3.

1 Mathematical Calculations:
Two kinds of mathematical calculations have been carried
out during casting in order to achieve the quality.
1. Mathematical calculations for pure elements.
2. Mathematical calculations for recycled material / scrap.
A computer program can be design in order to get the results
quickly.
These two calculations are interrelated if we use scrap.
Note:
The input variables are in red colour.
The output variables are blue in colour.
The variables used by the calculations itself and not to be needed
by us to see! are coloured as green.
"ariables are in the form of A! #! $%&eries.
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3.1.1 Mathematical calculations for pure elements:
Casting Batch = 10 kg. - X kg.
Part 1.
Element %age reuire!
"#-series$
#mount in X kg.
" #%100 ) X $ = B kg
&i 1*+ A1 1.* #1
,i 1.-.+ A2 /.1-. #2
Ti /.-+ A( /./- #(
Mn /...+ A- /./.. #-
Mg 1.(+ A. /.1( #.
$r /.'+ A' /./' #'
0e /.*.+ A* /./*. #*
Part 2.
#l-
master
allo&s
%age of
elements
in master
allo&s.
"C-'eries$
(euire! %ages )eight of
master
allo&s to
*e a!!e!
"100%C)+$
= E gms
)eight of
#l in these
allo&s.
E , + =
- gms
.g
B1
gms
"B)1000$=+
&i ./+ $1 1.* 1*// 21 (-// 31 1*//
,i 1/+ $2 /.1-. 1-. 22 1-./ 32 1(/.
Ti 1/+ $( /./- -/ 2( -// 3( ('/
Mn ./+ $- /./.. .. 2- 11/ 3- ..
Mg ./+ $. /.1( 1(/ 2. 2'/ 3. 1(/
$r 4/+ $' /./' '/ 2' *. 3' 1.
0e 4/+ $* /./*. *. 2* 5(.*. 3* 14.*.
(.4(.*.60
'-
The amount of aluminium which is obtained in the above
calculations is the amount of aluminium which is being added with
the master alloys so this much amount of aluminium is already
available with the master alloys so in order to make a 78kg91/ kg
batch this much amount must be subtracted from 78kg91/ kg and
the weight of all the added elements must also be subtracted from
the 78kg91/ kg and the remaining weight is the weight of the pure
aluminium to be added to make a 78kg91/ kg batch.
3.1./ Mathematical calculations for rec&cle!
Material % 'crap:
:hen the scrap is treated then the calculations are done according
to the following steps.
1. Take the sample from the crucible in a die of required
dimensions! analyse it! and get the percentages of the
elements present in it.
2. Minus this percentages from the Aseries and keep the results
as Aseries.
7:e can design a computer program for this which is same as
above but with some changes which is being done in the first
column i.e. a small difference table in the first column.9
(. After step no. 2 calculation! we get aluminium amount that is
being added with the added elements.
-. ,ow we add elements for this pure aluminium.
.. ;n order to do that we make calculations in the same manner
as did for the pure elements. $ertain points should be kept in
mind i.e. in batch place 789 we put the obtained aluminium
percentage and then we go for calculations and also keep
the percentages of the elements according to the standards or
literature i.e. Aseries.
'. Add the 3series obtained by this in the previous 3series so
that we get the amount of added components collectively.
7Modifications in the computer program can be done to do that9
'.
*. <ere again we get a small amount of aluminium which is
againbeing added with the added elements.
4. :e go for repeatedly calculations for the pure elements as
done in the step nos. . and '! until we get a very small
amount of aluminium.
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