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PROSMAN CHEAT SHEET -13406123

1) Metal Castinga) Total heat required

H = total heat required to raise thetemperature of the metal to the pouringtemperature, J; = density; g/cm3; Cs=weight specific heat for the solid metal,

J/g-C; Tm = melting temprature of the

metal, C; To = starting temprature;Hf = heat of fusion, J/g; Cl = weight specific heat of the liquid metal, J/g-

C; Tp = pouring temperature; V =volume of metal, cm3.

b) Velocity of the flowingmetal atthe base ofsprue

c) Flow rate

d) Time required to fillmold cavity

e) Chvorinovs rule

TST = total solidification time, min; V= volume of the casting, cm3; A =

surface are of the casting, cm2; n =exponent (usually n=2) ; Cm = mold

constant.f) Archimedes core lift

force

Fb = buoyancy force, Wm = weight ofmolten metal displaced, Wc = weight ofcore.

g) Casting alloys data.

Material Density

(g/cm3

)

Solid.

Shrink (%)

Solid.Thermal(%)

Aluminium

2.7 7 5.6

Alum-Silveralloy

2.6 7 5

Alum-

Copperalloy

2.81 7 5

Brass 8.62 n/a n/aGray castiron

7.16 1.8 3

Copper 8.73 4.5 7.5Lead 11.30 n/a n/a

Steel 7.82 n/a n/aLowCcaststeel

n/a 3 7.2

Centrifugal castingh) G-Factor

N = rotational speed, rpm; R = insideradius of the mold, m; optimal GF =

60-80.i) Rotational speed

R = inside diameter of the mold, m.j) Vertical centrifugal

casting

2) Plastic Processes

a) Die Swell

rs = swell ratio, Dx = diameter of theextruded cross-section, mm; Dd =

diemeter of the die orifice, mm.

b) Flight angle

P = pitch of screw; D = barrel

diamater, mm.c) Volume drag flow rate

v = velocity of the moving plate, m/s; d= distance separating the two plates, m

; w = width of the plates , m.d) Velocity of moving plate

(if wf

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u) Contact length

v) Power

P = power; N = rotational speed; F =rolling force; L = contact length.

Forgingw) True strain

x) Shape factor

= coefficient of friction; D =workpart diameter, mm; h = workpart

height, mm.

y) Force

Extrusionz) Extrusion/reduction

ratio

aa)True strain

bb)Pressure

cc) Extrusion strain

a,b = empirical constant.dd)Ram pressure (indirect

extrusion)

ee) Ram pressure (directextrusion)

ff) Ram force

gg)Power

hh)Die shape factor

Cx = perimeter of extruded x-section,mm; Cc = perimeter of cicle of the samearea as the extruded shape.

Wire and bar drawingii) Reduction area

jj) Draft

kk) True strain and stress

ll) Draw stress

d = draw stress, MPa; = frictioncoefficient; = die angle; D = average

diameter of work during drawing; Lc =contact length, mm.mm) Draw force

nn)Power

v = exit velocity.Sheet-metal cutting

oo)Clearance

Metal group aAlum alloy, all tempers. 0.04

5

Alum alloy;brass;softcold rolled stell;softstainless steel.

0.060

Cold rolled steel,halfhard;stainless steel.

0.075

a = allowance; t = thickness, mm.

pp)Diameters---figure 20.6---Blanking punch = Db 2cBlanking die = DbHole punch = DhHole die diameter = Dh + 2cqq)Cutting force

S = shear strength; t = stock thickness;

L = length of the cut edge; TS =ultimate tensile strength.

Sheet-metal bendingrr) Bend allowance

BA = bend allowance, mm; A = angle,

degree; R = radius, mm; t = stockthickness, mm; Kba = constant; Kba =

0.33, R