Professional Documents
Culture Documents
When solidified, the desired metal object is taken out from the
mold either by breaking the mold or taking the mold apart.
The mold, into which the metal is poured, is made of some heat
resisting material.
products.
Metal Casting:
1958 H.F. Shroyer is granted a patent for the full mold process,
the forerunner of the expendable pattern (lost foam) casting
process.
Casting Terms:
Casting Terms:
1. Flask: A metal or wood frame, without fixed top or bottom, in which
the mold is formed. Depending upon the position of the flask in the
molding structure, it is referred to by various names such as drag lower molding flask, cope - upper molding flask, cheek
- intermediate molding flask used in three piece molding.
3. Parting line: This is the dividing line between the two molding flasks
that makes up the mold.
on the inner surface of the mold cavity to give a better surface finish
to the castings.
Casting Terms:
6. Core: A separate part of the mold, made of sand and generally baked,
which is used to create openings and various shaped cavities in the
castings.
7. Pouring basin: A small funnel shaped cavity at the top of the mold into
which the molten metal is poured.
8. Sprue: The passage through which the molten metal, from the pouring
basin, reaches the mold cavity. In many cases it controls the flow of
metal into the mold.
9. Runner: The channel through which the molten metal is carried from
the sprue to the gate.
10.Gate: A channel through which the molten metal enters the mold
cavity.
11.Chaplets: Chaplets are used to support the cores inside the mold
cavity to take care of its own weight and overcome the metallostatic
force.
12. Riser: A column of molten metal placed in the mold to feed the
castings as it shrinks and solidifies. Also known as "feed head".
13. Vent: Small opening in the mold to facilitate escape of air and gases.
Patternmaking
Core making
Molding
Cleaning
Pattern making
The pattern is a physical model of the casting used to make
the mold. The mold is made by packing some readily
formed aggregate material, such as molding sand, around
the pattern. When the pattern is withdrawn, its imprint
provides the mold cavity, which is ultimately filled with
metal to become the casting. If the casting is to be hollow,
as in the case of pipe fittings, additional patterns, referred
to as cores, are used to form these cavities.
Core making
Cores are forms, usually made of sand, which are placed
into a mold cavity to form the interior surfaces of castings.
Thus the void space between the core and mold-cavity
surface is what eventually becomes the casting.
Types of patterns,
Patterns:
Definition of a Pattern
A pattern is a form of wood, metal, or other suitable
material around which molding material is packed to
produce the mold cavity.
Patterns:
Patterns:
Patterns:
Types of patterns:
Types of Patterns:
Types of Patterns:
Types of Patterns:
Types of Patterns:
Types of Patterns:
o
Split Pattern:
The split patterns are commonly used for the casting of steam
valve bodies, small pulleys, wheels and cylinders etc.
Types of Patterns:
Match plate pattern are used for moderate to high volume prod small
and medium size castings with considerable dimensional accuracy.
Types of Patterns:
Match plate pattern are used for moderate to high
volume production of small and medium size castings
with considerable dimensional accuracy.
Types of Patterns:
Gated Pattern
The gated pattern is used for mass production.
For small castings, multi cavity moulds are prepared i.e.
single moulds carry a number of cavities. Each pattern may
be provided with a gate pattern with it examples are Vice
Handle, Nuts and bolts etc.
Types of Patterns:
o
Types of Patterns:
Types of Patterns:
Skeleton Pattern:
For large castings pattern would require a considerable amount of
timber for fully solid pattern.
In such cases the pattern is made of wooden frame and rib
construction so that it will form an exterior or interior outline of
casting, this framework is known as skeleton.
The gaps between ribs and frame are filled with molding sand, the
shape is obtained by using strickle board.
Skeleton patterns are generally employed for symmetrical castings.
Castings, which are generally made by making bodies, pipe bends,
water pipes and boxes.
Types of Patterns:
Sweep Pattern:
Uniform moulds and cores are shaped by sweep pattern.
The sweep pattern consists of a wooden board having a
shape corresponding to the shape of desired casting.
It is arranged to rotate about a central axis.
Types of Patterns:
Segmental Patterns:
Types of Patterns:
Pattern allowances
Pattern Allowances:
Metallurgical considerations
Example: Shrinkage allowance is the result of
metallurgical phenomenon.
Mechanical considerations
Example: Machining, draft, distortion, shake and other
allowances are due to mechanical reasons.
Shrinkage or contraction
allowance.
2.
3.
4.
5.
6.
Shrinkage Allowance:
2. Solid Shrinkage:
It refers to the reduction in volume caused when metal loses
temperature in solid state.
To account for this, shrinkage allowance is provided on the patterns.
Themetalshrinkagedependsupon:
1. The cast metal or alloy.
2. Pouring temp. of the metal/alloy.
3. Casted dimensions(size).
4. Casting design aspects.
5. Molding conditions(i.e., mould materials and molding
methods employed)
Machining Allowance:
A Casting is given an allowance for machining,
because:
i.
ii.
iii. It
iv. Surface
i.
Nature of metals.
ii.
iii. The
iv. Casting
v.
conditions.
ii.
iii.
iv.
Figure (a)
Pattern having
no draft on
vertical edges.
It is of irregular shape,
ii.
iii.
It is u or v-shape,
iv.
v.
It has long, rangy arms as those of propeller strut for the ship,
vi.
vii.
Shake allowance:
b.
Fillets:
Sharp edges and corners are to be avoided so these are filled with
fillets of wood or paste or such materials. The change in cross
sectional area should be smooth, there also chmpher or arc is
provided to avoid defects and stress concentration.
Pattern layout
&
Pattern construction
Pattern Layout:
Steps involved:
Pattern Construction:
Pattern colors
Pattern Colors:
o
i.
ii.
iii. Identify
iv. Visualize
Pattern Colors:
1.
2.
3.
4.
5.
6.
Patterns:
Pattern Materials:
Wood,
Plastic,
Plaster of Paris,
Pattern Materials:
2.
Light in weight
3.
4.
5.
6.
7.
Patterns:
Patterns:
Molding materials
Molding sands,
Grain fineness;
Moisture content,
Molding sands:
Molding sands:
Composition of molding sand:
o
Molding sands are mixtures of three or more
ingredients.
o
A green sand contains
Water
Sand:
o
Sand (Cont..):
o
Sand (Cont..):
o
Clay:
o
Clay (Cont..):
o Clays are defined as essentially aggregates of
extremely minute crystalline, usually flaked shaped
particles that can be classified on the basis of their
structure and composition into a few groups which
are known as clay minerals.
o
Types of Clay
Clay (Cont..):
Water:
o
Special Additives:
Asphalt:
It is a by-product of the distillation of petroleum. It is used for
the same purpose as pitch.
Sea Coal:
It is a finely ground soft coal used in molding sand for cast
irons, principally for the purpose of improving the surface
finish and ease of cleaning the castings. It is usually ground to
fineness similar to that of the molding sand in which it is
used. Percentages employed in sands are about 2 to 8 percent.
Graphite:
Synthetic or natural graphite may be used in percentages of
0.2 to 2.0 percent for the purpose of improving
the mouldability of the sand and surface finish of the castings.
o
o
Fuel Oil:
It is sometimes used in very small percentages, 0.01
to 0.10 per cent, and seems to confer improved
moldability to the sand.
Wood Flour:
Ground wood flour or other cellulose materials such
as cob-flour, cereal hulls, and carbonized cellulose
may be added in amounts of 0.5 to 2.0 per cent to
molding sands. They may function to control the
expansion of the sand by burning out at elevated
o
o
o
o
Silica Flour:
Pulverized silica, finer than 200 mesh, is called
silica flour. It may be used in amounts up to 35
percent for the purpose of increasing hot strength of
the sand. It also increases the density of the sand for
resisting metal penetration.
Iron Oxide:
Fine iron oxide is used in small percentage in some
sands to obtain added hot strength.
Perlite
It is an expanded aluminium silicate mineral, useful
Molasses, Dextrin:
Cane molasses, unrefined and containing 60 to 70
per cent sugar solids, may be used for increases dry
strength of the sand and edge hardness of moulds.
Dextrins may be used for the same purpose.
Binders:
Binders (Cont..):
Binders (Cont..):
(2)
()
()
Fig. Schematic illustration of sand grains as they may appear under magnification.
Green Strength:
The molding sand that contains moisture is termed as green sand. The
green sand particles must have the ability to cling to each other to impart
sufficient strength to the mold. The green sand must have enough strength
so that the constructed mold retains its shape.
Dry Strength:
When the molten metal is poured in the mold, the sand around the mold
cavity is quickly converted into dry sand as the moisture in the sand
evaporates due to the heat of the molten metal. At this stage the molding
sand must posses the sufficient strength to retain the exact shape of the
mold cavity and at the same time it must be able to withstand the metallostatic pressure of the liquid material.
Hot Strength:
As soon as the moisture is eliminated, the sand would reach at a high
temperature when the metal in the mold is still in liquid state. The strength
of the sand that is required to hold the shape of the cavity is called hot
strength.
o
o
Refractoriness:
It is the ability of the molding material to resist the
temperature of the liquid metal to be poured so that
it does not get fused with the metal. The
refractoriness of the silica sand is highest.
Collapsibility:
The molding sand should also have collapsibility so
that during the contraction of the solidified casting it
does not provide any resistance, which may result in
cracks in the castings. Besides these specific
Sample preparation:
Tests are conducted on a sample of the standard
sand.
D.
Clay Content:
o
a.
3,360
b.
c.
Mesh numbers are 6, 12, 20, 30, 40, 50, 70, 100,
200, and 270.
140,
b.
a pan at
The dried clay free sand grains are placed on the top
sieve of a sieve shaker which contains a series of
sieves one upon the other with gradually decreasing
mesh sizes.
Example:
GFN 41 : steel castings 50 Kg and
more;
67 : Small steel castings ;
105: Light cast iron and copper
castings;
150: Aluminum alloy castings.
o.
o.
o.
2. Stripped specimen
may be baked and tested
for various conditions as
a core specimen.
3. Stripped specimen
may be tested for green-
Strength determination:
o
o
o
o
Mould HardnessTesting:
Core materials
&
Core making
Introduction:
Core Definition:
Cores are sand (Refractory materials) bars or items designed
to form holes, slots recess and cavities in castings and also to
shape outer surfaces of cast pieces.
Core Materials:
Core sands
Core Binders, oil, clay & Resin binders, Synthetic Resin
Binders.
Core cements to join split cores.
Core box parting sand, powders & Dust.
Cores Requirements:
Cores have to resist high temperature, chemical reaction with
molten metal, metal penetration, hydraulic pressure of molten
metal, permit escape of gases evolved from molten metal etc.
To mold a casting with holes and cavities of the desired dimensions, as specified in
the casting drawing, it is necessary to properly locate the core in the mold, apart
from making it to accurate geometrical size.
For this the core must have a sufficient number of core extensions of certain length.
Also they must have such a shape as to exclude any shifting of the core.
After pouring the metal into the mold, the core may be regarded
as a body submerged into a liquid. Then the upward force of the
core that acts on the cope is to be considered.
Classification of Cores:
Cores are classified according to geometrical
dimensions, configuration, operating conditions in
the casting mold.
Class I:
This class includes the cores of intricate
configuration, and skeleton type cores with small
core prints. These cores form cavities to beleft as
cast, the surface finish of which must meet high
requirements. Cores for casting the parts of internal
combustion engines are a11example of the cores of
this class.
Class III:
These class of cores comprise the cores of
moderately complex configuration, which do not
have too thin members with massive core prints.
These cores form cavities whose as-cast surface
finish must satisfy rather high requirements.
Class IV:
These class of cores consist of the cores of simple
configuration. They form surfaces both subject and
not subject to machining, the roughness of which
need not comply with stern requirements.
Types of Cores:
Core Frames:
These are the reinforcement means molded into cores to increase strength. The
frames are made from wire or shaped cast iron plates. The core reinforcement must
fulfill the following requirements: give sufficient strength and rigidity to the core,
not spring or come off the core sand (soft, annealed wire will do for the purpose),
deform readily to allow for contraction of the casting, not stand in the way of vent
holes being made, and permit easy shakeout of the core from the casting.
Thin cores are reinforced with 1 or 12-mm wire inserted into the core boxes during
core molding.
Small and moderately sized cores are made with 6 to 10-mm wire frames whose
separate parts are fastened with a thinner wire. The reinforcement means for large
sand-clay cores are iron and steel cast frames with 6 to 10-mm cast-in wire inserts.
The framework for medium-sized and large cores includes lifting arrangements by
which the cores are suspended on the crane for delivering them to the assembly site.
Fig. shows wire and cast frames made in various shapes. Wire frames are laid along
the length of the core. They should terminate at least 2 or 3 mm short of the core
ends. The frame should pass into the prints to add to the core strength. If the core
has two prints located opposite each other, the frame should extend into both.
Core venting:
While pouring the mold with molten metal, mold
walls and cores heat up rapidly and give off a large
volume of gases. Since the molten metal has a
particularly strong effect on cores, these must have
vent holes.
The venting consists in making holes with a vent
wire, with steel rods or pipes molded into the cores
and subsequently removed after core molding, by
inserting wicks (which form holes after wax melting
and cord removal), Capron (name of town) mesh
tubes, straw braids (in casting pipes and cylinders),
and by packing up coke ash inside large cores during
Finishing of cores:
After the corns are baked a certain number of
operations are performed on them before they can
be set in the mold.
These operations are termed as Corefinishing.
Finishing work may be classified as follows:
Cleaning
Core assembly
Cleaning operations include all work done on the core except sizing
or assembly of cores.
Fins arise from loose joints or loose piece in the core box.
Blow holes and vent plugs often leave marks on the core which must
smoothed off.
Cores coatings:
Cores may be coated with refractory or protective
materials which improve their resistance to molten
metal or produce a better casting.
Venting of cores:
In some cores with large flat surfaces exact height is necessary so that
casting-wall thickness and location are accurate.
Core Assembly:
o
o
o
o
Types of gates:
1. Runners and gates which are formed at the parting plane
of the mold are known as parting-line gates.
a.Parting-line gates are the most frequently used. They
may be cut manually or formed with gate patterns on a
match
plate.
b.Parting-line gates take on many variations designed
to properly feed the casting, help control shrinkage, and
clean the metal as it flows into the cavity.
2. Top gates, which open directly into the cavity from above,
are not used so often as parting-line gates but on occasion
serve to feed the casting more efficiently. Common
variations are
wedge gates, finger gates, and pencil gates.
3. Bottom gates feed the metal into the cavity near the
bottom. A horn-shaped gate stick may be built into the
mold and
carefully removed to form a horn gate carrying
metal to the
bottom of the cavity, while ceramic gate
tubes or special-sand
cores serve to form other types of
bottom gates.
2.
3.
4.
Disadvantages:
Skin-dry molds:
1. A sand mold with a dry-sand facing and a greensand backing is called a skin-dry mold.
2. Applications:
a. Skin-dry molds may be used when casting
practically all of the ferrous and nonferrous
alloys.
b. Skin-dry molds are more common in large
molds,
since smaller molds may be made
Advantages:
a.Skin-dry molds are less expensive to construct
than dry-sand molds but more expensive than
green-and molds of a given size.
b.Less equipment is needed than for making a
dry-sand mold.
c.The materials required for skin-dry molds are
cheaper than fot dry-sand molds.
d.Skin-dry molding takes less time than dry-sand
molding.
e.Less floor space is needed in skin-dry molding
Dry-sand molds:
l. A sand mold made entirely with sand that does not re
quire moisture to develop strength (the binder makes the
difference) is called a dry-sand mold.
2. Applications:
a.Dry-sand molds may be used for many alloys but are
more common in the casting of steel.
b.Dry-sand molds are used most in small and medium
sized operations, although for larger operations drysand
molds may be made in sections and assembled after the
baking.
Cement-bonded molds:
1.
2. Applications:
a.Can be used for casting any alloy but most commonly
used in very large ferrous work.
b.Can be used in pit molding and other cases where
baking is impossible.
3. Advantages:
a.Cement-bonded sand develops strength by air drying.
b.Cement-bonded sand generally provides the advan
tages of dry sand.
Cement-bonded molds:
4. Disadvantages:
a.Cement-banded-sand molds require storage space for
the air-drying operation.
b.The materials used in cement-banded-sand molds are
less reusable than materials used in molds made with
other types of sand.
Sand-molding methods:
1.
Bench molding:
a. Relatively small molds made at a convenient bench
are called bench molds.
b. Green-sand, dry-sand, or skin-dry molds may be
made by bench molding.
c. Bench molding is usually slow and laborious, since
hand ramming with loose patterns is frequently
used.
2. Machine molding:
a. Small, medium, and large molds may be made with
the aid of a variety of machines.
b. Green-sand, dry-sand, and skin-dry molds can be
made by machine methods.
Fig. Molding-sand hoppers and mold conveyors. (Courtesy at National Engineering Co.)
Sand-molding methods:
3. Floor molding:
a. Medium and large molds made directly on the
foundry floor are called floor molds. .
b. Green-sand, dry-sand, or skin-dry molds may
be
made on the floor with the proper flasks.
c. Floor molding is slow and laborious, since it
usually requires hand ramming with loose
patterns.
4. Pit molding:
a. Very large molds made in a pit constructed for
the purpose are called pit molds.
2.2Casting practices:
Casting defects.
Sand casting,
Shell-Mold casting,
Mold casting (plaster and ceramic),
Investment casting,
Vacuum casting,
Permanent mould casting,
o
o
o
o
Slush casting,
Pressure Die casting,
Centrifugal casting,
Continuous casting,
Squeeze casting,
Shell-molding Process
Shell-molding Process:
A.Since its introduction this process has been called the Croning
process, C process, and finally shell process, or shell molding.
B.This process concerns making a mold that has two or more
thin, shell-like parts consisting of thermosetting resin bonded
sand.
1. The shells are single-purpose in application.
2. Shells are usually 3 to 6 mm thick, hard, and easily handled
and stored.
3. Shells are made so that matching parts fit together easily,
held with clamps or adhesives and poured in either a vertical or
horizontal position.
4. The shell molds may be supported in racks or in a mass of
bulky permeable material such as sand, steel shot, or gravel.
2. Disadvantages:
a.Initial cost of metal patterns and other
specialized equipment can be a disadvantage.
b.The resin binder is more expensive than other
binders,
although the over-all materials cost is not a
major Issue.
c.In general, a size limitation is apparent. This
http://www.youtube.com/watch?v=hAHj2MoSBYs
Procedural
Steps:
Step
1.Model
or Master Pattern Making:
This is made from CAD file or Drawing.
Using the dimensional data of CAD file or
Drawing, pattern is made of wood.
Model is engineered to include following
A. Metal shrinkage
B. Mold taper if required.
C. Machining allowance or stock.
http://www.youtube.com/watch?v=xPSI1wUOBnk&feature=PlayList&p=
E1B44AF847FF7D99&playnext_from=PL&playnext=1&index=34
This
process is
variously called
precision-investment
Precision
Investment
Casting
Process: casting,
precision casting, or the lost-wax process.
B.The process concerns making a one-piece mold from which
the pattern is removed by a procedure which melts the pattern.
1. The molds are single-purpose molds.
2. The elimination of all parting planes provides improved
dimensional tolerances.
3. By using alined-particle-size investment material, smooth,
accurate surfaces can be produced.
4. Since the pattern is removed by melting or burning out,
casting
precision is increased through eliminating draft, rapping, and
shifts.
http://www.youtube.com/watch?v=4Yvm6fUXf1U&feature=channel
Hard Mould Or
Permanent Mould
Casting Process
http://www.youtube.com/watch?v=C6MKbSxQRaA&NR=1
Slush Casting
Slush Casting:
2.
3.
4.
5.
4.
5.
6.
7.
8.
9.
10.
https://www.youtube.com/watch?v=QvW2ytWKEus
(C) Gooseneck or Hot Chamber Die casting Machine operated with direct air
pressure
(d) Hot Chamber Die casting Machine operated with air operated ram.
The melting unit is usually separate, and molten metal must be transferred to
the injection mechanism by ladle.
Further distinctive characteristics of the process are very high metal pressures
and the fact that the casting alloy may be at a temperature somewhat less than
normal superheat; the melt may even be in a semi-molten condition.
http://www.youtube.com/watch?v=1AgDGLNE6Es&feature=related
http://www.youtube.com/watch?v=W6VgCaRozq8&feature=related
6. Magnesium alloys are noted for their extremely light weight, about
two-thirds that of aluminum.
a. They possess approximately the same mechanical properties as
aluminum alloys, and are cast in similar dies and at similar
temperatures.
b. Magnesium alloys are more valuable where higher strengthweight ratios are required.
c. These alloys have lower corrosion-resistance features, and
material costs are higher.
7. Lead alloys enjoy a limited production for specialty items such as Xray equipment and bearings.
a. Lead alloys generally possess relatively low tensile strengthsfrom 62.10 to 96.60 MPa, approximately.
b. Cost factor tends to place lead in a subordinate position to zinc.
c. Lead and its alloys must be handled with considerable care
owing to their toxicity.
b.Die casting requires less floor space than is required by other casting
processes, for equivalent production.
c.Die casting generally provides for precision of manufacture with a
consequent reduction in machining costs.
d.Die casting makes possible the casting of thin sections in fairly complex
shapes.
e.In actual casting there is a low labor cost per casting along with a minimum
of job training.
f. Die casting provides for greatly improved surface finish when compared with
most other casting techniques.
g. Castings produced in the die-casting process are usually less defective, owing
to increased casting soundness.
h.The increased soundness and reduction of defects provides increased yield.
Clamp force
(tone)
Clamp stroke
(mm)
Platen size
(mm)
Hot chamber
100
2100
275
150
625 x 600
Hot chamber
200
3500
400
250
750 x 750
Hot chamber
400
7500
550
300
950 x 950
Cold chamber
100
1050
300
150
575 x 575
Cold chamber
400
5000
550
300
950 x 950
Cold chamber
800
11750
750
400
1300 x 1300
Cold chamber
1600
31700
1000
500
1850 x 1975
Cold chamber
2000
45500
1250
640
2075 x 2075
Centrifugal-casting
Processes:
A.Any process in which
molten metal is poured and
allowed to solidify while the mold is revolving is a
centrifugal-casting process.
B.Castings produced under this centrifugal force
are called centrifugal castings.
C. There are three recognized centrifugal casting
processes.
Semi-Centrifugal Casting
Centrifuging Casting
Truecentrifugal
centrifugalcasting:
casting is that process wherein the
True
castings are made in a hollow, cylindrical mold
rotated about an axis common to both casting and
mold.
a.
Centrifuged
or Pressure
Centrifuged
or pressure
casting is casting:
applied to nonsymmetrical
castings.
The mold cavity is not rotated about its own axis but about the axis of
a
central down sprue common to the axis of spin, which feeds metal
into
the mold cavity under centrifugal force.
a.Centrifuging can be done only about a vertical axis.
b.Centrifugal force provides high fluid pressure to force the molten
alloy into the mold cavity.
of the casting.
Structure of the casting.
Distribution of slag inclusion.
Distribution of gas & shrinkage cavities.
Segregation in alloy castings.
Factors affection selection of speed:
The position of the axis of rotation.
Metal or alloy to be casted.
Casting dimensions.
Speed Calculations:
Speed Calculations:
Centrifugal Casting
COMPARISON with Sand Casting:
Conventional
static casting defects
like internal shrinkage, gas porosity and
Defects
in Centrifugal
Casting:
Hot Tears Hot tears are developed in centrifugal castings for which the highest
rotation speeds are used.
CONTINUOUS CASTING
Tundish
The shape of the tundish is typically rectangular.
Nozzles are located along its bottom to distribute
liquid steel to the mould. The tundish also serves
several other key functions:
- Enhances oxide inclusion separation.
- Provides a continuous flow of liquid steel to the
mould
during ladle exchanges.
- Maintains a steady metal height above the
nozzles to the mould, thereby keeping steel flow
mould.
Product Types
Depending on the design of the casting machine, the as-cast
products of the continuous cast process are slabs, blooms, billets,
or beam blanks. The cross sections of these products are shown
in Figure in the next slide.
Billets have cast section sizes up to about 200 mm square.
Bloom section sizes typically range from approximately 200 mm
to 400 mm by 600 mm.
Round billets include diameters of approximately 140 mm to
500 mm.
Slab castings range in thickness from 50 mm to 400 mm, and
over 2500 mm wide.
The aspect ratio (width-to-thickness ratio) is used to determine
the dividing line between blooms and slabs.
An aspect ratio of 2.5:1 or greater constitutes an as-cast product
PrinciplesFigure
of Continuous
(Cont..):
: ContinuouslyCasting
cast sections
By casting
theOf
steel
directly into
semi-finished shapes, the
The
Benefits
Continuous
Casting:
following steps are eliminated:
ingot teeming,
stripping, and transfer,
soaking pits,
primary rolling.
Labour cost
per unit
Equipment
Cost
Surface
finish
m CLA
Accuracy - mm
Minimum
Section mm
Sand (green)
Medium
low
500 -1000
2.5
5.0
Shell
low
medium
100 -300
0.25
2.5
Centrifugal
low
medium
100 -500
0.7
8.0
Investment
high
medium
25 -125
0.6
Die casting
Gravity
low
medium
100 -250
2.5
Die casting
Low Press
low
high
40 -100
1.2
Die casting
Pressure
very low
very high
40 -100
0.5
Continuous
low
high
100 -200
8.0
http://www.youtube.com/profile?user=CorusBCSATraining#p/u/65/d-72gc6I-_E
Squeeze casting
Squeeze casting :
o
* The bottom die is preheated around 200 - 250 OC with the help of a torch
and sprayed by a water based graphite lubricant to facilitate easy removal of
casting after solidification.
o
* Measured quantity of molten metal is poured into the bottom die. As the
metal starts solidifying, pressure is applied to the top die casting it to move
rapidly towards the bottom die. This causes molten metal to get squeezed
and fill the mould cavity.
o
* The casting is ejected by operating the lift pin provided in the bottom die,
and the die is then made ready for the next cycle.
* Low shrinkage and gas porosity, due to the applied pressure during
solidification.
Squeeze casting :
https://www.youtube.com/watch?v=CYXUfXsDh5I
Casting Defects:
o
o
o
a.
a.
a.
Gas Defects
These defects are due to lower gas passing
tendency of the mould which is caused by lower
venting , lower permeability of the mould and
improper design of the casting.
The lower permeability of the mould is due to use
of finer size grains of sand, higher percentage of
clay & moisture and excessive ramming of the
mould.
To hold the core in place during the mold assembly process, the
print design is required to maintain a balance in the body.
The print must be strong enough to resist the buoyancy force of
the molten metal during casting process.
The print should be stable enough during the process of filling
the mold.
The deflection of the core must be minimized.
The transfer of the heat from the core to the mold should be
maximized.
There should be a provision for escaping the internal gases
within the core.
To avoid inaccurate assembly structure, unsymmetrical holes
should have infallible prints.
Combining the prints of adjacent cores to form single structure.
The cored holes and undercuts increase the cost of the tooling and
production time; hence, they should be minimized in terms of
quantity.
Casting Core Design and Analysis: Quality problems & criterions to avoid:
Inter-core distance :
There are many considerations affecting the
limiting distance between two or more cores.
Too close holes lead to thin sections and thus
having following issues :
IRON CASTINGS
Two types of gating systems are used in ductile
iron castings:
Pressurized
Non-pressurized.
A combination of both sprue-runner and gaterunner systems can be used for castings that require
a complicated runner system.
1.
o.2.
o.3.
o.
Sprue Rules:
1.
o.
o.
o.
o.
o.
6.
7.
Riser Rules:
1.
8.
9.
Melting furnaces
Melting furnaces:
Rotary
Pit
Electric
Tilting and
Cupola.
Rotary furnace:
o
o
o
o
o
o
o
o
o
o
o
o
Crucible Furnaces:
Crucible furnaces are small capacity typically used for small
melting applications.
Crucible furnace is suitable for the batch type foundries
where the metal requirement is intermittent.
The metal is placed in a crucible which is made of clay and
graphite.
The energy is applied indirectly to the metal by heating the
crucible by coke, oil or gas.
The heating of crucible is done by coke, oil or gas. .
Crucible Furnaces:
Coke-Fired Furnace(Figure ) .
o
Primarily used for non-ferrous metals
o
Furnace is of a cylindrical shape
o
Also known as pit furnace
o
Preparation involves: first to make a deep bed of
coke in the furnace
o
Burn the coke till it attains the state of maximum
combustion
o
Insert the crucible in the coke bed
o
Remove the crucible when the melt reaches to
desired temperature
Crucible Furnaces:
The crucible is lifted out and used as a ladle for pouring the
molten metal.
Common fuels used in crucible melting are coke, gas, and oil.
Electric Furnaces:
o
Direct-arc,
Indirect-arc, and
Induction.
The Cupola:
o
When the coke has burned through, charges of iron, flux, and
additional coke are added in alternate layers.
a.The metal charge consists essentially of pig iron, scrap cast (either
domestic or purchased), and steel, in various proportions to meet the
approximate analysis prescribed by the metallurgist.
b.Pig iron provides the balance in the control of analysis with respect
to such elements as silicon, manganese, and phosphorus.
c.The flux charge of limestone, fluorspar, or soda ash is generally
about 20 per cent of the coke charge by weight.
(1) Flux reacts with the slag to lower its fusion point, thus providing
for removal of the slag, which carries the impurities out.
(2) Natural slag formed from sand, dirt, iron oxides, coke ash, and
eroded lining has a very high melting point, and would readily freeze
in the cupola blast.
(3) If the slag is not removed it seals the coke from the air and lowers
the oxidation rate, thus causing cold melting.
c.The total tuyre area of the cupola is important, and this varies
from 1/8 to 1/4 the cross-sectional area of the cupola.
d.The air required to melt one ton of iron is approximately 10,000
cubic meter, and this figure is the basis for determining the capacity
of blowers needed in cupola work.
7. Soon after the blast is turned on, molten metal collects in the
cupola well and is tapped out into a receiving ladle.
a.The melting rate is partially governed by cross-sectional area,
and will range from 2 to 2.8 kg per square meter per minute, or
approximately 7.5 gm per square mm per hour.
b.As metal is tapped off and fuel consumed, new charges may be
added at the charging level to provide a continuous operating cycle.
8. At the end of the melting operation the air blast is shut off, and the
bottom doors are opened to allow all residual materials left in the
cupola to drop onto the floor.