1.

It is required to produce the given tail stock by sand casting process from cast iron
material (GG20).
 Draw the casting drawing.
 Draw the pattern drawing.
 Draw the core only if it is required.
 Draw the assembly of the flask to illustrate the gating system and the
location of riser if it is required.
 State the suitable molding sand.
 Calculate the gating system if S=2.3, W casting=18 Kg, and µ=0.6.
 Pattern material:
- Assume Q < 500 Pieces Using wooden pattern (Split Pattern)

 Pattern Allowances:
- Machining allowance
1) At Z1= 52 & S1= 90 ( up= 5 ) , ( down=3.5 ≈ 5 )
2) At Z2,3= 52 & S2,3= 90 ( up= 5 ) , ( down=3.5 )
3) At Z4,5 (The slot width < 20 mm so it will be machined after casting)
4) At Z6= 25 & S6= 240 ( up= 5 ) , ( down=3.5 )
5) At Z7= 50 & S7= 60 ( up= 4.5 ) , ( down=3 ≈ 4.5 )

- Shrinkage allowance
For GG20 Pearlite C.I (Disabled shrinkage allowance = 0.9)

- Draft allowance
1) At H1=45 α =1° 30ʹ a = 1 mm
2) At H2,3=50 α =1° 30ʹ a = 1 mm
3) At H1=35 α =1° 30ʹ a = 1 mm

 Core Print dimension

- First we must add the machining allowance to main dimension
d1 =41 (L2=45 a1=1 a2=1.5 α =4)
d2 =180 (L2=90 a1=1.5 a2=2 α =4)
 Riser Calculations

𝜋
(Vfl) 1, 3= 4 ∗ 152 ∗ (30 + 10) + 70 ∗ 30 ∗ (30 + 10) = 91.1 𝑐𝑚3
100 s 100 6
(VR) 1, 3= (Vfl)1,3 ∗ ∗ 100 = 91.1 ∗ ∗ 100 = 54.66 𝑐𝑚3
c 10
2 𝜋 3 𝜋
(VR) 1, 3= 54.66 = 4 D1,3 ∗ 𝑙 = 2 D1,3 l = 2D
3 2∗54.66
D 1, 3= √ =3.3 cm=33 mm
𝜋 D D1 D2 V B r
From table (2-20) At D 1, 3=35 35 45 65 175 25 6
𝜋 𝜋
(VR) 1, 3 Standard = 4 D12 ∗ 𝑣 = 4 ∗ 4.52 ∗ 17.5=278.3 𝑐𝑚3

𝜋
(Vfl) 2= 4 (902 − 412 )(62 + 5) = 337.8 𝑐𝑚3
100 s 100 6
(VR) 2= (Vfl)1,3 ∗ ∗ 100 = 91.1 ∗ ∗ 100 = 54.66 𝑐𝑚3
c 10
𝜋 𝜋
(VR) 2= 202.68 = 4 D22 ∗ 𝑙 = 2 D32 l = 2D
3 2∗202.68
D 2= √ =5 cm=50 mm D D1 D2 V B r
𝜋
From table (2-20) At D 2=50 50 60 80 175 25 6
𝜋 𝜋
(VR) 2 Standard = 4 D12 ∗ 𝑣 = 4 ∗ 62 ∗ 17.5=494.8 𝑐𝑚3

G Riser = [2 ∗ V 𝑅 1,3 Standard + V 𝑅 2 Standard ] ∗ 𝜌 = [2 ∗ 278.3 + 494.8] ∗ 7.25 = 7.6 𝑘𝑔

 Total Casting Weight Calculations

G Gross = (1.15 − 1.4)(GRiser + GCasting ) = (1.4)(7.6 + 18) = 35.84 𝑘𝑔
From table (2-9) At G Gross =35.84 kg
a b c d e f
2∗70+100 70 70 50 50 60 90
H= = 120 𝑚𝑚
2
W = 87 + 45 + 90 + 100 = 322 𝑚𝑚
L = 100 + 50 + 240 = 390 𝑚𝑚

From table (2-10) H standard = 125

W standard = 350
L standard = 400
 Gating System Calculations

- Cast iron is pressurized system so (Fz:Fr:Fs = 1:1.2:1.4) (F=Fz)

1000 𝐺𝑔𝑟𝑜𝑠𝑠
F=
τ.μ.γ.√2𝑔.ℎ𝑝
- Sprue time (τ)
τ = 𝑠√𝐺𝑔𝑟𝑜𝑠𝑠 = 2.3√35.84 = 13.7 𝑠𝑒𝑐 ≈ 14 sec
- Static Pressure Head (hp)
𝑃2 (50)2
hp =𝐻 − 2𝑐 = 125 − 2∗100 = 112.5 𝑚𝑚
1000∗35.84 𝐹𝑧 1.25
⸫ Fz = 14∗0.6∗7.25∗√2∗981∗112 = 1.25 𝑐𝑚3 ⸫ Fz/ingate = No. = = 0.625 𝑐𝑚3
of ingate 2
𝐹𝑟 1.50
& Fr =1.50 𝑐𝑚3 ⸫ Fr/runner = No. = = 0.75 𝑐𝑚3
of runner 2
⸫ Fs =1.75 𝑐𝑚3
From table (2-14)
Fz/ingate a b c Fr/runner a b c Fs d
0.63 14 9 5.5 0.80 16 10 6 1.80 15
Fs d L D1
Or From table (2-15)
2 16 200 20

 Pouring Cup
4 𝐺𝑔𝑟𝑜𝑠𝑠 5 4 35.84 5
- v = 400 √( ) = 400 √( ) = 1295.3 𝑐𝑚3
𝜏 14
From table (2-16)
v L b h r1 r2 r3
1300 180 110 100 55 44 33