11 (1) 1
11 (1) 1
Processes
CHAPTER 11
PART I
Topics
• Introduction
• Sand casting
• Shell-Mold Casting
• Plaster-Mold Casting
Introduction
• Metal-Casting Processes
– First casting were made during 4000 – 3000 BC
– In time many casting processes have been developed
– Many parts can be made from castings
• Engine blocks
• Cameras
• Gun barrels
• Cook ware
• Etc
Die Casting Examples
Fig 11.1 (a) The Polaroid PDC-2000 digital camera with AZ91D die-cast, high purity
magnesium case. (b) Two-piece Polaroid camera case made by the hot-chamber die
casting process
Trends – impacting industry
– Continuing mechanization & automation of the casting
process
-Pattern making
Molding -Core making
-Gating systems
Sand Mold
• Sand molds
– Should have good collapsibility
– Sand should be mixed thoroughly with
• Clay (bentonite) – cohesive agent
• Zircon, olivine, and iron silicate sands are used in steel foundries for low thermal
expansion
• Chromites is used for its high heat transfer characteristics
• Types of sand molds
– Green mold sanding
• Mixture of sand, clay, and water
• “green” – sand in the mold is moist
• Least expensive method of making molds
Sand Casting Con’t
Skin-dried molds
• Mold surfaces are dried
• Used for large castings
• Have higher strength than green-sand molds
• Better dimensional accuracy and surface finish
• Drawbacks:
– Distortion to the mold is greater
– Castings susceptible to hot tearing
– Slower production rate
Cold-box molds
• Various organic and inorganic binders are blended into the sand for
greater strength
• Dimensionally more accurate
No-bake mold
• Synthetic liquid resin is mixed into the sand
• Hardens at room temperature
Sand Casting Con’t
• Major components of sand molds:
Flask – supports the mold
Pouring basin – in which molten metal is poured in to
Sprue – through which molten metal flows downward
Runner system – channels that carry molten metal from
the sprue
Risers - supply additional metal to the casting during
shrinkage.
Cores
• Inserts made of sand
• Used to make hollow regions
• Used to form letterings on the casting and other features
Vents – used to carry off gases that are produced and
exhaust air from the mold cavity as metal flows on to
the mold
• Patterns
– Used to mold the sand mixture
– Made from
• Wood
• Plastic
• Metal
– They must be tough enough to be used repeatedly
– Made of different materials to reduce wear
– Coated with a parting agent to facilitate there removal
– Patterns
• One-piece patterns – for simple low cost production
• Split patterns – each part forms a portion of the cavity
• Match-plate patterns – popular type of pattern
– Two-piece patterns are constructed by securing each half of one or
more split patterns to the opposite sides of a single plate
– Used in large production runs and in molding machines
– Rapid prototyping
• Used to make a mold quickly
• Reduces cost
Patterns