This is a casting design of a cylindrical liner. the design includes pattern making, feeder design, gate, and sprue runner design at last core design.

1. Cylindrical liner
Presented by
Hridoy Saha
1611042
Design project
MME-346 Foundry Engineering Sessional

3. Pattern Design
Length,
Contraction allowances For grey iron =
8
1000
∗ 20.32cm =0.1626cm
Machining allowances For grey iron = 4mm=.4cm
Total length of pattern =20.32+.4+.1626=20.883cm
Diameter ,
Contraction allowances For grey iron = (
8
1000
∗ 7.62cm) =0.061cm
Machining allowances For grey iron = 3mm=.3cm
Total Diameter of pattern =7.62+.3+.061=7.98cm

4. Taper allowance = 1 degree
In the figure, a= Do tan(1) = .1253cm
Thus, L2 = L1 – 2a = 20.88 – 2(0.1253) = 20.62cm

5. 3D model of the pattern 2D model of the pattern

6. Feeding System:
Freezing time criteria:
Casting volume, Vc = 283.14cm3
Modulus of casting, Mc =TH/2(T+H)
=.3078cm
Modulus of feeder, Mf = 1.33×Mc =.40014
For cylindrical feeder H=1.5D
MF=3D/16
D= =2.13408cm
H=3.20112cm
Volume of the feeder Vf=11.450 cm3

7. Volume criterion
For white pure Al solidification shrinkage, α = 1.5%
The efficiency of the feeder, € = 0.14
Volume of the feeder = α *Vc / (€-α)
= {(1.5/100)/(.14-.015)}*283.14 cm3
=33.978 cm3
Here, feeder volume is greater for volume criterion so volume criteria is
dominating.
Feeder diameter Vf=33.978 cm3

8. 3D model of the feeder 2D model of the feeder

9. The gating design
The volume of the cast piece= 283.14 cm3
The feeder volume from the volume criterion is, 33.978 cm3
Total volume of the cast= 283.14+33.978 cm3= 317.118 cm3
the mass required for the cast is= 2.28324 kg
Considering extra 40 % weight to allow shrinkage the modified weight will
be= 3.1965 kg

10. Pouring time:
For the calculation of pouring time of cast iron, the equation is, pouring time, t= SW.5
For the wall thickness of around 6.3mm the co-efficient S= 1.85
Then, the pouring time, t=3.3076 sec
Pouring rate
The pouring rate will be = weight/ pouring time= 3.1965/3.3076= 0.9664 kgs-1
To get the accurate pouring time the correction factor has to be considered.
Here, corrected pouring rate, Ra= R/kf = 1.07382 kg/sec
Choke area calculation:
Hence the choke area will be, 𝐴 𝑐 =
𝑊
𝜌𝑡𝑐 2𝑔ℎ 𝑝
= 92.827 mm2

11. From the basic assumption, the choke area = the sprue bottom area
= 10.87 mm φ
So, sprue top area, (considering the allowance of 15%)
A1=177.41 mm2= 15.02 mm φ
So, considering the gating ratio of 1:2:4
Runner area = 2* sprue bottom area= 92.827*2=185.654 mm2 = 15.3747 mm φ
Gate area= 2* runner area = 185.654*2 mm2 = 371.308 mm2
Considering the inclusion of 2 gates,
Area per gate= total gate area/2= 371.308/2= 185.654 mm2
Gate dimensions= 15.3747 mm φ
Sprue runner gate

12. Sprue in 3D
Sprue in 2D
Runner in 3D
Runner in 2D

13. Design of the core
Core buoyancy = (3.1416/4) *Di
2 *L (r1- r2)
= 3.94kg
Using factor of safety, compressive strength of core print
(2.0/5) kg/cm2 = (F/A) = 3.94 kg / (2aDi) cm2
Length of core print in each side, a = 0.7755cm
Core print area = 2aDi = 2 (.7755 cm) (6.35 cm) = 9.84 cm2
Chaplet Area
The maximum permissible length of core print, a = 15 mm
Core print support = (Strength of core / Factor of safety) x core print area (2aDi)= 18 kg
So there is no unsupported load as our buoyancy force is less than 18kg No chaplet needed

14. Core in 3D
Core in 2D
Core in a pattern

15. The final design