Solidification problems

1. In the casting of steel under certain mold conditions, the mold constant in Chvorinov's Rule is known to be 4.0 min/cm , based on previous experience. The casting is a flat plate whose length = 30 cm, width = 10 cm, and thickness = 20 mm. Determine how long it will take for the casting to solidify.
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Solution: Volume V = 30 x 10 x 2 = 600 cm

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Area A = 2(30 x 10 + 30 x 2 + 10 x 2) = 760 cm

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Chvorinovs Rule: TTS = Cm (V/A) = 4(600/760) = 2.49 min

2. A disk-shaped part is to be cast out of aluminum. The diameter of the disk D= 500 mm and 2 its thickness t= 20 mm. If the mold constant Cm = 2.0 sec/mm in Chvorinov's Rule, how long will it take the casting to solidify? Solution: Volume V = D t / 4 = (500) (20) / 4 = 3,926,991 mm
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Area A = 2 D / 4 + D t = (500) / 2 + (500) (20) = 424,115 mm

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Chvorinovs Rule: TTS = Cm (V/A) = 2 (3,926,991 / 424,115) = 171.5 s = 2.86 min

3. In casting experiments performed using a certain alloy and type of sand mold, it took 155 sec for a cube-shaped casting to solidify. The cube was 50 mm on a side. (a) Determine the value of the mold constant 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 D= 30 mm and length L= 50 mm.

Solution: (a) Volume V = (50) = 125,000 mm Area A = 6 x (50) = 15,000 mm

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(V/A) = 125,000 / 15,000 = 8.333 mm Cm = TTS / (V/A) = 155 / (8.333) = 2.232 s/mm
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(b) Cylindrical casting with D = 30 mm and L = 50 mm. Volume V = D L/4 = (30) (50) / 4 = 35,343 mm
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Area A = 2D / 4 + DL = (30) / 2 + (30)(50) = 6126 mm V/A = 35,343 / 6126 = 5.77 TTS = 2.232 (5.77) = 74.3 s = 1.24 min.
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