QUIZ MS203
Casting and Flow Stress
Lucas Montogue
PROBLEMS - CASTING
▐ Problem 1
In the casting of steel under certain mold conditions, the mold constant in
Chvorinov’s rule is known to be 4.0 min/cm², based on previous experience. The
casting is a flat plate with length = 30 cm, width = 10 cm and thickness = 20 mm.
Determine how long it will take for the casting to solidify.
A) 𝑡𝑡𝑆𝑆 = 1.33 min.
B) 𝑡𝑡𝑆𝑆 = 2.49 min.
C) 𝑡𝑡𝑆𝑆 = 3.61 min.
D) 𝑡𝑡𝑆𝑆 = 4.80 min.
▐ Problem 2
A rectangular casting having the dimensions 3 cm × 5 cm × 10 cm
solidifies completely in 12 minutes. Compute the mold constant.
A) 𝐵𝐵 = 10.1 min/cm²
B) 𝐵𝐵 = 14.5 min/cm²
C) 𝐵𝐵 = 19.3 min/cm²
D) 𝐵𝐵 = 22.2 min/cm²
▐ Problem 3 (Groover, 2013)
Total solidification times of three casting geometries are to be compared:
(1) a sphere with diameter 10 cm; (2) a cylinder with diameter and length both 10
cm; and (3) a cube with side 10 cm. The same casting alloy is used in all three cases.
Which geometry would completely solidify faster?
A) The sphere.
B) The cylinder.
C) The cube.
D) None of the above.
▐ Problem 4 (Groover, 2013)
A riser in the shape of a sphere is to be designed for a sand casting mold.
The casting is a rectangular plate with length = 200 mm, width = 100 mm, and
thickness = 18 mm. If the total solidification time of the casting itself is known to
be 3.5 min, determine the diameter of the riser so that it will take 25% longer for
the riser to solidify.
A) 𝐷𝐷 = 34.4 mm
B) 𝐷𝐷 = 47.5 mm
C) 𝐷𝐷 = 59.6 mm
D) 𝐷𝐷 = 67.4 mm
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▐ Problem 5 (Groover, 2013)
A steel casting has a cylindrical geometry with 4.0 in. diameter and weighs
20 lb. The casting takes 6.0 min to completely solidify. Another cylindrical-shaped
casting with the same diameter-to-length ratio weighs 12 lb. This casting is made
of the same steel, and the same conditions of mold and pouring were used. The
density of steel = 490 lb/ft³. True or false?
1.( ) The mold constant for either casting is greater than 10 min/in.²
2.( ) The lighter casting has diameter greater than 3.5 in. and length greater than 5 in.
3.( ) The solidification time for the lighter casting is greater than 5 minutes.
PROBLEMS – FLOW STRESS
▐ Problem 6
The strength coefficient = 550 MPa and strain-hardening exponent = 0.22
for a certain metal. During a forming operation, the final true strain that the metal
experiences = 0.85. Determine the flow stress at this strain and the average flow
stress that the metal experienced during the operation.
A) 𝜎𝜎𝑓𝑓 = 531 MPa and 𝜎𝜎�𝑓𝑓 = 341 MPa
B) 𝜎𝜎𝑓𝑓 = 531 MPa and 𝜎𝜎�𝑓𝑓 = 435 MPa
C) 𝜎𝜎𝑓𝑓 = 572 MPa and 𝜎𝜎�𝑓𝑓 = 341 MPa
D) 𝜎𝜎𝑓𝑓 = 572 MPa and 𝜎𝜎�𝑓𝑓 = 435 MPa
▐ Problem 7
A metal has a flow curve with strength coefficient = 850 MPa and strain-
hardening exponent = 0.30. A tensile specimen of the metal with gage length =
100 mm is stretched to a length = 157 mm. Determine the flow stress at the new
length and the average flow stress that the metal has been subjected to during the
deformation.
A) 𝜎𝜎𝑓𝑓 = 669 MPa and 𝜎𝜎�𝑓𝑓 = 515 MPa
B) 𝜎𝜎𝑓𝑓 = 669 MPa and 𝜎𝜎�𝑓𝑓 = 581 MPa
C) 𝜎𝜎𝑓𝑓 = 731 MPa and 𝜎𝜎�𝑓𝑓 = 515 MPa
D) 𝜎𝜎𝑓𝑓 = 731 MPa and 𝜎𝜎�𝑓𝑓 = 581 MPa
▐ Problem 8 (Creese, 1999)
The strength coefficient = 35,000 lb/in.² and strain-hardening exponent =
0.40 for a metal used in the forming operation in which the workpart is reduced in
cross-sectional area by stretching. If the average flow stress on the part is 20,000
lb/in.², determine the amount of reduction in cross-sectional area experienced by
the part. In the following answers, 𝐴𝐴𝑜𝑜 and 𝐴𝐴𝑓𝑓 denote initial and final cross-sectional
area, respectively.
A) 𝐴𝐴𝑓𝑓 = 0.331𝐴𝐴𝑜𝑜
B) 𝐴𝐴𝑓𝑓 = 0.442𝐴𝐴𝑜𝑜
C) 𝐴𝐴𝑓𝑓 = 0.565𝐴𝐴𝑜𝑜
D) 𝐴𝐴𝑓𝑓 = 0.689𝐴𝐴𝑜𝑜
▐ Problem 9 (Groover, 2013)
Determine the value of the strain-hardening exponent for a metal that will
cause the average flow stress to be 3/4 of the final flow stress after deformation.
A) 𝑛𝑛 = 0.143
B) 𝑛𝑛 = 0.215
C) 𝑛𝑛 = 0.333
D) 𝑛𝑛 = 0.416
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▐ Problem 10 (Groover, 2013)
In a tensile test, two pairs of values of stress and strain were measured for
the specimen metal after it had yielded: (1) true stress = 217 MPa and true strain =
0.35, and (2) true stress = 259 MPa and true strain = 0.68. Based on these data
points, determine the strength coefficient and the strain-hardening exponent.
A) 𝐾𝐾 = 201 MPa and 𝑛𝑛 = 0.135
B) 𝐾𝐾 = 201 MPa and 𝑛𝑛 = 0.271
C) 𝐾𝐾 = 290 MPa and 𝑛𝑛 = 0.135
D) 𝐾𝐾 = 290 MPa and 𝑛𝑛 = 0.271
SOLUTIONS
P.1 ■ Solution
The volume of the casting is 𝑉𝑉 =30×10×2 = 600 cm³ and the surface area
is 𝐴𝐴 = 2(30×10 + 30×2 + 10×2) = 760 cm². Appealing to Chvorinov’s rule, we
obtain
2 2
V 600
tS =
B =4.0 × 2.49 min
=
A 760
The casting should require about 2 and a half minutes to solidify.
♦ The correct answer is B.
P.2 ■ Solution
The surface area of the casting is 𝐴𝐴 = 2(3×5 + 5×10 + 3×10) = 190 cm²
and the volume is 𝑉𝑉 = 3×5×10 = 150 cm³. The solidification time is 12 min. The
mold constant can be established by substituting these data in Chvorinov’s rule,
namely
2 2
V 150
tS =B → 12 =B ×
A 190
∴12 = B × 0.623
19.3 min/cm 2
∴ B=
♦ The correct answer is C.
P.3 ■ Solution
For the sphere, the volume is 𝑉𝑉1 = 4𝜋𝜋𝑅𝑅3/3 = 4𝜋𝜋 × 53/3 = 524 cm3 and the
surface area is 𝐴𝐴1 = 4𝜋𝜋𝑅𝑅 2 = 4𝜋𝜋 × 5² = 314 cm². The time required for solidification
is calculated to be
n 2
V 524
tS ,1 =B 1 → tS ,1 =B ×
A1 314
2.78 B
∴ tS ,1 =
For the cylinder, the volume is 𝑉𝑉2 = 𝜋𝜋𝑅𝑅2 𝐿𝐿 = 𝜋𝜋 × 52 ×10 = 785 cm3 and the
surface area is 𝐴𝐴2 = 2𝜋𝜋𝑅𝑅 2 + 2𝜋𝜋𝜋𝜋𝜋𝜋 = 2× 𝜋𝜋 × 5² + 2𝜋𝜋 × 5 × 10 = 471 cm². The time
required for solidification is then
n 2
V 785
tS ,2 =B 2 → tS ,2 =B ×
A2 471
2.78 B
∴ tS ,2 =
For the cube, the volume is 𝑉𝑉3 = 𝐿𝐿3 = 10³ = 1000 cm³ and the surface area
is 𝐴𝐴3 = 6𝐿𝐿2 = 6×10² = 600 cm². The time required for solidification follows as
n 2
V 1000
tS ,3 =B 3 → tS ,3 =B ×
A3 600
2.78 B
∴ tS ,3 =
3
© 2020 Montogue Quiz
Given that 𝐵𝐵 is the same for all cases, we conclude that the solidification
time will be approximately the same for all three geometries.
♦ The correct answer is D.
P.4 ■ Solution
The casting volume is 𝑉𝑉 = 200×100×18 = 360,000 mm³ and the surface
area is 𝐴𝐴 = 2(200×100 + 200×18 + 100×18) = 50,800 mm². Given the
solidification time 𝑡𝑡𝑆𝑆 = 3.5 min for the casting, we can easily determine the mold
constant,
2 2
V A
tS = B → B = tS ×
A V
2
50,800 2
∴ B = 3.5 × = 0.0697 min/mm
360, 000
Now, the riser volume is 𝑉𝑉 = 𝜋𝜋𝜋𝜋³/6 = 0.524𝐷𝐷³ and the surface area 𝐴𝐴 =
𝜋𝜋𝜋𝜋² = 3.14𝐷𝐷², so that 𝑉𝑉/𝐴𝐴 = 0.524𝐷𝐷³/3.14𝐷𝐷² = 0.167𝐷𝐷. Appealing to Chvorinov’s
rule again, we have
2
V
= 0.0697 × ( 0.167 D )
2
t=
S B → 1.25 × 3.5
A
0.00194 D 2
∴ 4.38 =
47.5 mm
∴ D=
♦ The correct answer is B.
P.5 ■ Solution
1.True. The density of steel is 𝜌𝜌 = 490/123 = 0.284 lb/in.³ The volume of
the casting follows as
m m
ρ= →V =
V ρ
20
V
∴= = 70.4 in.³
0.284
Equipped with 𝑉𝑉, we can determine the length 𝐿𝐿 of the casting,
π D2 L 4V
V
= L
→=
4 π D2
4 × 70.4
∴L
= = 5.60 in.
π × 4.02
The surface area is determined next,
2π D 2 2π × 4.02
A
= + π DL
= + π × 4.0 × 5.60
= 95.5 in.²
4 4
We now have all the information necessary to determine the mold constant
𝐵𝐵,
2 2
V A
tS = B → B = tS ×
A V
2
95.5 2
∴ B = 6.0 × = 11.0 min/in.
70.4
2.False. We first require the volume of the lighter casting. Since weight is
proportional to volume, we can write
V1 V2 V
= → V2 = W2 × 1
W1 W2 W1
70.4
∴V2 = 12 × = 42.2 in.3
20
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We were told that the lighter casting has the same diameter-to-length
ratio as the heavier one, namely
D1 4.0
= = 0.714
L1 5.60
This means that the relation 𝐷𝐷2 = 0.714𝐿𝐿2 , or, equivalently, 𝐿𝐿2 = 1.40𝐷𝐷2
holds for the lighter casting. Thus,
π D22 L2 π D22 ×1.40 D2
V2
= V2
→=
4 4
0.35π D23
∴V2 =
1
V2 3
∴ D2 =
0.35π
1
42.2 3
∴ D2 =
= 3.37 in.
0.35π
Finally,
L2 =1.40 D2 =1.40 × 3.37 = 4.72 in.
3.False. From Part 2, we know that the volume of the lighter casting is 𝑉𝑉2 =
42.2 in.³ The surface area is calculated as
2π D22 2π × 3.37 2
A2
= + π D2=
L2 + π × 3.37 × 4.72
= 67.8 in.2
4 4
Lastly, the solidification time is determined to be
2 2
V 42.2
tS ,2 B 2 =
= 11.0 × 4.26 min
=
A2 67.8
P.6 ■ Solution
The flow stress is simply
σf =
Kε n =
550 × 0.850.22 =
531 MPa
The average flow stress is, in turn,
K ε n 550 × 0.850.22
σf
= = = 435 MPa
n +1 1.22
♦ The correct answer is B.
P.7 ■ Solution
The true strain in the specimen is
= (157 100 ) 0.451
ε ln=
The flow stress is then
σf =
K ε n =×
850 0.4510.30 =
669 MPa
while the average flow stress is calculated as
K ε n 850 × 0.4510.30
σf =
= = 515 MPa
n +1 0.30 + 1
♦ The correct answer is A.
P.8 ■ Solution
With recourse to the equation for average flow stress, we write
Kε n 35, 000 × ε 0.40
σ f = → 20, 000 =
n +1 0.40 + 1
∴ε =0.572
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Since 𝜀𝜀 = ln�𝐴𝐴𝑜𝑜 ⁄𝐴𝐴𝑓𝑓 �, it follows that
Ao A
ε= ln → 0.572= ln o
A
f Af
1.77
∴ Ao Af =
0.565 Ao
∴ Af =
♦ The correct answer is C.
P.9 ■ Solution
In accordance with the problem statement, we must have 𝜎𝜎�𝑓𝑓 = 0.75𝜎𝜎𝑓𝑓 .
Therefore,
Kε n
σ f =0.75σ f → =0.75 × K ε n
n +1
1
∴ 0.75
=
n +1
∴
=1 0.75n + 0.75
0.25
n
∴= = 0.333
0.75
♦ The correct answer is C.
P.10 ■ Solution
Using logarithms, the flow stress equation can be adjusted as
σ f =K ε n → ln σ f =ln ( K ε n )
∴ ln σ f =ln K + ln ε n
∴ ln σ f =ln K + n ln ε
Substituting the first data point, we have
ln 217
= ln K + n ln 0.35
∴ 5.38 = ln K − 1.05n (I)
Substituting the second data point, we have
ln 259
= ln K + n ln 0.68
∴ 5.56 = ln K − 0.386n (II)
Subtracting equation (II) from (I) brings to
5.38 − 5.56 = ln K − 1.05n − ( ln K − 0.386n )
∴−0.18 = −0.664n
0.271
∴ n=
Inserting this result into equation (I) yields
5.38 = ln K − 1.05 × 0.271
∴ 5.38 = ln K − 0.285
∴ ln K =
5.67
∴ K= e5.67= 290 MPa
♦ The correct answer is D.
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ANSWER SUMMARY
Problem 1 B
Problem 2 C
Problem 3 D
Problem 4 B
Problem 5 T/F
Problem 6 B
Problem 7 A
Problem 8 C
Problem 9 C
Problem 10 D
REFERENCES
• CREESE, R. (1999). Introduction to Manufacturing Processes and
Materials. New York: Marcel Dekker.
• GROOVER, M. (2013). Fundamentals of Modern Manufacturing. 5th
edition. Hoboken: John Wiley and Sons.
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