Production Engineering - 1

Dr: Soheir Backar

Production process
PE 011 Production
technology
Factory planning

Design

Material

PE 123 Production
engineering - 1

Quality control

Required specifications
(shape, dimensions)

Manufacturing
process

Parts of
product

Assembly

Final product

Storage

Forming

Machining
Measurements

Selected according to material, shape,

dimensions, cost,..

Transportation

Coarse contents:
Casting

Metal forming
Metal cutting

Welding process
Measurement and inspection

Week

Date

Lectures

11-10

Introduction + Sand Casting

18-10

Sand casting

25-10

Special casting processes

1-11

Bulk metal forming

8-11

Bulk metal forming + Quiz

15-11

Sheet metal forming

22-11

Mid year exam

29-11

Sheet metal forming

6-12

Machining processes

10

13-12

Machining processes

11

20-12

Measurement and inspection + Quiz

12

27-12

Welding techniques

13

3-1

14

10-1

Final exam

Semester work (Sheets

+ reports) +Quizzes

15%

Mid term exam

15%

Final exam

70%

References:
- E. Paul Degarmo, J T. Black, Ronald A. Kohser,
Materials and processes in manufacturing, John
Wiley & sons, Inc., 2003.

-R. L. Timings, Manufacturing Technology, Addison

Wesley Longman, 1998.
-Hassan El-Hofy, Fundamentals of Machining
Processes, Taylor & Francis, 2007.

-Helmi A. Youssef & Hassan El-Hofy, Machining

Technology, Taylor & Francis , 2008.

Manufacturing processes
Machining
Processes

Forming
Processes

Metal in liquid state

Casting processes

Metal in solid state

Bulk metal
forming

Sheet metal
forming

Sand casting Special casting

process

Casting Meaning:
Melt metals
Force liquid into
hollow cavity
Cool / Solidify
Remove
Finish
Short Introduction to Casting

Main advantages of casting process:

- Simple process.
- Produce complex shapes
with internal cavities or hollow sections.
- Produces near net shape parts (less machining
required)

- Can utilize brittle materials.

-

Produce products as a one part.

Can produce very large parts with high weights.

The least expensive process.

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Expendable molds:
Sand

Shell

Investment

Carbon dioxide

-Low production numbers.

- Lower molding cost.
Short Introduction to Casting

Permanent mold:

Permanent mold

Centrifugal

Die casting

-Molds made of metals that maintain their strength at high

temperatures (higher cost).
-Higher production rates.

Short Introduction to Casting

10

Classification of Metal casting processes:

Special casting processes

Sand casting
(expendable mold)

-Gravity die or permanent

mold
-Die casting

Precession or investment
-Lost wax method
-Ceramic shell process
-Co2 mold hardening process

-Hot chamber
-Cold chamber

Centrifugal casting
-True centrifugal
-Semi centrifugal
-Centrifuge

Continuous casting mold

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Examples for Casting

(a)

(b)

-Cameras.

-Mobile covers.

-Door handles.
Short Introduction to Casting

12

Examples for Casting

-Pulleys .

-Taps.
-Children toys.
-Automobile parts (Engine block, door handles, pistons) .

Sand Casting

Sand Casting

High Temperature Alloy, Complex

Geometry, Rough Surface Finish

Short Introduction to Casting

14

Sand Mold

Product

Sprue pin

riser pin

Pattern

cope

Drag

Drag

Mold cavity

Show video

15

Example:
-It is required to draw the mold
prepared for casting process.

16

17

Example:
-It is required to draw the mold prepared for casting process.

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Sand Mold
vents

Riser
Sprue

Cope

Drag

19

Sand

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Sand:
Silica sand (SiO2) is well suited for molding purposes

Withstand high
Temperatures
(melting point 1600 -1725 C)

Low in cost

Available for wide range of

grain sizes and shapes
(Sand grains from
0.0625 mm to 2mm dia.)

Silica sand can be classified according to its size or its shape.

Material

Aluminum

Copper

Cast iron

Magnesium

Steel

Zinc

Melting
temp. (C)

660

1084

1200

650

1500

419

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Sand:
1- Grain size:
- The size of sand grains may be fine, medium or course.
-For small castings a fine sand is desirable, so that all the details of
the mold are brought out sharply.
- As the casting size increases, the sand particles should be coarser
to permit the gases that are generated in the mold to escape.

Iso 14688 grades sands as fine, medium and coarse with ranges 0.063 mm
to 0.2 mm to 0.63 mm to 2.0 mm. In the United States, sand is commonly
divided into five sub-categories based on size: very fine sand (16 mm
diameter), fine sand ( mm mm), medium sand ( mm mm),
coarse sand ( mm 1 mm), and very coarse sand (1 mm 2 mm).

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Sand:
2- Grain shape:

- Sharp, irregular-shaped grains are usually preferred because they

interlock and add strength to the mold.

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Properties of molding sand:

1. Porosity or Permeability:
-

Molten metal always contains a certain amount of dissolved gases which

are evolved when the metal freezes.
Molten metal also coming in contact with the moist sand, generates
water vapors.
Sands which are coarse or have rounded grains exhibit more
permeability.
Sub-angular and angular grains exhibit low permeability.

To avoid open blows and porosity.

Open blows

Porosity

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Properties of molding sand:

2.
-

Strength :
Sub-angular grains give better strength than rounded sand grains.

Angular sand grains give higher mold strength.

To avoid drop of sand.

3.
-

Fineness:
Finer sand mold (grain size small) resist metal penetration and
produces smooth casting surface.

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4. Flow ability (plasticity):

- Flow ability assists molding sand to flow and pack all around the pattern
and take up the required shape.
-

Round sand grains exhibit greater flow ability.

Flow ability increases as clay and water content increases.

The sand must retain its shape when the pressure is removed.
5.
-

Refractoriness:
It is the ability of the molding sand to withstand high
temperature of the molten metal without fusion, cracking.

The higher the roughness of grain shape and size, the higher
the refractoriness of the sand.

To avoid fusion of sand.

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Properties of molding sand:

6. Collapsibility:
- It is that property of the sand due to which the sand mold
breaks (collapse) automatically (or with very less forces) after
the solidification of the casting occurs.
7. Durability:
- The molding sand should withstand repeated cycles of heating and
cooling.
8. Molding sand should be cheap and easily available.

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Testing of molding sand

28

Grain size or
Fineness test:

29

Mold and core hardness test:

indentation hardness tester

Refractoriness test:

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Test for Moisture content:

Moisture content should vary from 2 to 8%

Strength test:

Compressive test:

The green strength of sands is generally in the range of 30 to 160 KPa.

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How can the following tests affect the quality of castings?

1) Grain size test:
Selecting suitable grain size:
-Avoid material penetration problems.
- Avoid bad surface finish.
2) Moisture content test:
- Avoid porosities inside the casting, and open blows on the castings surface.
3) Hardness & strength tests:

-Avoid metal penetration.

- Avoid drop of sand.
4) Refractoriness tests:
-Avoid sand distortion.
- Avoid melting and adhesion of sand.
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Types of molds
(according to the types of molding sand)

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Types of molds:
Molds are classified as to the materials used:

Green sand molds

Skin dried molds

Dry sand molds

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Green sand molds:

Silica sand (silicon dioxide) 80-82%
8-30% clay
6-8 % water

-Green sand molds contain moisture, therefore certain defects like

blow holes may occur in casting. The surface finish is also not good.

Skin dried molds:

- These molds are dried only up-to a depth varying from 8 mm to 25 mm.
- If a skin dried mold is not poured immediately after drying, moisture
from green backing sand penetrate the dried skin and make dried sand
ineffective.
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Dry sand molds:

Dry sand molding is the green sand practice modified by baking the mold
at 204-316 C.

-A dry sand mold holds its shape when poured and is free from gas
troubles due to moisture.

-Dry sand molds posses higher strengths as compared to green sand

molds.
- They are more expensive and consume more time in making as
compared to green sand mold.
- Casting produced are having better surface finish.
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