Assignment 1

1. What is cast-ability?
How to compare different material cast-

ability?
Answer: Cast-ability is the case of Forming a quality casting. A very
cast-able part design is easily developed, incurs minimal tooling costs,
requires minimal energy and has few rejections.
Cast-ability can refer to a part design or a material property. we can also
compare different types of materials by its pouring temperature, fluidity,
solidification, shrinkage, slag/dross formation, tendencies.
2. Why are steels more difficult to cast then cast iron?
Answer: Steel is more difficult cost than cast iron because it has higher
melting point and greater shrinkage rate, which requires consideration
during mold design. Steel costing is specialized form of costing
involving various types of steel. Steel casting are used when cast iron
can’t deliver enough strength or shock resistance. This explains the
reason why steel is more difficult to casting.
3. What is shrinkage allowance? What is machining allowance?
Answer:
Shrinkage allowance: It is defined in DIN EN 12890 ENT specifies
the difference in length of cast partscasting mold and casting. Shrinkage
depends on the type of casting materials and its stability.
Machining allowance: It is referred to required on surface to be
machine in order to remove casting related inclusion in the casting skin
or due to effects of surface roughness.
4. What is the difference between Machining allowance and

dimensional tolerance?
Answer: Difference between machine allowance and dimensional
tolerance is as below:
Machining allowance is the prescribed differencebetween the
dimensions of show casting parts like hole and shaft.
Dimensional is the permissible variation in dimension of the part (hole
and shaft).
Machining allowance may be positive in clearance and negative in
inference.
Dimensional tolerance has an absolute value without a sign.
5. Describe the general design consideration pertaining of
metalcasting.
Answer: Design consideration pertaining of metal casting are given
below:
Design the parts of that the shape is cast easily.
Then selecta casting process and material suitable for the part, size,
mechanical properties etc.
Locate the parting line who is the mold in the part.
Then locate and design the gates to allow uniform feeding of the mold
cavity with molten metal.
Then select appropriate summer geometry for the system.
Finally locate Mall feature such as spare, screen and risers.
And be sure about proper control and good practice in place.
6. List casting process that are suitable for making hollow parts
with.
Answer: 1) Complex external features, 2) Complex internal features,
or 3) Both features.
This depends totally on the size of the part under consideration and the
materials used. Complex features are always difficult to cast, sometimes
they can be accommodated. For Example : the external features.
Within limit, plate can create intricate pattern in a sand mold, so sand
casting should be suitable. best man casting can utilize any pattern that
allow a metal to flow into and feel in the cavity.
Shell molding has similar abilities as sand casting with respect to
external features.
Die casting can produce complex feature as long as they don’t interfere
with ejection of parts from the dies.
Internal features are more difficult than possible one’s.
In sand casting, a core with complex features can be used when
necessary and investment casting internal feature can be produced as
long as they can be reproduced on the pattern.
An incorrect and correct design for casting are shown below.
Review the changes made and comment on their advantage.
The main advantage of the new part is that it can be easily cast without
using an external care. Original part requires two such pairs because the
shape is such that it cannot be of change in a sand mold without using
core
For the cast metal wheel illustrated in figure P3.31, Show how (a)
riser replacement ; (b) care replacement; (c) padding; (d) chills may
be used to help feed molten metal and eliminate porosity in the
isolated hub boss.
Solution:
Three sets of die casting shown. Note the changes made to designand
comment on the reasons for them.
There are many observationusuallywith the intent of minimizing
changes in section thickness ,eliminating inclined surface to simplify
mold construction, and to orient flanges so that they can be easily cast.
The blank of the spool shown in fig. An aluminum casting alloy.
Make a sketch of the wooden pattern of this part, and include
necessary allowances for shrinkage and machining.
Wooden pattern for the part:
The cope mold must be heavy enough or be weighted sufficiently to

keep it from floating when the molten is powered into the mold. The
force f , on the cope is exerted by the metallost pressure.(caused by the
metal in the cope and the parting line) and he can be calculated by this
formula, F=Pa.

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1. What is cast-ability?

How to compare different material cast-

4. What is the difference between Machining allowance and

The cope mold must be heavy enough or be weighted sufficiently to

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