Professional Documents
Culture Documents
Unit 1 : Casting
By
R.SARAVANAKUMAR
Assistant Professor
Mechanical Engineering Department
Category Course L T P C
Manufacturing Technology
P 3 0 0 3
Manufacturing Process
P 0 0 2 1
Laboratory
2
Syllabus
CASTING AND WELDING
Introduction to casting, Patterns, Types, Pattern materials, Allowances – Moulding
– types– Moulding sand, Gating and Risering, Cores &Core making. Special
Casting Process - Shell, Investment, Die casting, Centrifugal Casting.
Special welding– Laser, Electron Beam, Ultrasonic, Electro slag, Friction welding,
Electrical resistance welding.
Sheet Metal Operations: Blanking– blank size calculation, draw ratio, drawing
force, Piercing, Punching, Trimming, Stretch forming, Shearing, Bending– simple
problems– Bending force calculation, Tube forming – Embossing and coining,
Types of dies: Progressive, compound and combination dies.
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THEORY OF METAL CUTTING
Orthogonal and oblique cutting– Classification of cutting tools: single, multipoint –
Tool signature for single point cutting tool – Mechanics of orthogonal cutting – Shear
angle and its significance – Chip formation– Cutting tool materials– Tool wear and
tool life – Machinability – Cutting Fluids– Simple problems.
MACHINE TOOLS
Milling Machine – specification, Types, Types of cutters, operations, Indexing
methods– simple problems. Shaping, Planning and Slotting Machine – description,
Operations, Work and tool holding Devices. Boring machine – Specification,
operations, Jig boring machine. Broaching machine – operations, Specification,
Types, Tool nomenclature.
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TEXT BOOKS
1. Sharma, P.C., A textbook of Production Technology – Vol I and II, S. Chand &
Company Ltd., New Delhi, 1996.
2. Rao, P.N., Manufacturing Technology, Vol I & II, Tata McGraw Hill Publishing Co.,
New Delhi, 1998.
REFERENCE BOOKS
1. Chapman W. A. J., Workshop Technology Vol. I and II, Arnold Publisher, New
Delhi, 1998.
2. Hajra Choudhary, S. K. and Hajra Choudhary, A. K., Elements of Manufacturing
Technology, Vol II, Media Publishers, Bombay, 1988.
3. Jain. R. K., Production Technology, Khanna Publishers, New Delhi, 1988.
4. Kalpakjian, Manufacturing Engineering
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Product Life Cycle
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Introduction to Manufacturing Technology
Manufacturing is the backbone of any industrialized nation.
Manufacturing processes
Materials being processed
Tools and equipment's for manufacturing different components
Products with optimal process plan using proper precautions
Specified safety rules to avoid accidents
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Manufacturing Processes
Production or manufacturing can be simply defined as value addition
processes by which raw materials are converted into valued products.
Technologically acceptable
Technically feasible
Economically viable
Eco-friendly
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Terms
Solidify – To become solid / to make some thing solid.
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Deformation- changes in an object's shape or form due
to the application of a force
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Extrusion is a process used to create objects of a fixed cross-
sectional profile. A material is pushed or pulled through a die of the
desired cross-section.
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Broad classification of Manufacturing Processes
(a) Shaping or forming Manufacturing a solid product of definite
size and shape from a given material taken in three possible states:
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Casting
It is a earliest metal shaping technique known to human being since 3500BC.
Simple and complicated shapes can be made from any metal that can be melted.
3. Pattern
2. Sand
1. Molding Box
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Pattern - Casting Product –
Master Model piece Actual work piece
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Steps in Sand Casting
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Classification of casting processes
Expendable mould casting
Permanent mould Casting
Semi Permanent mould Casting
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Advantages
It is possible to cast any material be it ferrous or non-ferrous.
Tools required for casting moulds are very simple and inexpensive.
Casting of any size and weight, even up to 200 tonnes can be made.
Limitations
Dimensional accuracy and surface finish achieve.
Traditional casting methods are labour intensive.
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Applications
Cylinder blocks
Liners
Machine tool beds
Pistons
Piston rings
Mill rolls
Wheels
Housings
Water supply pipes
air compressor frame
Bells etc.,
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Casting Terms
1. Flask (Cope & Drag)
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2. Pattern
It is a replica of the object to be made.
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3. Parting Line
It is a dividing line between cope, drag and also for split pattern.
4. Bottom Board
It is made of wood, the pattern is first kept on the bottom board
5. Facing Sand
Carbonaceous material is sprinkled on the inner surface of the
moulding cavity to give better castings
7. Moulding Sand
Mixture of silica sand with 18 to 30 percent clay, having moisture content
from 6 to 8%. It is used to make mould cavity.
8. Pouring Basin
It is a funnel shaped cavity at the top of the mould into which molten
material is poured.
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Steps involved in making a sand mould
1. Initially a suitable size of moulding box for suitable wall thickness is selected
for a two piece pattern.
2. Next, place the drag portion of the pattern with the parting surface down on
the bottom (ram-up) board as shown below;
3. The facing sand is then sprinkled carefully all around the pattern so that the
pattern does not stick with moulding sand during withdrawn of the pattern.
4. The drag is then filled with loose prepared moulding sand and ramming of
the moulding sand is done uniformly in the moulding box around the pattern.
Fill the moulding sand once again and then perform ramming. Repeat the
process three four times,
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5. The excess amount of sand is then removed using strike off bar to bring
moulding sand at the same level of the moulding flask height to completes the
drag.
6. The drag is then rolled over and the parting sand is sprinkled over on the top
of the drag
7. Now the cope pattern is placed on the drag pattern and alignment is done
using dowel pins.
8. Then cope (flask) is placed over the rammed drag and the parting sand is
sprinkled all around the cope pattern.
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13. Rap and remove both the cope and drag patterns and repair the mould
suitably if needed and dressing is applied
14. The gate is then cut connecting the lower base of sprue basin with runner
and then the mould cavity.
15. Apply mould coating with a swab and bake the mould in case of a dry sand
mould.
16. Set the cores in the mould, if needed and close the mould by inverting cope
over drag.
17. The cope is then clamped with drag and the mould is ready for pouring
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Patterns
Pattern is the replica of the casting and it is embedded in moulding sand. The
pattern is then withdrawn for generating cavity (known as mould) in moulding sand,
so it is a mould forming tool.
Objectives of a pattern
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Types of Patterns
1. Single-piece or solid pattern
Solid pattern is made of single piece without
joints, partings lines or loose pieces. It is the
simplest form of the pattern.
•When solid pattern is difficult for withdrawal from the mold cavity, then
solid pattern is splited in two parts.
•Split pattern is made in two pieces which are joined at the parting line by means of
dowel pins.
•The splitting at the parting line is done to facilitate the withdrawal of the pattern.
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Types of Patterns
3. Gated pattern
•In the mass production of casings,
multi cavity moulds are used.
•These patterns are made of metals, and metallic pieces to form gates and runners
are attached to the pattern.
4. Cope and drag pattern
•This is done when the complete mould is too heavy to be handled by one operator.
•The pattern is made up of two halves, which are mounted on different plates. 32
Types of Patterns
5. Match plate pattern
After removing match plate mould cavity along with gating will be formed.
Several patterns can be fixed to a single match plate if they are small in size.
Used for small castings with higher dimensional accuracy and & large production.
Loose pieces are provided on the pattern and they are the part of pattern.
First main pattern is removed finally the loose piece is withdrawal separately 33
Types of Patterns
7. Follow board pattern
8. Sweep Pattern
The pivot end is attached to a stake of metal in the center of the mould.
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Types of Patterns
9. Skeleton pattern
Used for large castings having simple geometric shape.
These are simple wooden frames that outline the shape of the part to be cast.
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Pattern Materials
Wood is most commonly used because of easily available, machinability and low
Weight.
Metal patterns are used for large scale casting productions, close tolerances,
Smooth, Surface finish. Aluminium and white metals are commonly used.
Plastics are used because of their low weight, easier formability, smooth surface.
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Difference Between Tolerance and Allowance
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Pattern Allowances
Final dimensions of casting are different from pattern because of various reasons
1. Shrinkage allowances
Metal Shrinks on solidification and contracts further cooling at room temperature.
Liquid Shrinkage refers to reduction in volume when metal changes from liquid to
solid state. Risers are used to compensate this.
Solid Shrinkage refers to reduction in volume when metal loses temperature in
solid state. Shrinkage allowance is used to overcome this.
Shrink rulers are used for different castings.
2. Draft allowances
Vertical faces of pattern are continual contact with the sand and may
damage during withdrawal.
It is a positive allowance and is given on all the vertical surfaces of
pattern so that its withdrawal becomes easier.
Inner details of the pattern require higher draft than outer surfaces.
More draft is needed for hand molding
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Pattern Allowances
3. Machining allowance
To get better surface finish for casting
4. Shake allowance
Pattern is rapped all around the faces to remove and it enlarges the final casting.
5. Distortion allowance
This allowance is considered only for casting of irregular shape which are
distorted in the process of cooling because of metal shrinkage.
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Moulding Types
Commonly used traditional methods of molding are bench molding, floor
molding, pit molding and machine molding.
1. Bench Molding
In this process, a minimum of two flasks, namely cope and drag molding flasks
are necessary.
But in certain cases, the number of flasks may increase depending upon the
number of parting surfaces required.
2. Floor Molding
This type of molding is preferred for medium and large size jobs.
In this method, only drag portion of molding flask is used to make the mold
The floor itself is utilized as drag
It is usually performed with dry sand. 41
Moulding Types
3. Pit Molding
Usually large castings are made in pits instead of drag flasks because of their
huge size.
In pit molding, the sand under the pattern is rammed by bedding-in process.
The walls and the bottom of the pit are usually reinforced with concrete and a
layer of cope is laid on the bottom of the pit to enable easy escape of gas.
The cope bed is connected to atmosphere through vent pipes which provide an
outlet to the gases.
One box is generally required to complete the mold, runner, sprue, pouring basin
and gates are cut in it.
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Moulding Types
4. Machine Molding
For mass production of the casting
The main advantage of machine molding, besides the saving of labor and
working time, is the accuracy and uniformity of the castings which can otherwise
be only obtained with much time and labor.
Molding machines thus prepare the moulds at a faster rate and also eliminate the
need of employing skilled molders.
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Types of moulding sand
1. Green sand
Green sand is damp, when squeezed in the hand and it retains the shape
and the impression to give to it under pressure.
Moulds prepared by this sand are not requiring baking and hence are
known as green sand moulds.
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2. Dry sand
Green sand that has been baked in suitable oven after the making mould
and cores
It possesses more strength, rigidity and thermal stability.
It is mainly suitable for larger castings.
3. Facing sand
It is sprinkled on the inner surface of the moulding cavity to give better
castings
It is directly next to the surface of the pattern and it comes into contact
molten metal when the mould is poured.
It is made of silica sand and clay, without the use of used sand.
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4. Backing sand
Repeatedly used moulding sand is mainly employed for this purpose.
Black in colour due to addition of coal dust and burning on coming in
contact with the molten metal.
To keep the green sand not to stick to the pattern and also to allow the sand
on the parting surface the cope and drag to separate without clinging.
6. Core sand
Core sand is used for making cores and it is sometimes also known as oil sand
This is highly rich silica sand mixed with oil binders such as core oil which
composed of linseed oil, resin, light mineral oil and other bind materials.
Pitch or flours and water may also be used in large cores for the sake of
economy. 46