Professional Documents
Culture Documents
Dept.Elective (Mechanical)
Introduction to foundry
History
Dates back to 5000 BC
Founds in the excavations of Mohenjodaro and Harappa
Knives, arrows and household articles
Copper and Bronze were common
2000BC- Iron came to use much restricted
500 BC Religious unheavels god statutes- lost wax
processes
Armoury and war materials
Since Alexander-III the metal foundry (founding)
emerged as science
Technology and methods have changed considerably
but no change in the basic principles
Manufacturing Processes
Shaping metals including machining, joining to make a engineering
or domestic components
Metals- Refined from metal ores, classified as Ferrous and NonFerrous
Casting or Founding is the foremost manufacturing process
Defined as introducing molten metal into a cavity in the mould,
previously shaped as desired and allowing it to solidify
solidify
Well defined role in modern equipments of
Tranportation
T
t ti
Communication
Power
g
Agriculture
Construction
Industry
Advantages of Castings
Design
Structural and functional shapes that
Withstand stress and strain, service
conditions,
1. Size as much as 200 tons or small
wire of 0.5 mm dia.
2. Complexity
3. Weight Saving
4. Prototypes and models
5. Wide range of properties and Versatility
- less variation
- achieved all mechanical strength,
wear resistance, corrosion resitancestrength to weight ratio - statisfied by
castt alloys
ll
LOW COST
DIMENSIONAL ACCURACY
MASS PRODUCTION
VERSATILITY IN PRODUCTION
Metallurgical Advantages
1. Fibrousstructure:Castalloysdoesnot
exhibitfibrousstructurelikewroughtalloy
nodirectionalproperties
di ti
l
ti
2. Grainsize:Cancontrolingrainsize(of
highyieldstrength)bymelttreatment
cheaperthatwroughtalloys
3. Density: allmostsameaswroughtalloys
(ie,minimizeporosityorotherdefects)
unlikepowdermetallurgicalroutes
lik
d
t ll i l
t
Melting
g and Casting
g
-Melting the metal or alloy
-Melt treatment
-Pouring into the mould
-Solidfication
S lidfi ti
Fettling
-Removing unwanted materials (risers, gates etc
g
-Sand blasting
-Cleaning and removing sands
Type of patterns
Loose pattern
Single Pattern
Split
p Pattern
Mutiple piece pattern
Gated Pattern
Special Patterns
Sweep and Skeleton (big castings)
Match Plate patterns
Small casings in large numbers
Gated pattern
Sweep pattern
Skeleton pattern
Allowances in Patterns
Pattern allowances is a vital feature in Pattern design
- dimensional characteristics of the casting
Contraction allowance:
Other Factors affecting
1.
2.
3.
4.
Impurities
Composition
Mould design
Mould materials
cooling rate
5. Pouring temperature
Allowances in Patterns
Machining Allowance
Extra
E
t material
t i l added
dd d tto certain
t i partt off the
th casting
ti
to enable machining or finishing
Factors affection machining
allowances
1. Method of moulding casting
used
2. Size and shape of casting
3. Casting orientation
4 Metal
4.
M t l characteristics
h
t i ti
5. Functional requirement of
casting
g
of accuracy
y and finish
- degree
required
Machining Allowance
Allowances in Patterns
Draft or Taper allowance
The amount of draft depends
on
1. Length of the vertical side
2. Intricacy of the pattern
3. Method
3
et od o
of moulding
ou d g
4. Pattern materials
Allowances in Patterns
Rapping or Shake Allowance
For easy withdrawl from mould of pattern rapping
The
Th cavity
it size
i iincreases so the
th pattern
tt
is
i made
d smaller.
ll
desided by experience no guidline is available
Distortion (cambered) allowance
Pattern Materials
Selection of Pattern Materials
Service requirements
Quality, quantity, intricacy in
casting, minium thickness desired
degree of accuracy and finish
required
Possibility of design and change
Type of producing of casting, moulding
methods and equipment used
Pattern Materials should be:
Possibility of repeat orders
Easily worked shaped and joined
Light weight in handling and working
Resistant to wear, abarasion, corrosion
and chemical actions
Stable dimension, even in variation of
temp and humidity
Available at low cost
Repaired and reused
Good surface finish should be obtained
Wood Patterns
Advantages:
Ad
t
Li ht weight,
Light
i ht llow cost,
t easily
il shaped
h
d and
d jjoined
i d any complex
l
shapes and easily available
Limitation: Moisture swelling,
g, Poor wear resistance,, poor
p
strength
g
Wood = 50 to 60% Cellulose and 20 to 35% Liginin (complex amorphous
materials) + carbohydrates (pentosannes, resin, gums and mineral matter
Cell wall are hygroscopic and cellolose and hydroxly groups are hydrophylic
water absorbant and swells dimensional instability
Dried- cell cavity empty
Dried
empty- but 25 to 30% moisture present
EMC- Equillibrium moisture content 60% relative humiditz and 20 C temp EMC is 11%
Wood Patterns
Seasoning of Timber
Natural (i) air drying full cycle weather condition
(ii) immersed in flowing water and air drying
To make it light, take preservatives, paint and polish
Pine
Compressed wood
laminate
Metallic Patterns
Repetitive Production large quantities
Al, cast iron, steel, bronze or brass
Cast Iron- IS 210-1962 BHN 197-241 - heavy weight small size
patterns
Aluminium is used largely - 4223,
4223 4600 and 4420 (Al-Si)
(Al Si) IS: 617
6171975, precipiation hardend and solution treated - Duraluminium
Brass and Bronze high physical strengh
Low metling point metals : whilte metal and cerro alloys contains tin
and bismuth Low coefficient of thermal expansion and melting point is
138C
38 C
Metal electro deposiioin electro plating for nickel, copper chromium
Frozen Mercury MercastMercast prohibitively high cost
Metal patterns are cast from master patterns for large quntitites
Metallic Patterns
Plaster Patterns
Gypsm (plaser of paris) - 300 kg/cm2 - High compressive strength
Can
C b
be mixed
i d with
ith ttalc
l or portland
tl d cementt tto gett h
hardness
d
Pouring the slurry (water+gypsm) into desired shape by the sweep
and strickle method
Epoxy resin
Castable machining superfluous
High strength to weight ratio (better
than Al and Cast iron)
Wear and abrasion resistant
No moisture no heating when
reacting with sand
Resin combination two component
materials
t i l : liliquid
id bi
binder
d + liliquid
id h
hardner
d
+
time
1. Gel coat and surface coat resin
2 L
2.
Laminating
i ti resin
i
3. Casting resin
4. Polyster resin
5. Polyester resin a cheaper substitute
Waxes
Used
U
d ffor iinvestment
t
t casting
ti history
hi t
jewelleries
j
ll i
Parafin wax, carnauba wax, shellac wax, bees wax, cerasin wax and
microcrystalline wax.
Burnt ash content is < 0.05%
Coat for investment casting
High tensile strength
Hardness, good wettabiliy, resistance to oxidation, low shrikage
9
1. Pattern wax
(a) straight or unfilled wax 9
(b) Emulsified pattern wax 9
9
(c) Filled pattern wax
9
9
2. Runner Wax
9
3. Reclaimed or reconstituted wax
9
4 Water soluable wax
4.
9
5. Special waxes
9
Storage area
1.
2.
3.
4
4.
1. W
1
Weather
th prooff , fire
fi prooff
2. Expensive patterns needs
temperature and humidity
control
3. Seperate area or floors for
heavy medium and light
patterns
4 Small patterns can be kept in
4.
racks with proper
identification mark
Machine moulding
Floor Moulding
Contains no special arrangement or passages for the melt
to reach the cavity
Simple
Si l casting
ti nott much
h surface
f
finish
fi i h
Floor plates, weights, mould boxes, manhole covers and
drain covers
g , risers is placed
p
at that top
p_
Flask ((contains runners,, gate,
similar to cope
Odd s
side
de moulding
ou d g
St k moulding
Stack
ldi
large no. of
castings with
small size
Drag
Runner
Cope
Drag
Cope
Drag
Sand Moulding
Types
Green sand
moulding
Dry sand
moulding
Skin dry
moulding
Sand Moulding
Loam
moulding
Oil sand
moulding
Linseed oil
oil, blends of oils (vegetable oil
oil, animal oils
oils, natural resin
resin,
known as core oil is used
Sand and dextrin and bentonite
Mostly for making cores slide 53
Sand: 100 Kg, core oil: 1-2 Kg, dextrin: 0.5-1Kg, bentonite: 0.5-1kg,
water: 2Kg
Baked at 220-230oC
200 220, green compressibility: 400-500
400 500 g/cm2
Green permeability 200-220
(0.004-0.005 MPa), baked tensile strength, 0.5 to 1.5 MPa
Equipment Moulding
Moulding machines
Equipment Moulding
Power operated machines
Hydraulic or pneumatic
Raising /lowering the table
Ramming by squeezing and jolting
and rolling over the mould boxes,
Pattern withdrawal
Mould is conveyed to assembly and
pouring
i
Squeezing
Flaskk (or
Fl
( box)
b ) is
i filled
fill d with
ith mould
ld
sand and it is squeezed against
the pressure board to achieve
desire densityy
Disadvantages is density
decreases with depth
Pin-lift moulding
machine
Equipment Moulding
Jolting
Flask (or box) is filled with mould sand and mechanical lifted and dropped
repeatedly. Sand get packed and rammed.
Disadvantages good density in the parting plane and around the pattern
less dense in the top surface-needed hand ramming after jolting
Jolt and squeeze To over come both the
disadvantages the combine jolt
and squeeze is done
specification
ifi ti
for
f a moulding
ldi
box
b
800mm X 630 mm
Slinging
Sand is throwed through a slinging head at high velocity to the patternsand particles settles down instantly and get rammed
high speed rotary impellers, pipes band conveyer , bucket elevator and
ejecting head ( to move evenly to attain uniform density through out )
Equipment Moulding
Schematic Diagram of Sand Slinger
Equipment Moulding
Stationary Sand Slinger
Equipment Moulding
High Pressure moulding (for high compaction pressure)
Force of compaction is 5 to 10 times greater than conventional moulding
Suitable for all cast metals
Considered worthwhile for mass
production due to high investment
cost
Flask- less moulds used due to high
pressure
Design specification IS: 10518-1983
Equipment Moulding
1 Bl
1.
Blow squeeze
Sand is blown pneumatically on the pattern and squeezing
2.
Impact moulding
Air impulsed or gas injection- high degree of compaction at
very short time
3. Shoot squeeze
q
sand is ejected from the shooter head - impinge at pattern
at heavy force 500 kg of moulds in cycle of 45 to 60
seconds
4. Vacuum Press
Vacuum is created in the moulding chamber sand shot
enabling filling vacuum is squeezed to achieve complete
compaction close tolerance intricate castings
Moulding using machines depends upon the requirement,
Close tolerance, uniform density/mould hardness/ green
strength, minimize rejection (foundry and machine shop
like 1-2%),
3. Moisture
Water is added into the clay which foams a microfilm over the particle.
Thickness increases with the increase in water content and at a stage become
fluid
Moisture content is the most important parameter
Si
Sieve
Shaker
Sh k
Total Product
Total sum of pct. Collected in
each sieve
vh
pa.t
v - volume of air in cc
h - height of the sample
in cm
p - pressure of air g/cm2
t time in minutes
IS: 10498-1983
Thermo lab
dilatometer
Sintering point of
sand
High silica sand, clay, core oil (mixture of oils) ref. slide 32, resin, ext.,
Pouring basin
plug
dam
Spr e
Sprue
Runner
Parting gate
Top GATES
R=
(W ) p
t
(1.34 +
13.77
R=b W
R
Ra =
k .c
a
H = h
2c
As = Ra (d 2gH )
1 V
t =
2
q A
If casting solidifies rapidly, the feeder volume need to be only equal to the
solidification shrinkage of the casting. Or if the feeder of the casting solidify
at the same rate, the feeder must be infinitely large
X =
+C
Y B
3 Types of riser
3.
Explosive in the
bli d riser
blind
i
cavity
it
blind riser
Open riser
Use of Padding
Adding excess metals avoid shrinkage- directional solidification cannot be
achieved padding is useful
Casting Process
Casting Process
Sand Casting
Most common casting process
High tonnage of castings
Includes moulds core and pattern
making
Only gravity pouring
Temporary mould
G d dimensional
Good
di
i
l accuracy
Slow cooling rate homogeneity in
composition minimal segregation
Surface cleaning
g and finishing
g is
required
Casting Process
Pressure die casting die casting, die
casting machines and types
Dies
High pressure melt or high
velocity melt need strong
die/mould
Die-cast machining
Cover die
die- the stationery
Ejector die opens and close
Dies- alloy steel wear
resistance withstand heat
checking- not to get solder with
cast alloys tough and resist
erosion
Casting Process
Casting Process
Casting Process
Hot Chamber Machine
Casting Process
Casting Process
Cold Chamber Machine
Casting Process
Casting Process
Casting cycle for Cold -Chamber Machine
Casting Process
Casting Process
Casting Process
Casting Process
Investment casting or Lost wax Process
Casting Process
Investment casting or Lost wax Process
Polystyrene shell
coating,
ti
stuccoing,
t
i
and
d hardening.
h d i
Final Product
Magnesium based alloys will be challenging
Casting Process
I
Investment
t
t casting
ti
or Lost
L t wax Process
P
Steps involved
P tt wax is
Patten
i injected
i j t d iinto
t th
the metal
t l die
di tto fform a di
dispensable
bl pattern
tt
Adding gates, sprue, runner using wax (cluster of waxes)
3. a) Solid moulding - A flask is put over the cluster and sealed to the base
plate to form a container. A hard setting moulding materials is poured filling
the patter cluster completely
(b) Shell moulding- Ceramic shell is formed by different coating (ceramic
grain) until required thickness is arrived
Pattern removal: Backed at 600C wax vapourizes
Casting: The shell is filled with molten metal- after solidification Knocked
off.
off
Casting Process
I
Investment
t
t casting
ti
or Lost
L t wax Process
P
Primary Coat
Si(OC2H5)4 + 4H2O 4C2H5OH + Si(OH)4
Gives Silica gel in a hydrolysed solution of water, that imparts bond
Stuccoed or stuccoeing dipping in a coating of slurry with granulated
refractor sprinking or suspended
Refractory particles 20 to 100 mesh final grain initial coat
followed by coarse grain coat Zircon
Pattern using expandable materials
Wax or polystyrene is used due to its greater dimensional
accuracy for patterns
Mercury is used mercast cooling it at < -56C working
temperature is at 38C then bring to room temperture and pour it
out
Casting Process
I
Investment
t
t casting
ti
or Lost
L t wax Process
P
Advantages
High degree of accuracy 0.1 mm, surface finish 1-5 m
All metals and alloys can be casting Bimetallic castings
Complex shaped parts - extremely difficult by other methods
Close control in microstructures grain size, orientation, defects
hence good mechanical properties
Adopted for mass production
Disadvantages
Best applicable
pp
for small casting
g weighing
g g for few g
grams to 5 Kg
g
Precise control is required for every stages of production pattern,
moulding - making investment
Raw materials
materials- tooling,
tooling equipments and technology are expensive
Casting Process
Squeeze Casting
Forging or hot deformation + Casting
Squeeze action from all direction
Melt temperature is controlled metal
die interface should be at solidus
Need accurate control compression
ti
time,
compression
i pressure,
compression temperature, punch and
lubricant die
Used to produce composite need good
distribution fibre- particles - nano
Casting Process
Centrifugal Casting
Moulds
Green sand
Dry sand
CO2 moulding
Permanent mould - graphite
is used
Grey casting iron
Steel
Aluminium alloys
Faster cooling causes
uniform fine grain structure
Casting Process
Centrifugal Casting
Casting Process
P
Permanent
t mould
ld casting
ti
Permanent Mold Casting (or Gravity Die Casting): Making a metal
mold, pouring molten metal (of lower melting point) into the cavity,
and
d removing
i the
th partt when
h solidified.
lidifi d
Dies used in PMC
Simple
Simple die
Recessed Die
Hinged Die
Multi-staged die
Casting Process
P
Permanent
t mould
ld casting
ti
Casting Process
Continous casting
Casting Process
Continous casting
1. Continous production of casting billets, rods, plates
and tubes
2 Vertical axis or vertical + partly horizontal
2.
3. Non- ferrous (copper mould is used) and Ferrous
water cooled
Casting Process
Electro-slag
Electro
slag casting
Casting Process
Defects in Casting
Major Defects- cannot be rectified
rejected
Defects can be remedied cost of
repair may effect
Minor defects- economically
salvaged
DEFECTS
Warpage
Swell
Fin
Blowholes
Pinholes
Gas holes
Shrinkage cavity
Porosity
Drops
Dirt
Metal penetration and rough surfaces
Slag holes
Scabs
Hot tears
Cold cracks
Cold shut and Mis-run
Air furnaces
Advantages
1. No wastage
g of fuel regulated
g
2. Output in given time is greater due to
higher efficiency
3. Better temp control
4 Less contamination
4.
5. Saving floor space
C t IIron, Malleable
Cast
M ll bl IIron, B
Brass and
d bronze
b
Operation
Preparation of cupolaCleaning the refractory lining removing the slag in
the surface
Soaking
S
off Iron
Opening of Air Blast
Pouring the Molten Iron
Closing the Cupola
Air requirements for Cupola
8750
8750 7
=2
= 2 x 52.77 = 105.54 cm
I d ti
Induction
melting
lti furnace
f
Fastest
Fastest melting
0.3 to 6 tonnes
700 to 1000 kWh
Graphite
flakes
Visual
Inspection
p
Dimensional
inspection
p
Mechanical and
Chemical Testing
g
Non-destructive
methods
Metallurgical
Inspection
p
Standard
measuring
instruments
Tensile and
compressive test
Bend, notch bend,
impact test
Fatigue test
Damping capacity
test and wear
resistance
Sound and
percussion test
Chill test
Chemical analysis
Electrical
Conductivity
Templates and
contour gauges
Limit gauges
Special fixtures
Coordinate
measuring and
marking
machine (CMM)
Fracture test
Impact test
Pressure test
Radiography (RT)
Macro-etching
test
Sulphur print
Magnetic particle
(MT)
Fluorescent
uo esce t dye
penetrant test (PT)
Ultrasonic testing
(UT)
Eddy current test
(ET)
Microscopic
Examination
o Etching
o SEM
With skill cracks longer that 1mm and a fraction mm deep can be detected
High frequencies
Case depth, case hardness,
surface flaws, segregation
Low Frequencies
Sub-surface flaws, segregation,
grain structure and chemical
composition.
iti
Testing hardness of rolled, forged,
extruded,, sintered or cast
components, in ferrous and nonferrous alloys.
Metallography
Optical Microscope
Grinding
Polishing
Etching
Microscopic
Mi
i
examination