This document provides information on various metal casting processes including die casting, centrifugal casting, and sand casting. It discusses the key steps in each process, their advantages and disadvantages, and common applications. Die casting is characterized by forcing molten metal into a mold cavity under high pressure and can produce large quantities of parts quickly. Centrifugal casting is used to cast thin-walled cylinders and involves pouring molten metal into a rotating mold. Sand casting uses sand as the mold material and is commonly used for ferrous and non-ferrous metals.
This document provides information on various metal casting processes including die casting, centrifugal casting, and sand casting. It discusses the key steps in each process, their advantages and disadvantages, and common applications. Die casting is characterized by forcing molten metal into a mold cavity under high pressure and can produce large quantities of parts quickly. Centrifugal casting is used to cast thin-walled cylinders and involves pouring molten metal into a rotating mold. Sand casting uses sand as the mold material and is commonly used for ferrous and non-ferrous metals.
This document provides information on various metal casting processes including die casting, centrifugal casting, and sand casting. It discusses the key steps in each process, their advantages and disadvantages, and common applications. Die casting is characterized by forcing molten metal into a mold cavity under high pressure and can produce large quantities of parts quickly. Centrifugal casting is used to cast thin-walled cylinders and involves pouring molten metal into a rotating mold. Sand casting uses sand as the mold material and is commonly used for ferrous and non-ferrous metals.
This document provides information on various metal casting processes including die casting, centrifugal casting, and sand casting. It discusses the key steps in each process, their advantages and disadvantages, and common applications. Die casting is characterized by forcing molten metal into a mold cavity under high pressure and can produce large quantities of parts quickly. Centrifugal casting is used to cast thin-walled cylinders and involves pouring molten metal into a rotating mold. Sand casting uses sand as the mold material and is commonly used for ferrous and non-ferrous metals.
DRAWING 1 QUESTION 1 Hot, cold die casting, centrifugal casting process, sand casting. Its use for process equipments. Advantages and disadvantages. 2 CASTING Casting is a manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. 3 TYPES OF CASTING METHODS The different types of methods used for casting are: 1) Die Casting a) Hot Die Casting b) Cold Die Casting 2) Centrifugal Casting 3) Sand Casting 4 DIE CASTING 5 DIE CASTING Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mould cavity. The advantage to the die casting process is the ability to make large quantities of well defined components quickly and cheaply that will require few secondary operations to obtain a finished part. 6 DIE CASTING The two types of die casting process that we are going to see are: 1) Hot die casting 2) Cold die casting
7 COLD DIE CASTING 8 COLD DIE CASTING During the cold-chamber die casting process, the molten charge (more material than is required to fill the casting) is ladled from the crucible into a shot sleeve, where a hydraulically operated plunger pushes the metal into the die. The extra material is used to force additional metal into the die cavity to supplement the shrinkage that takes place during solidification. Injection pressures over 10,000 psi or 70,000 kPa can be obtained from this type of machine. 9 10 Operating Sequence of the Cold-Chamber Die Casting Process
11 1. The die is closed and the molten metal is ladled into the cold-chamber shot sleeve 12 2. The plunger pushes the molten metal into the die cavity where it is held under pressure until solidification.
13 3. The die opens and the plunger advances, to ensure that the casting remains in the ejector die. Cores, if any, retract.
14 4. Ejector pins push the casting out of the ejector die and the plunger returns to its original position 15 ADVANTAGES
The big advantage of cold chamber die castings is that the procedure can make denser metal castings. Denser metal is produced due to the higher pressure used during the injection process. Low maintenance cost. Through cold chamber castings, producers can manufacture more parts with lower overhead costs. This drives down the market prices. 16 DISADVANTAGES
Cold chamber processing has slower production cycles. The molten metal in the cold chamber can cool down even before injection. The molten metal in the cold chamber is more exposed to oxidation and other contaminants especially if the production floor does not have strict quality control. 17 APPLICATIONS
Since the liquid metal is brought in from an outside source and is not always in contact with the machine apparatus it can be used for the casting of higher melting point metals. Consequently, higher melting point alloys of aluminium, brass, copper, and aluminium-zinc are often metal cast in manufacturing industry using cold chamber die casting. 18 HOT DIE CASTING 19 HOT DIE CASTING In this process, the injector is submerged in the molten metal (Hot chamber). The apparatus consists of a shot cylinder connected to plunger rod, which provides power for the injection of the molten metal into the die. The plunger is in contact with the molten metal.
20 HOT DIE CASTING 21 HOT DIE CASTING At the start of a casting cycle the plunger is at the top of the hot chamber. Intake ports allow this chamber to fill with liquid metal.
22 1 2 3 4 23 APPLICATIONS The hot chamber process is used for metals of low melting point and high fluidity such as tin, zinc, and lead that tend not to alloy easily with steel at their melt temperatures.
24 ADVANTAGES Good surface finish Very economical process at high volume production Fine Grain structure and good mechanical properties are achieved. Small size parts may be produced 25 DISADVANTAGES Not applicable for high melting point metals and alloys (e.g.: steel) Large parts can not be cast. High die cost Some gases maybe entrapped in form of porosity.
26 CENTRIFUGAL CASTING 27 CENTRIFUGAL CASTING Centrifugal casting or rotocasting is a casting technique that is typically used to cast thin-walled cylinders Centrifugal casting was the invention of Alfred Krupp, who used it to manufacture cast steel tyres for railway wheels in 1852. Materials that can be casted using centrifugal casting are iron, steel, stainless steel, glass, and alloys of aluminium, copper and nickel.
28 PROCESS 1) Mold preparation - The walls of a cylindrical mold are first coated with a refractory ceramic coating and the mold is rotated about its axis at high speeds (300-3000 RPM), typically around 1000 RPM.
2) Pouring - Molten metal is poured directly into the rotating mold. The centrifugal force drives the material towards the mold walls as the mold fills.
3) Cooling - With all of the molten metal in the mold, the mold remains spinning as the metal cools. Cooling begins quickly at the mold walls and proceeds inwards. 4) Casting removal - After the casting has cooled and solidified, the rotation is stopped and the casting can be removed.
5) Finishing - While the centrifugal force drives the dense metal to the mold walls, any less dense impurities or bubbles flow to the inner surface of the casting. As a result, secondary processes such as machining, grinding, or sand- blasting, are required to clean and smooth the inner diameter of the part.
29 30 ADVANTAGES Good mechanical properties Good surface finish and accuracy Low equipment cost Low labour cost Little scrap generated Can form very large parts
31 DISADVANTAGES Only cylindrical shapes can be produced with this process. Secondary machining is often required for inner diameter Long lead time possible
32 APPLICATIONS Shock Absorber Cylinders, Stabilizers, and Dumper Cylinders for off-road heavy-duty mining trucks Shear and Crusher Cylinders for demolition or recycling applications Riser Tensioner Cylinders for offshore oil platforms Building Stabilizer Cylinders for earthquake protection.
33 SAND CASTING 34 SAND CASTING Also known as sand molded casting Characterized by using sand as the mold material. Over 70% of all metal castings are produced via a sand casting process Materials used to make patterns: Wood, plastics, aluminum, fiberglass, cast iron
35 BASIC PROCESS
1. Place a pattern in sand to create a mold. 2. Incorporate the pattern and sand in a gating system. 3. Remove the pattern. 4. Fill the mold cavity with molten metal. 5. Allow the metal to cool. 6. Break away the sand mold and remove the casting.
36 FORMATION PROCESS SAND CAST FORMATION: 1. Metal springs called densiments are placed into the mold-provide uniform solidification of the metal throughout the mold. 2. Nails are inserted into thin parts- reinforcement 3. alcoholic liquid is sprayed over the cope and heated with flames- harden and to dry the surface.
METAL CASTING : 1. Metal box is made of two halves called mould which is separated by a parting line- the removal of the part. 2. The upper part of the mold is called the cope and the lower part called the drag. 3. Cope and drag are united and metal is poured into it through a canal called sprue 4. At the bottom of the sprue there is a gap called well for the collection of the unwanted sand, which comes with the flowing metal.
37 SUPPLEMENTARY PROCESS Chill: A casting may show micro porosity due to solidification. Eliminated with directional solidification by 1. Incorporating a metal chill into the mold 2. Tapering the thinnest section of the runner Electric-Arc Furnaces: Steel melted in the electric arc process is melted and the molten metal is filed into mould basin. A powder is added to the mold's surface to prevent metal's rapid cooling during pouring and prevent the oxidation of the molten metal and is removed using vibrating platform. Excess parts are cut either by oxygen if the casting is of steel (hard), or by hammering if the casting is of cast iron (brittle). 38 ADVANTAGES 1) Complex pad geometries, including Goth external arid internal shapes. 2) Performed on any metal that can be heated to the liquid state. 3) Highly suited for mass production. 4) Easiest and quickest way (technique) from drawing (design) to the production. 5) Used in specialized factories called foundries
39 DISADVANTAGES 1) Limitation on mechanical properties 2) Porosity (empty spaces within the metal - reduces the strength of metal) 3) Poor dimensional accuracy and surface finish 4) Safety hazards to humans and environmental problems 5) Removal of pattern of the thin and small parts is very difficult
Oxy-Acetylene Welding and Cutting: Electric, Forge and Thermit Welding together with related methods and materials used in metal working and the oxygen process for removal of carbon
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