Professional Documents
Culture Documents
Jan-May 2018
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Sand casting
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Pattern
•Functions of the pattern
•Pattern material
•Pattern allowances
•Types of patterns
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Pattern
•A pattern is a replica of the object to be made by the casting
process, with some modifications.
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Functions of the pattern
•It defines the mould cavity.
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Pattern material
•Wood
•Metal and alloys
•Plaster of Paris
•Plastics and rubbers
•Wax
•Resins
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Pattern material (wood)
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Pattern material (Polymer)
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Pattern material (wax)
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Pattern material characteristics
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Pattern allowances
•Pattern always made larger than the final object
•Excess dimensions - Pattern allowance
•Shrinkage allowance (Contraction of casting)
Liquid (pouring temperature to liquidus)
Compensated from liquid feeding from the riser
Solidification (Liquidus to solidus temperature)
Compensated from liquid feeding from the riser
Solid (Solidus to room temperature)
Compensated by providing shrinkage allowance on the patterns
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Pattern allowances (Shrinkage)
Room Pouring
temperature temperature
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Pattern allowances (Shrinkage)
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Pattern allowances
•Draft allowance
To withdraw pattern from the mould
•Machining allowance
To obtain the final shape (finishing operation)
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Pattern types
Choice of pattern depends upon
•Configuration of casting
•Number of objects required from one processing cycle
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Pattern types
•Single piece pattern
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Pattern types
•Spilt pattern
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Pattern types
•Match plate pattern
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Pattern types
•Cope and drag pattern
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Casting process flow chart (sand casting)
•Pattern and mould
•Melting and pouring
•Solidification and cooling
•Removal, cleaning, finishing and inspection
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Mould
Open and closed mould
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Mould types
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Casting processes
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Sand casting process
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Sand casting process
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Main constituents of moulding sand
•70-85% base sand: silica sand, zircon sand, Chromite
sand, and olivine sand
Size: Small, medium, large silica sand grain
Shape: Angular, sub-angular and rounded
•10-12% bonding material (binder)
Kaolinite or fire clay (Al2O3 2 SiO2 2 H2O) and Bentonite
(Al2O3 4 SiO2 nH2O). Bentonite can absorb more water
which increases its bonding power.
•Additives
Coal dust, wood flour etc.
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Properties of moulding sand
Refractoriness
Ability of molding sand to withstand high temperatures
without breaking down or fusing thus facilitating to get sound
casting. The refractoriness of the silica sand is highest.
Permeability
Porosity of the molding sand in order to allow the escape of any
air, gases or moisture present or generated in the mould when
the molten metal is poured into it.
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Properties of moulding sand
Adhesiveness
It is property of molding sand to adhere with foreign material
such as sticking of molding sand with inner wall of molding box
Collapsibility
The molding sand should be easily collapsible. It should not
resist the contraction of the solidified casting, which may result
in cracks in the castings.
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Effect of moisture, grain size and shape on mould quality
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Effect of moisture, grain size and shape on mould quality
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Effect of moisture, grain size and shape on mould quality
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Temperature dependence of the green tensile strength
Sand + Bentonite
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Na effect
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Casting process flow chart (sand casting)
•Pattern and mould
•Melting and pouring
•Solidification and cooling
•Removal, cleaning, finishing and inspection
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Melting and pouring
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Melting
•Metal => Molten/liquid state
•Furnace: basic ore refining process and to melt the metal
•Different furnaces are employed for melting and re-melting
ferrous and nonferrous materials
Important factors
Casting alloy, its melting point and pouring temperature
Capacity requirement of the furnace and its efficiency
Cost of investment, operation and maintenance
Environmental pollution considerations
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Furnace for melting different materials
Cupola furnaces (Cast Iron, Steel)
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Furnace for melting different materials
Cupola furnaces (Combustion fuel: Coke)
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Blast furnace
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Crucible furnace
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Electric arc furnace
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Induction furnaces
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Melting
•Raw material (Charge)
-Alloying materials, scrap
•Atmosphere
-Air (oxygen), vacuum, inert gas (argon)
•Heating source
-External: electric, gas, oil
-Internal: induction, mix fuel with charge
- Steel making in blast furnace-mix coke with iron
•Furnace material
-Refractory ceramics
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What is the time req for melting in furnace
•Idli making
W= calculated from
volume change in idli
H V [cs (Tm Ti ) H f cl (T p Tm )]
Problem
Calculate the time required to raise the temperature of a 130 kg
aluminum billet from 25 ºC to 100 ºC above its melting point
using a 20 KW furnace (Efficiency: 75%).
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Melting time (data required)
Problem
Calculate the time required to raise the temperature of a 130 kg
aluminum billet from 25 ºC to 100 ºC above its melting point
using a 20 kW furnace (Efficiency: 75%).
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Pouring
Pouring: process by which the molten metal is delivered into the
mould. It involves melt flow through the gating system and into
the main cavity
Goal: Metal must flow into all regions of the mould, particularly
the casting's main cavity, before solidifying.
Important parameters:
a) Pouring temperature
b) Pouring rate
c) Turbulence
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Pouring
Pouring temperature: temperature of
the molten metal used for the casting
as it is poured into the mould.
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Fluidity
Fluidity: Capability of the molten metal to fill the mould cavities
•Characteristics of molten metal
•Casting parameters
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Fluidity
Characteristics of molten metal
Viscosity
Surface tension
Inclusions
Solidification pattern of the alloy
Casting parameters
Mould design
Mould material and surface characteristics
Degree of superheat
Rate of pouring
Heat transfer
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Fluid flow and gating design
Minimize turbulent flow to reduce
•Absorption of gases,
•Oxidation of metal and
•Erosion of mould surfaces
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Fluid flow and gating design
Basic components of a simple gating system
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Fluid flow and gating design
Pouring (fluid flow)
•Reynold’s number
•Bernoulli’s equation
•Continuity
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Fluid flow and gating design
Reynold’s number (Re)
Ratio of momentum (inertia) to viscosity
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Fluid flow and gating design
•Bernoulli’s equation
Used to calculate flow velocities
Assumptions: steady state, incompressible, inviscid flow
v 2
P gh f cons tan t
2
P= pressure g= gravity
ρ= density h= height
V= velocity f= loses due to friction
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Fluid flow and gating design
•Continuity
Assumptions: steady state, incompressible, inviscid flow
Q Q
0 1
A v Av
0 0 1 1
Where,
Q = volumetric flow rate
A = area
v = velocity
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Fluid flow and gating design
Sprue top
Velocity at point 3?
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Fluid flow and gating design
v12 v3 2
P1 gh1 P3 gh3
2 2
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Mould filling time estimation
•Gate is at point g
•Using continuity
Q A v A v
g g 3 3
•Assuming Ag A3
v gate v3 2 ght
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Problem
•Given
-Height of the sprue (ht) = 20 cm
-Area of sprue (A3) = 2.5 cm2
-Volume of the mould cavity (V) = 1560 cm3
•Find
-Vsprue
-Flow rate (Q)
-Mould filling time
-flow type
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Solution
Vbase of sprue = 2 ght = 2 * 981* 20 = 198.1 cm/s
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Number of gates in a system
•The number of gates needed to fill a casting cavity in an
acceptable time is determined by the:
-Casting size
-Casting complexity
Plate casting
Objective: Uniform and quick filling
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Number of gates in a system
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Flow through sprue
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Changes in cross sectional of a flow channel
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Flow through sprue
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Casting process flow chart
•Pattern and mould
•Melting and pouring
•Solidification and cooling
•Removal, cleaning, finishing and inspection
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Riser design
•Liquid shrinkage
Riser
•Solidification shrinkage
•Solid shrinkage Pattern making
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Riser design
Volumetric contraction of various cast metals
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Chvorinov’s rule (Riser design)
•Solidification time as a function of shape and size
n
V
ts k
A
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Riser design
•Purpose: to accommodate the liquid shrinkage and to
supply liquid feed metal to compensate for the
solidification shrinkage within the casting
•Design issues:
Riser must solidify after the casting
Risers must feed a volume of metal equal to the part’s
shrinkage
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Riser design
•Riser must solidify after the casting (sand casting)
2 2
V V
A riser A casting
V
Modulus(M )
A
M =a/6
M =t/2
L = W >> t
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Location, shape and size of a riser
Example: Step bar
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Other expendable mold casting process
•Shell molding
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Other expendable mold casting process
•Vaccum molding
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Other expendable mold casting process
•Expandable polystyrene
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Other expendable mold casting process
•Investment casting or lost wax
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Permanent mold casting
•Slush casting,
•Low pressure casting, Self study
•Vaccum permanent mold casting
Hot Cold
chamber chamber
7 -35 MPa 14 -140 MPa
Centrifugal
centrifuge
Semi centrifugal
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Horizontal true centrifugal casting
True centrifugal
•Centrifugal force
𝒎𝒗𝟐
•𝑭 =
𝑹
v-velocity, R-inside radius
𝑭 𝒎𝒗𝟐 𝒗𝟐
•G factor, 𝐆𝑭 = = =
𝒘𝒆𝒊𝒈𝒉𝒕 𝑹𝒎𝒈 𝑹𝒈
𝟐𝝅𝑹𝑵
•S𝐮𝐛𝐬𝐭𝐢𝐭𝐮𝐭𝐢𝐧𝐠 𝐯 = ;
𝟔𝟎
𝟑𝟎 𝒈 𝑮𝑭
•𝑵 =
𝝅 𝑹 87
Horizontal true centrifugal casting
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Casting process flow chart
•Pattern and mould
•Melting and pouring
•Solidification and cooling
•Removal, cleaning, finishing and inspection
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Casting solidification
•Transformation of molten metal into solid state
Solidification differs:
-Pure element
-Alloy
•Solidification process influence the final casting quality
•Influence the material properties of the final casting
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Solidification (pure metals)
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Solidification (pure metals)
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Dentritic solidification
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Solidification (Alloy)
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Solidification (Alloy)
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Solidification (freezing range)
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