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    Casting Process PDF

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    Arip Budi
    1. Sand casting is one of the most commonly used casting processes and involves making a mold from sand and pouring molten metal into it to form a casting. 2. Other casting processes include shell mold casting, which uses a ceramic shell to achieve high precision, investment casting (lost wax process), and die casting, which injects molten metal into a steel mold under high pressure. 3. The appropriate casting process depends on factors like the required tolerances, production quantities, material properties, and part size and complexity. Sand casting is versatile but has lower precision while die casting can produce parts with thin walls but is limited to smaller parts and lower

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    Casting Process PDF

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    Arip Budi
    333 views36 pages
    1. Sand casting is one of the most commonly used casting processes and involves making a mold from sand and pouring molten metal into it to form a casting. 2. Other casting processes include shell mold casting, which uses a ceramic shell to achieve high precision, investment casting (lost wax process), and die casting, which injects molten metal into a steel mold under high pressure. 3. The appropriate casting process depends on factors like the required tolerances, production quantities, material properties, and part size and complexity. Sand casting is versatile but has lower precision while die casting can produce parts with thin walls but is limited to smaller parts and lower

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    1. Sand casting is one of the most commonly used casting processes and involves making a mold from sand and pouring molten metal into it to form a casting. 2. Other casting processes include shell mold casting, which uses a ceramic shell to achieve high precision, investment casting (lost wax process), and die casting, which injects molten metal into a steel mold under high pressure. 3. The appropriate casting process depends on factors like the required tolerances, production quantities, material properties, and part size and complexity. Sand casting is versatile but has lower precision while die casting can produce parts with thin walls but is limited to smaller parts and lower

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    333 views36 pages

    Casting Process PDF

    Uploaded by

    Arip Budi
    1. Sand casting is one of the most commonly used casting processes and involves making a mold from sand and pouring molten metal into it to form a casting. 2. Other casting processes include shell mold casting, which uses a ceramic shell to achieve high precision, investment casting (lost wax process), and die casting, which injects molten metal into a steel mold under high pressure. 3. The appropriate casting process depends on factors like the required tolerances, production quantities, material properties, and part size and complexity. Sand casting is versatile but has lower precision while die casting can produce parts with thin walls but is limited to smaller parts and lower

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 36
    At a glance
    Powered by AI
    The key takeaways are the history of casting and the different casting processes like sand casting, investment casting and die casting.

    The different types of molds used in casting are expendable molds, permanent molds and composite molds.

    The main casting processes discussed are sand casting, investment casting and die casting.

    Casting Process

    Casting History

    Ancient Greece; bronze


    statue casting circa 450BC
    Iron works in early Europe,
    e.g. cast iron cannons from
    England circa 1543
    Casting History

    • The first castings were made during period 4000-3000


    B.C., using stone and metal mold for casting copper
    • Two trends are currently having a major impact on the
    casting industry. The first is continuing mechanization
    and automation of casting process. The second major
    trend is the increasing demand for high quality castings
    with close dimensional tolerances and no defect.
    Example sand casting product
    Example Investment casting product
    Example die casting product
    Categories casting processes
    • Expendable molds, which are made of sand, plaster,
    ceramics and similar materials. These are generally
    mixed with binders or bonding agents.
    • Permanent molds, which are made of metals that
    maintain their strength at high temperatures. They are
    used repeatedly and are designed in such a way that the
    casting can be easily removed and the mold used for the
    next casting.
    • Composite molds, which are made of two or more
    different materials, such as sand, graphite, and metal,
    combining the advantages of each material. They are
    used in various casting processes to improve mold
    strength , control the cooling rates and optimize the
    overall economics of the process
    Sand casting
    Sand casting
    Simply stated, sand casting
    consist of,
    a) Placing a pattern having the
    shape of the desired casting
    in sand to make imprint
    b) Incorporating a gating
    system
    c) Filling the resulting cavity
    with molten metal
    d) Allowing the metal to cool
    until it solidifies
    e) Breaking away the sand
    mold
    f) Removing the casting
    -pattern making
    Molding -Core making
    -Gating system

    Sand Mold

    Melting of Pouring in Heat Cleaning and


    Casting
    metal the mould treatment finishing

    furnace solidification shakeout

    Inspection

    Defects
    Pressure tightness
    Dimensions
    Sand casting
    • Advantages : almost any metal cast, no limit size, shape
    or weight, low tooling cost
    • Disadvantages : some finishing required, somewhat
    coarse finish, wide tolerances
    • Two generally types of sand : naturally bonded and
    synthetic, it’s prefer used because its composition can
    be controlled more accurately
    • Important factor in selection sand for molds : sand
    having fine, round grain can be closely packed and form
    a smooth mold surface.
    • Good permeability and collapsibility (allow for the casting
    to shrink while cooling)
    Sand casting
    Components of Sand mold
    • The mold itself, which is supported by a flask. Two piece molds consist of a
    cope on top and a drag on the bottom. The seam between them is the
    parting line.
    • A pouring basin or pouring cup, into which the molten metal is poured
    • A sprue, through which the molten metal flows downward
    • The runner system, which has channels that carry the molten metal from
    the sprue to the mold cavity. Gates are the inlets into the mold cavity
    • Risers, which supply additional metal to the casting as it shrinks during
    solidifications.
    • Cores, which are inserts made from sand. They are placed in the mold to
    form hollow regions or otherwise define the interior surface of the casting
    • Vents, which are placed in the molds to carry of gases produced when the
    molten metal comes into contact with the sand in the mold and core. They
    also exhaust air from the mold cavity as the molten metal flows into the
    mold.
    Patterns
    Sand molding machines
    Shell-Mold Casting

    • Advantages: good dimensional accuracy and surface


    finish, high production rate
    • Disadvantage : part size limited, expensive pattern and
    equipment required, the sand has lower permeability
    than green-sand casting, the decomposition of the shell-
    sand binder produce a high volume of gas; unless the
    molds are properly vented, trapped air and gas can
    cause serious problems in shell molding of ferrous
    casting
    Shell-Mold Casting
    Shell-Mold Casting

    • Nearly any metal suited for sand casting may be cast by


    the shell-mold process
    • The cost of the resin binders is offset somewhat by the
    fact that only one-twentieth of the sand used in sand
    casting in necessary
    • The relatively high cost on metal patterns becomes a
    smaller factor as the size of production runs increases.
    • Shell-molding applications include a small mechanical
    parts requiring high precision, such as gear housing,
    cylinder head and connecting rods.
    Composite Molds

    • Composite molds are made of two or more different


    material and are used in shell molding and other casting
    processes.
    • Generally, they are employed in casting complex shapes
    such as impleler for turbines
    Composite Molds
    Expendable-Pattern Casting
    (Lost Foam)
    • Expendable-pattern casting process uses a polystyrene
    pattern, which evaporates upon contact with molten
    metal to form a cavity for the casting.
    • More important casting processes for ferrous and
    nonferrous metals, particularly for automotive industry
    Expendable-Pattern Casting
    (Lost Foam)
    Expendable-Pattern Casting
    (Lost Foam)
    Expendable-Pattern Casting
    (Lost Foam)
    Advantages :
    • The process is relatively simple because there are no parting lines,
    cores, risers system, hence it has design flexibility
    • Inexpensive flasks are sufficient for the process
    • Polystyrene is inexpensive and can be easily processed into
    patterns having complex shapes, various sizes and fine surface
    detail
    • The casting requires minimum finishing and cleaning operations
    • The process can be automated and is economical for long
    production runs. A major factor is the cost to produce the die used
    for expanding the polystyrene beads to make the pattern
    Expendable-Pattern Casting
    (Lost Foam)
    • Limitations : pattern have low strength and can be costly
    for low quantities
    • Applications : cylinder heads, crankshaft, brake
    components and manifolds for automobile and machine
    bases. Aluminum engine blocks and other component of
    General Motor company are made by this process.
    Investment Casting

    The investment-casting
    process, also called
    the lost-wax process,
    was first used during
    the period 4000-3500
    B.C. The pattern is
    made of wax or a
    plastic such as
    polystyrene. The
    sequences involved in
    investment casting are
    shown in Figure 11.18.
    The pattern is made by
    injecting molten wax or
    plastic into a metal die
    in the shape of the
    object.
    Investment casting

    • Slurry of refractory material such as very fine silica and


    binder, including water, ethyl silicate and acids.
    Investment casting
    Investment casting

    • Advantages : intricate shapes , excellent surface finish


    and accuracy, almost any metal cast
    • Limitations : part size limited, expensive patterns, molds
    and labor
    Permanent Mold
    Casting

    • Mold removed, not


    destroyed
    • Uses gravity to fill mold
    • Metal flow is slow
    • Mold is steel - has
    comparatively good
    thermal conductivity
    • Machines smaller
    Die Casting

    • Liquid metal injected into reusable steel mold, or die,


    very quickly with high pressures
    • Reusable steel tooling and injection of liquid metal with
    high pressures differentiates die casting from other metal
    casting processes
    Die Casting
    • Hot Chamber • Cold Chamber
    – Zn or Zn alloys only – Al, Mg, Zn
    – Higher production rate 15 – Melt is poured into
    cycles per minute for cylinder, which is then
    small parts shot into chamber
    – Metal injected directly
    from melt zone
    Die Casting
    Die Casting

    • Advantages • Disadvantages
    – High production rates – High tooling cost
    possible, with high – Long lead times
    level of automation (months)
    – Very thin walls – Limited size (<25 lbs)
    possible (0.020” for
    Mg die casting) – Limited in alloys (low
    temperature only)
    – Good surface finish
    • Zn
    – Economical in large
    quantities • Al
    – Better control of mold • Mg
    temps • Cu
    Assignment
    Make a paper and presentation for next week about :
    • Composite mold casting
    • Centrifugal casting
    • Casting defect
    • Plaster mold casting
    • Ceramic mold casting

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