PART. Q1! (a) The total solidification times of three casting shapes are to be compared: (1) a sphere, (2) acylinder, in which the LID ratio = 1.0, and (3) a cube. For all three geometries, the volume = 1000 cm?. The same casting alloy is used in the three cases. (i) Determine the relative solidification times for each geometry. (ii) Based on the results of part (i), which geometric element would make the best riser? (6) (b) Accylindrical riser must be designed for a sand-casting moukl. The casting itself is a stee! rectangular plate with dimensions 7.5 cm x 12.5 cm x20 cm. Total solidification time for this casting is 1.6 min and the cylinder for the riser will have a diameter-to- height ratio of 1. Determine the dimensions of the riser so that its total solidification time is 2 min. vo Ina sand mould, a sprue of 175 mm height is provided to maintain the flow rate of liquid at 1,000,000 mm*/s, What should be the area at the base ofdown sprue to prevent aspiration of molten metal? The value of g = 9815 mm/s* (6) (b) Make a curve showing qualitatively the relationship between the green permeability and the percentage of water content with different compactness of 3, 6 and 10 rams. [4] Q3 G@) A cylindrical bar with 200 mm diameter is being turned with a tool with geometr (0° 99-790 15°-30°-0.5 mm (ASA). If the tool geometry is changed to 0°-9°-7°-8”-15- 0°-0.5 mm (ASA) and all other parameters remain unchanged, what will be the expected percentage change in the cutting component of the machining force? Indicate whether it will increase or decrease. {6] (®) A cast iron block of 200 mm length is being shaped in a shaping machine with a depth of cut of 4 mm, feed = 0.25 mnvstroke, principal cutting edge angk = 30°. If the operation is performed with 60 strokes/min, what will be the average power consumption in Watt? Specific energy coefficient for cast iron is 0.81 J/mm?. {6} Q.4 (@) The cutting force and thrust force in an orthogonal cutting operation are: Fe = 1470 N and Ft=1589 N. The rake angle = 5°, the width of the cut= 5,0 mm, the chip thickness before the cut =0.6 mm, and the chip thickness ratio = 0.38, Determine (i) the shear strength of the work material and (ii) the coefficient of friction in the operation. [6] (6) In a surface grinding operation performed on hardened plain carbon steel, the grinding wheel has a diameter = 200 mm and width = 25 mm. The wheel rotates at 2400 rev/min, with a depth of cut (infeed) = 0.05 mm/pass and a cross-feed = 3.50 mm. ‘The reciprocating speed of the work is 6m/min, and the operation is performed dry. ermine: (i) the length of contact between the wheel and the work, (ii) the volume of metal removed. (iii) If C = 0.64 active grits/mm?,estimate the number of chips per unit time. (iv) What is the average volume per chip? 07]