Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                
Scribd Logo
Upload

Welcome to Scribd!

  • 334 views

    Casting Process

    Uploaded by

    Paras Thakur
    This document discusses various metal casting processes including sand casting, shell molding, vacuum molding, expanded polystyrene, investment casting, plaster mold casting, ceramic mold casting, permanent mold casting, die casting, and centrifugal casting. For each process, the key advantages and disadvantages are outlined. Product design considerations for castings such as geometric simplicity, draft guidelines, dimensional tolerances, and machining allowances are also covered.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd

    Casting Process

    Uploaded by

    Paras Thakur
    334 views30 pages
    This document discusses various metal casting processes including sand casting, shell molding, vacuum molding, expanded polystyrene, investment casting, plaster mold casting, ceramic mold casting, permanent mold casting, die casting, and centrifugal casting. For each process, the key advantages and disadvantages are outlined. Product design considerations for castings such as geometric simplicity, draft guidelines, dimensional tolerances, and machining allowances are also covered.

    Original Description:

    casting processes explained with figures and gud theoretical details....

    Copyright

    © Attribution Non-Commercial (BY-NC)

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document discusses various metal casting processes including sand casting, shell molding, vacuum molding, expanded polystyrene, investment casting, plaster mold casting, ceramic mold casting, permanent mold casting, die casting, and centrifugal casting. For each process, the key advantages and disadvantages are outlined. Product design considerations for castings such as geometric simplicity, draft guidelines, dimensional tolerances, and machining allowances are also covered.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    334 views30 pages

    Casting Process

    Uploaded by

    Paras Thakur
    This document discusses various metal casting processes including sand casting, shell molding, vacuum molding, expanded polystyrene, investment casting, plaster mold casting, ceramic mold casting, permanent mold casting, die casting, and centrifugal casting. For each process, the key advantages and disadvantages are outlined. Product design considerations for castings such as geometric simplicity, draft guidelines, dimensional tolerances, and machining allowances are also covered.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 30

    METAL CASTING PROCESSES

    1. Sand Casting
    2. Other Expendable Mold Casting Processes
    3. Permanent Mold Casting Processes
    4. Product Design Considerations
    Factors to Choice of process
    „ Production cost
    „ Production rate
    „ Size, shape
    „ Surface finish
    „ Physico-mechanical properties
    Other Expendable Mold Processes
    „ Shell Molding
    „ Vacuum Molding
    „ Expanded Polystyrene Process
    „ Investment Casting
    „ Plaster Mold and Ceramic Mold Casting
    Shell Molding
    Advantages and Disadvantages
    „ Advantages of shell molding:
    … Smoother cavity surface permits easier flow of
    molten metal and better surface finish
    … Good dimensional accuracy - machining often not
    required
    … Mold collapsibility minimizes cracks in casting
    … Can be mechanized for mass production
    „ Disadvantages:
    … More expensive metal pattern
    … Difficult to justify for small quantities
    Vaccum processing
    Advantages and Disadvantages
    „ Advantages of vacuum molding:
    … Easy recovery of the sand, since no binders
    … Sand does not require mechanical reconditioning done
    when binders are used
    … Since no water is mixed with sand, moisture-related defects
    are absent
    „ Disadvantages:
    … Slow process
    … Not readily adaptable to mechanization
    Expanded Polystyrene Process
    Uses a mold of sand packed around a polystyrene foam pattern
    which vaporizes when molten metal is poured into mold
    „ Other names: lost-foam process, lost pattern process,
    evaporative-foam process, and full-mold process
    „ Polystyrene foam pattern includes sprue, risers, gating system,
    and internal cores (if needed)
    „ Mold does not have to be opened into cope and drag sections
    Advantages and Disadvantages
    „ Advantages of expanded polystyrene process:
    … Pattern need not be removed from the mold
    … Simplifies and speeds mold-making, because two mold
    halves are not required as in a conventional green-sand
    mold
    „ Disadvantages:
    … A new pattern is needed for every casting
    … Economic justification of the process is highly dependent
    on cost of producing patterns
    Investment Casting (Lost Wax Process)
    A pattern made of wax is coated with a refractory material to
    make mold, after which wax is melted away prior to pouring
    molten metal
    „ "Investment" comes from a less familiar definition of "invest"
    - "to cover completely," which refers to coating of refractory
    material around wax pattern
    „ It is a precision casting process - capable of producing castings
    of high accuracy and intricate detail
    Investment Casting
    Advantages and Disadvantages
    „ Advantages of investment casting:
    … Parts of great complexity and intricacy can be cast
    … Close dimensional control and good surface finish
    … Wax can usually be recovered for reuse
    … Additional machining is not normally required - this is a
    net shape process
    „ Disadvantages
    … Many processing steps are required
    … Relatively expensive process
    Plaster Mold Casting

    Similar to sand casting except mold is made of plaster of Paris


    (gypsum - CaSO4-2H2O)
    „ In mold-making, plaster and water mixture is poured over
    plastic or metal pattern and allowed to set
    … Wood patterns not generally used due to extended contact
    with water
    „ Plaster mixture readily flows around pattern, capturing its fine
    details and good surface finish
    Advantages and Disadvantages
    „ Advantages of plaster mold casting:
    … Good accuracy and surface finish
    … Capability to make thin cross-sections
    „ Disadvantages:
    … Mold must be baked to remove moisture, which can
    cause problems in casting
    … Mold strength is lost if over-baked
    … Plaster molds cannot stand high temperatures, so limited
    to lower melting point alloys
    Ceramic Mold Casting
    Similar to plaster mold casting except that mold is made of
    refractory ceramic material that can withstand higher
    temperatures than plaster
    „ Can be used to cast steels, cast irons, and other
    high-temperature alloys
    „ Applications similar to those of plaster mold casting except for
    the metals cast
    „ Advantages (good accuracy and finish) also similar
    Permanent Mold Casting Processes
    „ Economic disadvantage of expendable mold casting: a new
    mold is required for every casting
    „ In permanent mold casting, the mold is reused many times
    „ The processes include:
    … Basic permanent mold casting
    … Die casting
    … Centrifugal casting
    Permanent Mold Casting
    Advantages and Limitations
    „ Advantages of permanent mold casting:
    … Good dimensional control and surface finish
    … More rapid solidification caused by the cold metal mold
    results in a finer grain structure, so castings are stronger
    „ Limitations:
    … Generally limited to metals of lower melting point
    … Simpler part geometries compared to sand casting because of
    need to open the mold
    … High cost of mold
    Die Casting
    A permanent mold casting process in which molten metal is
    injected into mold cavity under high pressure
    „ Pressure is maintained during solidification, then mold is
    opened and part is removed
    „ Use of high pressure to force metal into die cavity is what
    distinguishes this from other permanent mold processes

    Two main types:


    •Hot- chamber machine
    •Cold- chamber machine
    Hot-Chamber Die Casting

    „ Metal is melted in a container, and a piston injects liquid metal


    under high pressure into the die
    „ Applications limited to low melting-point metals that do not
    chemically attack plunger and other mechanical components
    „ Casting metals: zinc, tin, lead, and magnesium
    Cold-Chamber Die Casting
    Molten metal is poured into unheated chamber from external
    melting container, and a piston injects metal under high pressure
    into die cavity
    „ High production but not usually as fast as hot-chamber machines
    because of pouring step
    „ Casting metals: aluminum, brass, and magnesium alloys
    „ Advantages of hot-chamber process favor its use on low
    melting-point alloys (zinc, tin, lead)
    Advantages and Limitations
    „ Advantages of die casting:
    … Economical for large production quantities
    … Good accuracy and surface finish
    … Thin sections are possible
    … Rapid cooling provides small grain size and good strength
    to casting
    „ Disadvantages:
    … Generally limited to metals with low metal points
    … Part geometry must allow removal from die
    Centrifugal Casting
    The group includes:
    … True centrifugal casting
    … Semicentrifugal casting
    … Centrifuge casting
    Semicentrifugal Casting
    Centrifugal force is used to produce solid castings rather than
    tubular parts
    „ Molds are designed with risers at center to supply feed metal
    „ Density of metal in final casting is greater in outer sections
    than at center of rotation
    „ Often used on parts in which center of casting is machined
    away, thus eliminating the portion where quality is lowest
    „ Examples: wheels and pulleys
    Centrifuge Casting
    Mold is designed with part cavities located away from axis of
    rotation, so that molten metal poured into mold is distributed
    to these cavities by centrifugal force
    „ Used for smaller parts
    „ Radial symmetry of part is not required as in other centrifugal
    casting methods
    Casting Quality
    The defects can be classified as follows:
    … General defects common to all casting processes
    … Defects related to sand casting process

    Depression in surface or internal


    void caused by solidification
    shrinkage that restricts amount of
    molten metal available in last region
    to freeze
    Sand Casting Defects: Sand Blow
    Product Design Considerations
    „ Geometric simplicity:
    … Although casting can be used to produce complex part
    geometries, simplifying the part design usually improves
    castability
    … Avoiding unnecessary complexities:
    „ Simplifies mold-making

    „ Reduces the need for cores

    „ Improves the strength of the casting

    „ Corners on the casting:


    … Sharp corners and angles should be avoided, since they are
    sources of stress concentrations and may cause hot tearing
    and cracks
    … Generous fillets should be designed on inside corners and
    sharp edges should be blended
    Product Design Considerations
    „ Draft Guidelines:
    … In expendable mold casting, draft facilitates removal of
    pattern from mold
    „ Draft = 1° for sand casting

    … In permanent mold casting, purpose is to aid in removal of


    the part from the mold
    „ Draft = 2° to 3° for permanent mold processes

    … Similar tapers should be allowed if solid cores are used


    Product Design Considerations
    „ Dimensional Tolerances and Surface Finish:
    … Significant differences in dimensional accuracies and finishes
    can be achieved in castings, depending on process:
    „ Poor dimensional accuracies and finish for sand casting

    „ Good dimensional accuracies and finish for die casting and


    investment casting

    „ Machining Allowances:
    … Almost all sand castings must be machined to achieve the
    required dimensions and part features
    … Additional material, called the machining allowance, is left on
    the casting in those surfaces where machining is necessary
    … Typical machining allowances for sand castings are around 1.5
    and 3 mm (1/16 and 1/4 in)

    You might also like