Casting Process II
Casting Process II
Casting Process II
Shrinkage allowance
Draft allowance
Finish or machining allowance
Distortion allowance
Casting Process
Shrinkage allowance
All most all cast metals shrink or contract
volumetrically on cooling.
Rate of contraction with temperature is
dependent on the material
Liquid Shrinkage: Reduction in volume when
the metal changes from liquid state to solid
state. Shrinkage riser is provided.
Solid Shrinkage: Reduction in volume caused
when metal loses temperature in solid state.
Casting Process
Draft allowance
Taper given to all the vertical walls of the pattern for
easy and clean withdrawal of pattern.
Expressed in mm per meter on a side or in degrees.
Taper on inner surface is more as compare to outside
surface.
Casting Process
Machining Allowance
The surface finish obtained in sand
castings is generally poor (dimensionally
inaccurate), and hence in many cases, the
cast product is subjected tomachining
processes like turning orgrindingin order
to improve the surface finish.
During machining processes, some metal
is removed from the piece. To compensate
for this, a machining allowance should be
given in the casting
Casting Process
Casting Process
Casting Process
Types of pattern
Casting Process
Casting Process
Casting Process
Sweep pattern
Moulds of large size and symmetrical in shape can be
easily prepared by using sweep pattern
Arranged to rotate about a central axis by mounting it
on a spindle
Eliminates expensive pattern construction
Casting Process
Casting Process
Casting Process
Moulding materials
Moulding Sand
Sand Binders
Additive Materias
Casting Process
Moulding Sand
Quartz and other silica rocks are the sources
of sand
Silica sand consists of 80-85% of the total
material in moulding sand
Silica Sand-80.8%, Alumina-14.9%, Iron oxide1.3%, Combined water-2.5%
Casting Process
Sand Binders
Material added to the sand that imparts
cohesiveness to it, is called binder
Clay type
Organic type binder-Molasses, starches,
linseed oil, resins
Inorganic binders Bentonites (form of clay),
Sodium silicate, iron oxide
Casting Process
Casting Process
Refractoriness
It is the ability of the molding material to with
stand high temperatures (experienced during
pouring) with out
1.
2.
3.
Fusion,
Cracking, buckling
Experiencing any major physical change.
Casting Process
Permeability
During pouring and subsequent solidification of a
casting, a large amount of gases and steam is
generated.
These gases are those that have been absorbed by
the metal during melting, air absorbed from the
atmosphere and the steam generated by the molding
and core sand.
If these gases are not allowed to escape from the
mold, they would be entrapped inside the casting
and cause casting defects.
To overcome this problem the molding material must
be porous.
Proper venting of the mold also helps in escaping
Casting Process
the gases that are generated inside the mold cavity.
Cohesiveness
Property by which sand grains stick together
during ramming
Three types: green strength, dry strength,
Hot strength
Casting Process
Flowability
Property of sand due to which it behaves like
a fluid, when rammed, it flows to all portions
of a mould and distribute the ramming
pressure evenly.
Increases with decrease in green strength and
decreases in grain size
Casting Process
Collapsibility
Property of sand due to which the sand
mould collapses automatically after the
solidification of the casting in order to allow
free contraction of the metal
Casting Process
Adhesiveness
It is the property of molding sand owing to
which, it
1.
2.
3.
Casting Process
USES OF CORE
It is defined as sand bodies used to form hollow
portion of desired shape and cavities.
Core is made of green sand and is placed in the
mould after the pattern is withdrawn
Core are subjected to high heat of molten metal
when it a poured and it has a good strength, good
permeability, high refractoriness and sufficient
collapsibility.
Casting Process
Melting furnaces
Cupola furnace
Open hearth furnace
Electric furnace
Crucible furnace
Casting Process
Oxy-fuel Furnace
Resistance Furnace
A current passed through a material
resulting in ohmic heating
Radiation heats charge material
Some convection and conduction
occurs
Resistance Furnace
Defects in casting
MISRUN: A casting that has solidified before
completely filling mold cavity
Casting Process
Cold Shut
Two portions of metal flow together but there is
a lack of fusion due to premature freezing
Casting Process
Shrinkage
Depression in surface or internal void caused by
solidification shrinkage that restricts amount of
molten metal available in last region to freeze
Casting Process
Casting Process
Penetration
When fluidity of liquid metal is high, it may
penetrate into sand mold or core, causing
casting surface to consist of a mixture of sand
grains and metal
Casting Process
Misrun
A step in cast product at parting line caused
by sidewise relative displacement of cope and
drag
Casting Process
Casting Process