Faculty of Engineering and Applied Science

MANE 3190U: Manufacturing and Production Processes

Instructor: Dr. Sayyed Ali Hosseini

Assignment # 2
First Name: _________________

Last Name: ______________

Student ID: _________________

Section: _________________

Date Assigned:

Sunday, October 4th, 2015

Date Due:

Tuesday, October 13th, 2015, 3:30 PM (see the announcement)

Q1 (30)

Q2 (20)

Q3 (30)

Q4 (20)

Total (100)

Instructions for completion:

Clearly write your name and student number at the top of this title page and each solution
page.
Staple all solution pages to the title page of the assignment.
For the long answer questions, write out the entire solution (do not skip steps).
Any form of plagiarism will not be tolerated.
Late submissions will not be accepted.

Question #1
Answer the following questions based on the presented Cupper-Nickle binary phase diagram.

(a) What phase/phases can be observed at 60

1250 ?

At 60

at 1100 : Single phase solid

At 50

at 1270 : Two phases liquid + solid

at 1100 ? What about 35

at

(b) A certain Cupper-Nickle alloy contains 35 % Nickle. Determine the number of phases,
composition of each phase ( % of Nickle and cupper in solid and liquid phase) and % of
each phase ( % of liquid and % of solid) at the following temperatures, 1320 , 1190 ,
1250 ?
Solution #1:

At
35

1320 : Single phase liquid 100

and 65 % .

At
35

1190 : Single phase solid

and 65 %

100

, and the liquid phase contains

, and the solid phase contains

At
1250 : Two phases liquid + solid , and according to the intersections of the
tie line drawn in the exaggerated figure, the solid phase contains 43 %
and
57 % . The liquid phase contains 32 % and 68 % . In order to determine
how much of the mixture is solid and how much is the liquid, the lever rule must be used:
43
43

35
32

73

35
43

32
32

27

Question #2
A certain mold has a sprue whose length is 20 cm and the cross-sectional area at the base of the
. The sprue feeds a horizontal runner leading into a mold cavity whose volume is
sprue is 2.5
. Determine: (a) velocity of the molten metal at the base of the sprue, (b) volume rate of
1560
flow, and (c) time to fill the mold. (Neglect the height of pouring basin)

Solution #2:
(a) Considering the reference point at the top of sprue and downward direction positive, the
velocity of the flowing metal at the base of the sprue is:
2

9.81

0.2

1.981 /

(b) The volumetric flow rate is

2.5

10

1.981

(c) Time required to fill a mold cavity of 1560

1560

10

4.95

10

4.95

10

at this flow rate is

3.15

Question #3
A cylinder with a diameter of 2.0 in. and a height of 3 in. solidifies in three minutes in a sand
casting operation. What is the solidification time if the cylinder height is doubled? What is the
time if the diameter is doubled? Assume
2.
Solution #3:
The surface area of the cylinder is given by
2

and the volume is

1
we can evaluate the constant

as:

3
8

If the height is doubled, so that

2

21.33

6 ., then
2

14

so that from Chvorinov's rule, we have

which represents an increase of about 0.917
2

6
14

21.33

3.917

. If the diameter is doubled to 4 ., then

21.33

Thus, the solidification time increases by 4.678

20

12
12
20

7.678

Question #4
If an acceleration of 100 g is necessary to produce a part in true centrifugal casting and the part
has an inner diameter of 10 in., a mean outer diameter of 14 in., and a length of 25 ft., what
rotational speed is needed?
Solution #4:
The angular acceleration is given by
. Recognizing that the largest force is experienced
at the outside radius, this value for is used in the calculation:
100

3220 /

Therefore solving for

3220

3220

5

12

0.416

87.98

839.8