Bangladesh University of Engineering and Technology

Experiment Number: 08

Experiment Name: Effect of casting shape and solidification time

Date of Performance: 20/2/2023

Date of Submission: 01/3/2023

Name: Md. Masuma Akther Lovely

Student ID: 1811016

Level/Term: 3/2

Department: MME

Group: A3
Objective:

The objective of this experiment is

1. To understand the variable affecting solidification

2. To understand the importance and limitations of Chvorinov’sRule for predicting the

solidification time of a casting.

Introduction:

Casting shape and size can have a significant effect on the solidification time of casting. The
solidification time, which is the amount of time needed for molten metal to solidify entirely, is
dependent on a number of elements, such as the casting's size, shape, etc.

The amount of superheat and the volume of the casting, or the quantity of metal in the casting, are
directly proportional to the amount of heat that must be removed from the casting in order for it to
solidify. On the other hand, the quantity of exposed surface area through which the heat can be
extracted and the insulating quality of the mould are both directly related to the ability to remove
heat from a casting. Chvorinov's Rule, which says that tr, the total solidification time, can be
calculated by

𝑽
tf = 𝑪( )𝒏
𝑨

Here,

V = Volume of casting

A = Surface area

n = Constant (varies from 1.5 to 2)

C = Mould constant (depends on the characteristics of the metal being cast, the mould material,
the mould thickness, and the amount of superheat)

𝑉
Modulus=
𝐴
Therefore, if the values of either C or modulus change, the solidification period may also change.
C is based on how the mold is shaped. The constant C needs to be adjusted when the shape of the
casting changes. Besides that, the modulus is susceptible to changes in both form and size.

Chvorinov's Rule has certain limitations as it is an application of a one-dimensional analytical

model into a three-dimensional actual casting. To overcome those limitations some assumptions
are made such as,

• No superheat.

• Liquid metal can be pure metal or eutectic alloy.

• Temperature of mould/metal interface is constant.

• Physical constants of the metal and mould are not affected by temperature.

The shape of the cast:

Dimension of Casting (D=Diameter, H=Height, L=Length. W=Width, T=Thickness)

Sphere Sphere Cylinder Block

D D Length×Dia Lx WxT

mm mm mm mm

100 120 100× 93 200×85×40

Experiment Procedure:

1. Moulds were prepared using the bottom/side pouring CO2 process or greensand
moulding process days in advance.
 2. One K-type thermocouple tip was inserted at the center of the mould cavity to record
the temperature of the solidifying casting.

3. Required amount of materials was melted using a crucible/induction furnace and pour
the liquid into the mould at about 1200 °C.

4. Temperature of the solidifying casting was recorded at an interval of 10 second until

the temperature of the casting is decreased to 800 C.

Result:
Data Table for solidification time:

Shape Volume Surface Area (V/A) Ratio Solidification Time (s)

(cc) (cm2)
Cylinder 680 428.03 1.59 620
Block 680 568.00 1.20 370
Ball 523.60 314.16 1.67 260
Ball 904.70 452.39 2.00 540
Discussion:

1. Effect of casting volume on the solidification time

According to the graph, increasing volume will result in a longer solidification time for a given
shape, which is consistent with our theoretical understanding. And the relation between
solidification time and volume is

Y= 0.7347X – 124.7

Here,

Y= solidification time

X= Volume of casting
 2. Effect of surface area of the casting on the solidification time.

The graph shows that, for a given shape, a rise in surface area results in a longer solidification
time. Additionally, a larger surface area reduces the time needed for solidification for a given
amount. This is due to the fact that casting has more exposed surface area where heat can be
extracted when surface area is increased while maintaining a consistent volume. The cast will also
be thinner. Cast will solidify quicker as a consequence. However, for the same shape, adding
surface area will make the cast more shaped, which results in a longer solidification time.

Relation between solidification time and surface area;

For same shape, y= 2.026x- 376.4

For same volume, y= 1.786x+1384

Here,

Y= solidification time

X= Surface area of casting

3. Effect of volume/surface area ratio on the solidification time.

𝑽
From the Chvorinov’s Rule it is known that tf = 𝑪( )𝒏
𝑨
 𝑉𝑜𝑙𝑢𝑚𝑒
So increasing ratio will always result in increase in solidification time as value of n is
𝐴𝑟𝑒𝑎

generally in the range of 1.5-2. From the graph we can see that, our experimental data follows
theoretical knowledge.

𝑉𝑜𝑙𝑢𝑚𝑒
Relation between solidification time and ratio;
𝐴𝑟𝑒𝑎

For same shape, y= 420x- 1140

For same volume, y= 638.6x-394.5

Here,

Y= solidification time

𝑉𝑜𝑙𝑢𝑚𝑒
X= ratio of casting
𝐴𝑟𝑒𝑎

4. Combined expression for the Chvorinov's Rule and determining the constants.

We know that,

𝑉 𝑛
𝑡𝑓 = 𝑐 ( )
𝐴

𝑉
Hence, 𝑙𝑛𝑡𝑓 = 𝑙𝑛𝑐 + 𝑛𝑙𝑛
𝐴

For sphere of same shape,

Volume (cc) tf (sec) Volume / Area

523.7 260 1.67
904.7 540 2.00
 ln(260) = 𝑙𝑛𝑐 + 𝑛𝑙𝑛(1.67) … … … … (1)

ln(540) = 𝑙𝑛𝑐 + 𝑛𝑙𝑛(2.00) … … … … … (2)

By solving equation 1 and 2;

n = 4.05

c = 32.84

𝑉 4.05
𝑡𝑓 = 32.84 ( )
𝐴