The document details the design project of a cylindrical liner focused on foundry engineering, outlining calculations for pattern dimensions, feeding systems, and gating design. Key figures include the total pattern length of 20.883 cm, feeder volume of 33.978 cm3, and a required cast mass of 3.1965 kg. Additionally, it addresses pouring time calculations, choke area specifications, and core print design, concluding with the final design considerations.

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