Project Report

EQUIPMENT DESIGN AND

DRAWING
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QUESTION 1
Hot, cold die casting, centrifugal casting process, sand
casting. Its use for process equipments. Advantages and
disadvantages.
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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.
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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
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DIE CASTING
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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.
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DIE CASTING
The two types of die casting process that we are going to see
are:
1) Hot die casting
2) Cold die casting

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COLD DIE CASTING
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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.
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Operating Sequence of the Cold-Chamber
Die Casting Process

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1. The die is closed and the molten metal is ladled into the cold-chamber
shot sleeve
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2. The plunger pushes the molten metal into the die cavity where it is
held under pressure until solidification.

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3. The die opens and the plunger advances, to ensure that the casting
remains in the ejector die. Cores, if any, retract.

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4. Ejector pins push the casting out of the ejector die and the plunger
returns to its original position
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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.
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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.
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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.
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HOT DIE CASTING
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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.

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HOT DIE CASTING
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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.

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1 2
3
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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.

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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
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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.

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CENTRIFUGAL CASTING
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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.

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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.


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ADVANTAGES
Good mechanical properties
Good surface finish and accuracy
Low equipment cost
Low labour cost
Little scrap generated
Can form very large parts

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DISADVANTAGES
Only cylindrical shapes can be produced with this process.
Secondary machining is often required for inner diameter
Long lead time possible

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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.

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SAND CASTING
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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


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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.



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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.

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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).
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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

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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

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