorinov's rule = 19.5
min/in2, determine the dimensions of the riser so that the riser will take 0.5 min longer to freeze than the
casting itself
Repeat the calculation for diameter-to-length ratio = 0.75 and diameter-to-length ratio = 1.25
Comment on the effect of three riser designs on the casting quality

Analysis:
The riser's proportions must be determined so that it takes 0.5 minutes longer to freeze than the
casting itself. The length can be calculated using the Chvorinov's rule, which is 19.5 minutes per
inch squared. Aside from that, we'll need to figure out the mould casting's entire volume and
surface area.
After we've finished with geometrics, we'll utilise Chvorinov's formula to calculate the riser's
radius. We can readily compute the length of the riser using the specified diameter-to-length
ratios.
Systematic Diagram:

Solution:
Time for solidification is:
TTS = Cm x (V/A)n
Where Cm = 19.5 min/in2
For Volume and Surface Area:
Total Volume of the casting = VRectangle + VSemi-circle + VTube - VCutout
VT = [12.5*5*1] + [π*(2.5)2*1]/2 + [3π(1.25)2 - 4π(0.75)2] – [6*3*1]
VT = 61.97 in3
Total Surface Area of the casting = 1*[5 + 12.5 + 2.5π + 12.5] + 2*[6+3] + 1.5π*[3+1] +
5*[12.5] - 3*[6] + 2*[0.5π(2.5)2] – 2*[(0.75)2 π + 2.5π*[3]
 AT = 203.36 in2
Time interval can be calculated as:
TTS = Cm x (VT/AT)n
61.97 2
TTS = 19.5( )
203.36
TTS = 1.8 min
The solidification time for the riser is 0.5 minutes longer than that of the casting, according to the
statement. As a result, the riser's solidification time will be:
TTS’ = TTS + 0.5 = 1.8 + 0.5

TTS’ = 2.3 min

We'll now apply Chvorinov's formula for the riser to determine its length and diameter, and then
find the riser's volume to surface area ratio:TTS’ = Cm x (VR/AR)n
The ratio VR/AR = 0.25πD3/1.5πD2 = D/6
This is after we assume the diameter of the riser is equal to its length (as given in the statement).
We can now utilise it in the following formula:
TTS’ = Cm x (DR/6)2
2.3 = 19.5 (DR/6)2
We rearrange the equation to get the diameter of the riser:

DR = 2.07 in

i) Case I (when the ratio of diameter to length is 1):

LR = DR

LR = 2.07 in

ii) Case II (when the ratio of diameter to length is 0.75):

Upon calculation, the Riser Area and Volume comes out to be:
VR = 0.1406πL3
AR = 1.03πL2
By Chvorinov’s formula:
TTS = Cm x (VR/AR)2
2.31= 19.5*(1.36L)2

LR = 0.25 in
DR = 0.75(0.25)

DR = 0.189 in

iii) Case III (when the ratio of diameter to length is 1.25):

Upon calculation, the Riser Area and Volume comes out to be:
VR = 0.39πL3
AR = 1.875πL2
By Chvorinov’s formula:
TTS = Cm x (VR/AR)2
2.31= 19.5*(2.08L)2

LR = 1.65 in
DR = 0.75(0.25)

DR = 2 in

Graph:

Relati on between D/L & V

9
8
7
6
Volume V

5
4
3
2
1
0
0.7 0.8 0.9 1 1.1 1.2 1.3
Diameter-to-Length ratio D/L
Comments:
When the diameter to length ratio is 1.0, we get the maximum volume of riser, as shown in the
graph. Aside from that, volume continues to fall. Once we've proved that a D/L ratio of 1.0
equals maximum volume, we may be confident that the riser's maximum voltage will result in
little material waste. As a result, the quality of our casting process improves.
The D/L ratio of 1.0, as seen in the graph, provides the finest casting quality. Similarly, a D/L
ratio of 1.25 is the next best casting design. Last but not least, the D/L ratio of 0.75 has the
poorest casting quality.
________________________________________________________________
 (Question 02)
The total solidification times of three casting shapes are to be compared: (1) a sphere, (2) a cylinder,
in which the length-to-diameter ratio = 1.0, and (3) a cube. For all three geometries, the volume =
1000 cm3. 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 the mold constant = 3 min/cm 2 in Chvorinov's rule, compute the total
solidification time for each casting.

Analysis:
We must calculate the relative solidification time for each geometry with a volume of 1000 cm3.
The casting permissions are the same. We'll also talk about which form will provide us the finest
riser. We'll additionally calculate the entire solidification time in each casting because the mould
constant is 3 min/cm2.

Solution:
a) We must compute the general solidification time for each geometry in this section. As a result,
we'll start by calculating their volume to surface area ratio.
For Sphere:
4 3
Vs = π r = 1000 cm3 (given)
3
rS = 6.2 cm
Using this radius in surface area,
AS = 4πr2 = 4π(6.2)2 = 483 cm2
Now, putting these values in Chvorinov’s rule:
TTS = Cm (1000/483)2

TS = 4.29 Cm
For Cylinder:
Vcy = πr2L = 1000 cm3 (given)
Where L = D (acc to ratio being 1) = 2r
So, 2πr3 = 1000
rcy = 5.4 cm
Using this radius in surface area,
Acy = 2πrL + 2πr2 = 2π(5.4)[2*5.4] + 2π(5.4)2 = 550 cm2
Now, putting these values in Chvorinov’s rule:
TTS = Cm (1000/550)2
 Tcy = 3.31 Cm
For Cube:
Vcu = L3 = 1000 cm3 (given)
Lcu = 10 cm
Using this radius in surface area,
Acu = 6L2 = 6(10)2 = 600 cm2
Now, putting these values in Chvorinov’s rule:
TTS = Cm (1000/600)2

Tcu = 2.78 Cm
The relative time of solidification of the three geometries will be:

TS: Tcy: Tcu = 4.29: 3.31: 2.78

b) We discovered that the spherical had the highest volume to surface area ratio after examining
the solidification timings. As a result, it has the longest solidification time. A sphere is the best
riser of the three since it takes the longest to firm. Because the riser is expected to be as liquid as
possible, we'll get the best results by employing a sphere.
c) The solidification time when Cm = 3 min/cm2

Sphere: TTS = 4.29(3) = 12.87 min

Cylinder: TTS = 3.31(3) = 9.93 min

Cube: TTS = 2.78(3) = 8.33 min

______________________________________________________________________________
 (Question 03)
A plastic extruder barrel has a diameter D = 75 mm. The screw rotates at N = 1 rev/s. Channel
depth dc = 6.0 mm and flight angle A = 20degrees. Head pressure at the end of the barrel p = 7.0 x
106 Pa, length of the barrel L = 1.9m, and viscosity of the polymer melt is assumed to be h= 100 Pa-
s. Determine the volume flow rate of the plastic in the barrel Q x. Determine (a) Qmax and pmax, (b)
shape factor Ks for a circular die opening in which Dd = 6.5mm and Ld = 20 mm, and (c) values of
Qx and p at the operating point
Recalculate for D = 100mm and D = 125mm.

Analysis:
Given data is:
D = 75 mm = 0.075 m
N = 1 rev/s
dC = 6 mm= 0.006 m
A = 20°
P = 7 x 106 Pa
L = 1.9 m
Η = 100 Pa-s
And you've been requested to calculate Qx, Qmax, and Pmax, the volume flow rate of the plastic
in the barrel. Also, for a circular dye opening with Dd = 6.5 mm and Ld = 20 mm, calculate the
shape factor KS. At the operational point, we must also calculate the values at Qx and p. Then,
for D = 100 mm and 125 mm, recalculate.Solution:
As we know that;
Qd = 0.5π2D2 Ndc cosθsinθ = 0.5π2 (0.075)2 (1) (0.006) (sin20) (cos20)
Qd = 53535 x 10-9 m3/s
Also, we know that:
3 2
pπD dc 3 ( sin A )2 π ( 0.0075 ) ( 0.006 ) ( sin 20 )
Qb = =
12 ηL 12 ( 100 ) ( 1⋅ 9 )
Qb = 18276 x 10-9 m3/s
Finally, Qx = Qd – Qb = (53535 – 18276) x 10-9

Qx = 35249 x 10-9 m3/s

a) For Qmax and Pmax, we know that:

Qmax = 0.5π2D2 N dc cosθ sinθ = 0.5π2 (0.0075)2 (1) (0.006) (sin20) (cos20)

Qmax = 53535 x 10-9 m3/s

 6 πηDNLcot ( A) 6 π ( 0.0075 ) ( 1.9 ) (1 )( 100 ) cot 20
Pmax = =
dc 2 ( 0.006 )2

Pmax = 20.5 MPa

π Dd4 π ( 0.0065 )4
b) Ks = =
128 ηLd 128 ( 100 )(0.02)

KS = 21.9 x 10-12 m5/Ns

c) We must first know the dye and extruder characteristics for the assembly before we can find
Qx and p at the operating point.
Dye Charasteristic:
Qx = Ks p
Qx = (21.9 x 10-12) p

Extruder Characteristic:
Qmax
Qx = Qmax – (
Pmax
p)
53535 x (10−9)
Qx = (53535 x 10-9) – ( ¿p
20.5× 106
We will solve these both equations simultaneously to determine both Qx and p:

p = 2.184 x 10-6 Pa
and
Qx = 47.82 x 10-6 m3/s

In the question, we have also been asked to recalculate for D = 100 mm and D = 125 mm.
For D = 100 mm:

Qx = 7.06 x 10-5 m3/s

Qmax = 9.517 x 10-5 m3/s
Pmax = 27.3 MPa
KS = 21.9 x 10-12 m5/Ns
p = 2.184 x 10-6 Pa
 Qx = 47.82 x 10-6 m3/s
For D = 125 mm:

Qx = 1.1 x 10-4 m3/s

Qmax = 1.4 x 10-4 m3/s
Pmax = 34.1 MPa
KS = 21.9 x 10-12 m5/Ns
p = 2.184 x 10-6 Pa
Qx = 47.82 x 10-6 m3/s
Table:
Diameter Qx (m3/s) Qmax (m3/s) Pmax (MPa)
75 mm 3.5 x 10-5 5.35 x 10-5 20.5
100 mm 7.06 x 10-5 9.517 x 10-5 27.3
125 mm 1.1 x 10-4 1.4 x 10-4 34.1

Trend of Diff erent Factors

60
Qmax Ks p Qx Pmax Q

50

40

30

20

10

0
70 80 90 100 110 120 130
Diameter D (mm)

Comments:
Factors such as Q, Qmax, and Pmax rise as shear viscosity is increased. The values of p, Ks, and
Qx, on the other hand, stay constant.
________________________________________________________________
 (Question 04)
Consider an extruder in which the barrel diameter = 4.5 in and length = 11 ft. The extruder screw
rotates at 60 rev/min; it has channel depth = 0.35 in and flight angle = 20°. The plastic melt has a
shear viscosity = 125 x 10-4 lb-sec/in2. Determine: (a) Qmax and pmax; (b) the shape factor Ks for
a circular die opening in which Dd = 0.312 in and Ld = 0.75 in; and (c) the values of Q and p at the
operating point.
Recalculate for shear viscosity value of 100 x 10-4 lb-sec/in2 and 150 x 10-4 lb-sec/in2. Discuss the
variation trends in the values of Q and p at operating points.

Analysis:
We’ve been given the following data:
D = 4.5 in
L = 11ft = 132in
N = 60 rev/min = 1 rev/s
dc = 0.35 in
A = 20°
Η = 125 x 10-4 lb.s/in2
Dd = 0.312 in
Ld = 0.75 in
And you've been asked to figure out what the Qmax and Pmax are. Also, for a circular die
opening with Dd = 0.312 in and Ld = 0.75 in, calculate the shape factor KS. At the operational
point, we must also calculate the values at Q and p. Then, for H = 100 x 10-4 lb-sec/in2 and 150
x 10-4 lb-sec/in2, recalculate.

Solution:
a) As we know that;
Qmax = 0.5π2D2 N dc cosθ sinθ = 0.5π2 (4.5)2 (1) (0.35) (sin20) (cos20)

Qmax = 11.24 in3/s

6 πηDNLcot ( A) 6 π ( 125 x 10−4 )( 4.5 ) (1 )( 132 ) cot 20
Pmax = =
dc 2 (0.35)2

Pmax = 3139 psi

π Dd4 π ( 0.312 )4
b) Ks = =
128 ηLd 128(125 x 10−4)(0.75)

KS = 0.0248 in5/lb-s
c) Before we can get Qx and p at the operating point, we need to recalculate the dye and extruder
characteristic equations for the assembly.
Dye Charasteristic:
Qx = Ks p
Qx = (0.0248) p

Extruder Characteristic:
Qmax
Qx = Qmax – ( Pmax )p
11.24
Qx = (11.24) – ( ¿p
3139
We will solve these both equations simultaneously to determine both Qx and p:

p = 396 psi
and
Qx = 9.82 in3/s

In the question, we have also been asked to recalculate for H = 100 x 10-4 lb-sec/in2 and H = 150
x 10-4 lb-sec/in2
For H = 100 x 10-4 lb-sec/in2:

Qmax = 11.24 in3/s

Pmax = 2511 psi
KS = 0.0310 in5/lb-s
p = 317 psi
Qx = 9.82 in3/s
For H = 150 x 10-4 lb-sec/in2:

*Qmax = 11.24 in3/s

Pmax = 3767 psi
KS = 0.0207 in5/lb-s
p = 475 psi
Qx = 9.82 in3/s
Graph:

Trend of Diff erent Factors

50
Qmax Ks p Pmax Qx
45

40

35

30

25

20

15

10

0
90 100 110 120 130 140 150 160
Shear viscosity H (*10-4 lb-sec/in2)

Comments:
Factors like p and Pmax rise when we increase the value of shear viscosity. Qmax and Qx do not
change. And the value of Ks steadily declines.
__________________________________________________________________