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    Casting

    Uploaded by

    Amrut

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    © All Rights Reserved
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    Casting

    Uploaded by

    Amrut
    12 views34 pages

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    © © All Rights Reserved

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    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    12 views34 pages

    Casting

    Uploaded by

    Amrut

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 34

    OVERVIEW

    Manufacturing
    processes

    Metal casting Metal forming


    processes
    Metal joining
    processes
    METAL CASTING
     Introduction

     Principle of casting

     Types

     Advantages & applications

     Defects

     Patterns

     Sand molding

     Properties of molding sand

     Gating system
    CASTING

     Definition: Process in which molten metal flows by gravity or other


    force into a mold where it solidifies into required shape ( shape of the
    mould cavity)

     The term casting also applies to the part made in the process

     Steps in casting seem simple:

    1. Melt the metal

    2. Pour it into a mold

    3. Let it cool down


    Principle of Casting
     A material in a liquid or semisolid form is poured or forced to flow into
    a cavity and allowed to solidify, thus taking the solid shape of the
    cavity.

     The process can be applied on metals and plastics. The term casting is
    commonly used for metals and the term molding is used for plastics.

     Examples: Engines, door handles, locks, the outer casing or housing for
    motors, pumps, etc., wheels of many cars.
    Advantages of Casting

    • Can create complex part geometries that can not be made by any other
    process

    • Can create both external and internal shapes

    • Can produce very large parts (with weight more than 100 tons), like
    machine bed

    • Casting can be applied to shape any metal that can melt

    • Some casting methods are suited to mass production

    • Can also be applied on polymers and ceramics


    Disadvantages of Casting

     Limitations on mechanical properties

     Poor dimensional accuracy and surface finish for some processes; e.g.,

    sand casting

     Safety hazards to workers due to hot molten metals

     Environmental problems
    TYPES OF CASTING
     Green Sand Casting

     Die Casting

     Investment Casting

     Centrifugal casting

     Continuous casting
    Green Sand Casting
     This is a metal casting process in which sand is used as mold material.
    Majority of all castings are produced by this method.

     Green sand moulds are prepared with natural molding sands or with
    silica sand, bonding clay and water mixed in proper proportions.

     Facing sand is used on the surface of cavity (refractory material-


    smoother surface of casting)
    SAND CASTING TERMINLOLOGIES

    LADDLE Vent
    holes

    Mould
    DEFECTS IN CASTING
     Blowholes
     These are smooth, round holes appearing in the form of cluster of a
    large number of small holes below the surface of the casting.
     These are entrapped gas bubbles with smooth walls.
     Caused by excessive moisture in mold sand.
     Metal penetration and rough surface
     This defect appears as an uneven rough external surface of the
    casting.
     Because of metal penetration between sand grains due to large grain
    size, low strength, high permeability and soft ramming.
     Hot tears (Pulls)
     Internal or external cracks having ragged edges occurring
    immediately after solidification of metals
     Because of poorly designed casting, incorrect pouring temperatures,
    improper gating and also hard ramming.

     Shrinkage cavity
     Is a void or depression in the casting caused by uncontrolled and
    haphazard solidification
     Occurs when pouring temperature is too high
     Cold shut and misrun

     A cold shut is an external defect formed due to imperfect fusion of two


    streams of metals in mould cavity or unequal sections of pattern assembled
    together. The defect may appear like a crack or seam with rounded edges.

     A misrun is a defect caused because of incomplete filling of molten metal


    in the cavity.

     Reasons include intermittent pouring, poor fluidity, thin sections, improper


    gating.
     Drop

     This occurs when upper surface of the mould cracks and pieces of sand
    fall into molten metal

     Caused by soft ramming

     Warpage

     Due to different rates of solidification at different sections of casting,


    stresses are setup in adjoining walls resulting in warpage.
     Mismatch or mould shift

     Caused due to mismatch of top and bottom parts at parting line. Also
    due to misalignment of flask.
    Advantages and disadvantages of sand casting

     Advantages:

    1. Green sand molding is adaptable to machine molding

    2. No mold baking is required

    3. Lesser mold distortion as compared to dry sand molding

    4. Time and cost associated with mold baking or drying is eliminated

    5. In green sand molds flasks are ready for reuse in a minimum amount of
    time

    6. Green sand mold provides good dimensional accuracy across parting


    line
    Disadvantages:

    1. Green sand molds posses lower strengths

    2. They are less permeable

    3. Chances of occurrence of defects (like blow holes etc) are more

    4. Surface finish deteriorates as weight of the casting increases

    5. Dimensional accuracy decreases with increase in size of the casting


    DIE CASTING

     The method of rapidly producing accurately dimensioned parts by


    forcing molten metal under pressure into split metal dies which
    resemble a permanent mold.

     Low temperature dies- casting solidifies quickly permitting the die


    halves to be separated and casting to be ejected.

     Several parts may be cast together if the part size is small- multiple
    cavity die

     Process suitable for lead, magnesium, tin


    INVESTMENT CASTING
     A technique for making small, accurate castings in refractory alloys
    using a mould formed around a pattern of wax or similar material
    which is then removed by melting.
     Investment casting (known as lost-wax casting in art) is a process that has
    been practiced for thousands of years, with lost wax process being one of
    the oldest known metal forming techniques.
     From 5000 years ago, when bees wax formed the pattern, to today’s high
    technology waxes, refractory materials and specialist alloys, the castings
    ensure high quality components are produced with the key benefits of
    accuracy, repeatability and versatility
     Investment casting derives its name from the fact that the pattern is
    invested, or surrounded, with a refractory material
    Applications:

     aerospace and power generation industries to produce turbine blades


    with complex shapes or cooling systems.
    CENTRIFUGAL CASTING
     Molten metal is poured into moulds while they are rotating

     The molten metal entering the mould axially is thrown out by


    centrifugal force under sufficient pressure towards periphery

     Solidification occurs from outer surface inwards

     Examples: hollow cylindrical bodies such as cast iron pipes, gun


    barrels, disc wheels.
    CONTINUOUS CASTING

     The molten metal is poured through tall tower at a steady rate


    uninterruptedly.

     This in general is used for production of rods, pipes, sheet metal and
    other semi-finished products.
    PATTERNS

     Pattern is the principal tool during the casting process.

     Forms an impression called mould in damp sand

     Pattern is the replica of the part to be cast and is used to prepare the
    mould cavity.

     The process of making a pattern is known as pattern making


     Single piece pattern (a.k.a, solid pattern)
     Split piece pattern (a.k.a, two-piece pattern)
     Sweep pattern
     Loose piece pattern
    i) Solid or single piece pattern:

    oPatterns made without joints, partings, loose


    pieces
    oRunners, feeding gates and risers
    for large castings of simple shapes are to be cut
    manually.
    ii) Split pattern:

     Split patterns are made in two or more parts, which may or may not be
    of same size and shape.

     proper relative positions by means of dowel-pins fastened in one piece and


    fitting holes bored in the other.

     Spindles, cylinders, steam valve bodies, water stop cocks and taps, bearings,
    small pulleys and wheels are few examples of castings

     Split patterns with more than two pieces is known as multiple-piece


    pattern
    iii) Sweep pattern
     Making moulds for large symmetrical casting
     For intricate complex castings
    iv) Loose piece pattern
     Patterns with complex internal grooves
    SAND CORE

     Cores are separate shapes of sand


    required to form hollow interior of a
    casting or holes through the casting.

     Core is removed after casting.

     Need for core: To shape the parts of


    casting which are not obtainable
    from the mold produced directly
    from the pattern.
    MOLDING SAND PROPERTIES:

    1. Permeability or Porosity

    2. Refractoriness

    3. Green strength

    4. Dry strength

    5. Hot strength

    6. Collapsibility

    7. Flowability

    8. Adhesiveness

    9. Cohesiveness
    GATING SYSTEM

     The term gate is defined as a channel that leads into mold cavity.

     Gating system refers to all channels by which molten metal is


    delivered into mold cavity. Includes Pouring basin, sprue, runners

     Need for gating system:


    1. To provide continuous and uniform feed of molten metal with least
    turbulence to cavity.
    2. To supply molten metal at best location to achieve proper directional
    solidification.
    3. To fill in cavity in shortest possible time duration
    4. To provide minimum excess metal
    5. To prevent erosion of mold walls
    PATTERN ALLOWANCES
     Shrinkage allowance: During the solidification of metal, it shrinks. In
    order to compensate for this, the pattern size is made larger than
    required size of casting. This allowance to compensate for reduction in
    size of casting during solidification is known as Shrinkage allowance.
    Depends on metal being cast.
     Finishing allowance: Also known as Machining allowance. Rough
    surfaces are to be machined to obtain final product from casting and
    since machining is a metal removal process, certain allowance has to be
    provided in terms of final size of casting to obtain actual dimensions of
    the product in the end. The allowance provided in the pattern to
    compensate for loss of material during machining is known as
    Machining or Finishing allowance.

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