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Samavedam Santhi
Mahatma Gandhi Institute of Technology
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Introduction
Metal casting is a manufacturing process where molten or
liquid metal is poured into a mould cavity and allowed to
solidify to acquire the shape of the mould. Metal Casting is
unique among metallurgical processes as complex physics
is involved in it[1]. Any type and shape of an alloy can be
produced using sand casting technique. Sand moulds
refractoriness helps to retain its shape and size, and shows
a slight expansion when subjected to high temperature
for a long period. Sand casting technique is the most
cost-effective and design-flexible in foundry[2]. Innovative
and well-planned management of sand is essential for
maintaining quality of the product and process according
to Ravneet Kakria[3]. The greatest percentage of castings
is produced by sand casting route which is the most
economical with optimum efficiency and reclaimability[4].
In sand moulds, the temperature distribution in the molten
metal is uniform and the temperature of the inside surface
of the mould is equal to the temperature of the liquid
metal, because the heat conductivity of the sand is very
low compared to molten metal[5].
Gating System
20
Vol 61 No. 1 January 2015
Equation 1
Equation 2
Equation 3
Equation 4
Equation 8
Equation 5
Equation 6
Equation 7
= 1.2 Mcasting
Equation 10
Equation 12
0.5
Runner
2*As
Gate
Riser
1.5*As
Mr=1.2Mc
21
Vol 61 No. 1 January 2015
#include<math.h>
void main()
{
float Wc,H,Mc,D,V,R,Sa;
printf("\n weight of the casting ");
scanf("%f",&Wc);
printf("\n enter the height of the casting in inches");
scanf("%f",&H);
H=H*2.5;
printf("\n enter the diameter of the riser in inches");
scanf("%f",&D);
D=D*2.5;
Mc=(D*H)/((4*H)+(2*D));
R=D/2;
V=3.14*H*pow(R,2);
Sa=V/Mc;
printf("\n the volume of the riser is: %f",V);
printf("\n the surface are of the riser is: %f",Sa);
printf("\n the modulus of riser is: %f",Mc);
}
Runner
Gate
Riser
13.755193
27.510386
20.632790
380.234374
Experimental Studies
Moulding, Melting and Pouring
CO2 moulding is the moulding technique used for the
current experiment. The composition of the moulding sand
considered for the present sand is SiO2 78%, Al2O3 12%,
Na2O(SiO2) 5%, Cr2O3 3% and ZrO2 2% and consistency of
the mixture is achieved by mulled in a 50 kg sand muller.
After ramming into the desired shape by hand hardening,
CO2 gas has been passed into the mould to achieve desired
properties as shown in Fig. 5. Shellac coating is applied on
the mould surfaces of cope and drag and fired just before
pouring to ensure non-adherence to surface of the mould
Conclusions
With the help of well-designed gating system, the grate
bar casting is free from inclusions, shrinkage and other
defects. Appropriate riser design removed the undesirable
shrinkage cavity resulting into desirable shape and quality
of the grate bar castings.
Acknowledgements
The authors thank the Managing Director of Sri
Mahalakshmi- Earth Movers Limited, Vishakapatnam and
the Principal, MGIT, Hyderabad for providing support and
permission for carrying out this R&D work.
References
1.
2.
3.
4.
5.
6.
7.
8.
9.
Inspection
Figure 6 depicts the solidified stainless steel casting. Nondestructive testing results show acceptable amount of
pin holes and blow holes in the casting as per standard.
quality of the casting is meeting requirement of the ASTM
A297 standard.
Indian Foundry Journal
Guleyupoglu
Johnstown,