CHAPTER 12

Metal Casting:
Design, Materials, and Economics
 Casting Design Modifications

應力集中

應
力
集
中

曲率

Note that sharp corners are avoided to reduce stress concentrations.

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 Elimination of Hot Spots

Figure 12.2 Examples of designs showing the importance of maintaining

uniform cross-sections in castings to avoid hot spots and shrinkage cavities.
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Avoiding Shrinkage Cavities
by Design Change

Examples of design
modifications to avoid
shrinkage cavities in castings.
Source: Steel Castings
Handbook, 5th ed. Steel
Founders' Society of America,
1980. Used with permission.

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Avoiding Shrinkage Cavities by Chills

The use of metal padding

(chills) to increase the rate
of cooling in thick regions
in a casting to avoid
shrinkage cavities. Source:
Steel Castings Handbook,
5th ed. Steel Founders'
Society of America, 1980.
Used with permission.

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Linear Shrinkage Allowance for
Some Metals Cast in Sand Molds
TABLE 12.1
Metal Percent
Gray cast iron 0.83–1.3
White cast iron 2.1
Malleable cast iron 0.78–1.0
Aluminum alloys 1.3
Magnesium alloys 1.3
Yellow brass 1.3–1.6
Phosphor bronze 1.0–1.6
Aluminum bronze 2.1
High-manganese steel 2.6

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 Volumetric Solidification
Contraction for Various Cast Metals

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 Desirable and
Undesirable Die-
Casting Practices

Examples of undesirable and

desirable design practices for die-
cast parts. Note that section-
thickness uniformity is maintained
throughout the part. Source:
American Die Casting Institute.

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 Allowance between Pattern and Casting
Add 2-5(up to 25)mm around
for machining

0.5° -2° draft

allowance

P.L.
V slot to be machined
Original outline with shrinkage
rule
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_ _
+

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Table 12.6, 11.1和11.2 重要

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 General Cost Characteristics of
Casting Processes
TABLE 12.6
Cost*
Production
Process Die Equipment Labor rate (Pc/hr)
Sand L L L–M <20
Shell-mold L–M M-H L–M <50
Plaster L–M M M–H <10
Investment M–H L-M H <1000
Permanent mold M M L–M <60
Die H H L–M <200
Centrifugal M H L–M <50
* L, low; M, medium; H, high.

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13
TABLE 11.1
Process Advantages
Sand Almost any metal cast; no limit
to size, shape or weight; low
tooling cost.
Shell mold Good dimensional accuracy and
surface finish; high production
rate.
Expendable pattern Most metals cast with no limit
to size; complex shapes
Plaster mold Intricate shapes; good
dimensional accu- racy and
finish; low porosity.
Ceramic mold Intricate shapes; close
tolerance parts; good surface
finish.
Investment Intricate shapes; excellent
surface finish and accuracy;
almost any metal cast.
Permanent mold Good surface finish and
dimensional accuracy; low
porosity; high production rate.
Die Excellent dimensional accuracy
and surface finish; high
production rate.
Centrifugal Large cylindrical parts with
good quality; high production
rate.
Limitations
Some finishing required;
somewhat coarse finish; wide
tolerances.
Summary of
Part size limited; expensive
patterns and equipment
Casting
required.
Patterns have low strength and
can be costly for low quantities
Processes
Limited to nonferrous metals;
limited size and volume of
production; mold making time
relatively long.
Limited size.
Part size limited; expensive
patterns, molds, and labor.
High mold cost; limited shape
and intricacy; not suitable for
high-melting-point metals.
Die cost is high; part size
limited; usually limited to
nonferrous metals; long lead
time.
Equipment is expensive; part
shape limited.
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 General Characteristics of Casting Processes
TABLE 11.2
Typical
Typical Weig ht (kg) surface Section thic kness (mm)
materials finish Shape Dimensional
Process cast Minimum Maximum (mm, Ra) Porosity* complexity* accuracy* Minimum Maximum
Sand All 0.01 No limit 5-25 3-5 1-2 3 3 No limit
Shell All 0.01 100+ 1-3 4-5 2-3 2 2 --
Expendable
mold
pattern All 0.01 100+ 5-20 3-5 1-2 3 2 --C7
Nonferrous
Plaster (Al, Mg, Zn,
mold Cu) 0.01 50+ 1-2 4-5 1-2 2 1 --
All
(High melting
Investment pt.) 0.001 100+ 0.3-2 5 1 1 1 75
Permanent
mold All 0.1 300 2-6 2-3 2-3 1 2 50
Nonferrous
(Al, Mg, Zn,
Die Cu) <0.01 50 1-2 1-3 3-4 1 0.5 12
Centrifugal All 0.01 5000+ 2-10 1-2 3-4 3 2 100
*Relative rating: 1 best, 5 worst.
Note : These ratings are only general; significant variations can occur, depending on the methods used.

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16
 Ch 12

精讀：12.1, 12.4
略讀： 12.2 (except 12.2.3), 12.2.4

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