100 pieces of the aluminium component in Figure 2 below are to be cast. You have the choice between (i) lost foam sand casting and (ii) squeeze casting. a) Which one of the 2 casting processes would you select? Justify! b) Without completing any calculations and considering only the solidification sequence, estimate (1) the appropriate mould configuration by showing 2 views and (2) positions for the sprue and riser(s) if any? Illustrate and justify your methodology! c) State 1 potential defect you would expect and how you can prevent it? 150 mm 190 mm Constant thickness in third direction = 80 mm Figure 2 Material: Low carbon steel Following process parameters apply: Coefficient of friction = 0.6 (hot) = 0.15 (cold) K = 600 MPa; C = 300 MPa; n = 0.27; m = 0.13 Radius of rolls in rolling stand = 0.6 m Shear yield strength of low carbon steel = 110 MPa (hot) =320 MPa (cold) Tensile yield strength of low carbon steel = 210 MPa (hot) = 620 MPa (cold) Ultimate tensile strength of low carbon steel = 410 MPa (hot) Forging speed = 0.25 m/sec Roll surface speed = 1.2 m/sec Extrusion speed = 0.12 m/sec. Max. length of extruder = 5 m. a = 14 (for drawing) = 820 MPa (cold) OTaverage DEPARTMENT OF MECHANICAL ENGINEERING Q=K& n+1 m OT = CET In () L = R(ho-h) V hf A = LxW Fa average = C O yield 2 [6vin Close book Equations F = OTaverage* R *w* MF F = o*A*MF hfaverage = ho Aoriginal ET=In Afinal F average = 1.7* A* OTaverage V hfaverage A projected In hfaverage ho L Taverage (original)] Do m In (A) Aoriginal [0.8+1.2In (origina)] Afinal