Casting Project

• Design the process sheet for producing the shown Aluminum component. The design should include the following:

• Design the wooden pattern by calculates the changes in the nominal dimensions of the shown Aluminum component due to adding the machinging allowances (all the surfaces of the part should be machined), shrinkage allowances and drafting allowances.

• Design the gating system: calculate the spree dimensions that verify suitable volumetric flow rate, minimum time to fill the mold and laminar flow ( 0 < R₀ < 2000).

• Design the risers to solidify last by having its volume-to-area (V/A) ratio larg compared with the main casting.

• Design the mold and calculate the required weight that should be used to prevent the buoyancy force from lifting the upper flask.

• Sketch the wood pattern for producing the shown Aluminum component using sand casting process.

• Write with the aid of sketches the process sheet table for the shown metal sand casting component.