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Consider the casting process at 645 B.C, the first traces of the Sand Molding was found. Now consider the stateof-the-art Electromagnetic casting process. Truly, the Casting process has traversed a long path and impacted human civilization for nearly five millennia. With technological advances, metal casting is playing a greater role in our everyday lives and is more essential than it has ever been.
Special requirements such as, magnetism, distribution choice Process. of corrosion, also the Metal stress the Casting influence
Views of the Tooling Designer; Foundry / Machine House needs, customer's exact product requirements, and secondary operations like painting, must be taken care of before selecting the appropriate Metal Casting Process.
Tool cost. Economics of machining versus process costs. Adequate protection / packaging, shipping constraints, regulations of the final components, weights and shelf life of protective coatings also play their part in the Metal Casting process.
The
Hot
Metal
Casting
or
just
Casting
process
may
be
divided
into
two
groups:
Process
Forming
Examples are Centrifugal casting, Extrusion, Forging, Full mold casting, Investment casting, Permanent or Gravity Die casting, Plaster mold casting, Sand Casting, Shell Mold casting. The method to be used depends upon Cold the nature of the Forming products to be cast. Process
Examples are Squeeze casting, Pressure die casting, Gravity die casting, Burnishing, Coining, Cold forging, Hubbing, Impact Extrusion, Peening, Sizing, Thread rolling.
Least
Expensive (less
in than
small Dimensional accuracy inferior to Use when strength/weight ratio 100) other processes, requires larger permits tolerances Tolerances, surface finish and low usually exceed machining cost does not warrant a weight more expensive process calculated
quantities
Possible to cast very large parts. Surface finish of ferrous castings • Least expensive tooling usually exceeds 125 RMS
Permanent and Semi-permanent Mold Casting Less expensive than Investment or Only non-ferrous metals may be Use when process recommended Die Dimensional than Castings cast Tolerances Sand by this process for parts subjected to hydrostatic pressure closer Less competitive with Sand Cast cores Castings are dense and pressure tight Higher tooling cost than Sand Cast Plaster Cast Smooth "As Cast" finish (25 RMS) More Closer dimensional tolerance than Sand Cast Limited number of costly than Sand or Use when parts require smooth tolerances than possible with Sand sources or Permanent Mold Processes are required no cores and quantities in excess of 300 Castings process when three or more sand Ideal for parts having low profile,
Permanent
• Intricate shapes and fine Requires minimum of 1 deg. draft details including thinner "As Cast" walls are possible
• Large parts cost less to cast than by Investment process Investment Cast
are
higher Mold
than or
Sand, Use when Complexity precludes Plaster use of Sand or Permanent Mold Castings The process cost is justified
through savings in machining or Ferrous and non-ferrous metals may be cast Weight savings justifies increased As-Cast" finish (64 - 125 RMS) Die Casting Good dimensional tolerances are Economical only in very large Use when quantity of parts justifies possible Excellent part-part quantities due to high tool cost the high tooling cost cost brazing
dimensional Not recommended for hydrostatic Parts are not structural and are pressure applications subjected to hydrostatic pressure
post For Castings where penetrant (die) or radiographic inspection are not required. Difficult to guarantee minimum mechanical properties
machining