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Summer Training Report Casting
Summer Training Report Casting
Plant Manager:
Engg. Khursheed Anwar
At
__________________
Table of Contents
I.
ABSTRACT
II. INTRODUCTION
III. TRAINING DESCRIPTION
1.
CASTING
..4
..5
..6
6
1.1. Definition
6
1.2. Types of Casting
6
1.2.1.
Sand Casting
6
1.2.2.
Die casting
7
1.2.3.
Investment Casting
7
1.2.4.
Centrifugal casting
8
1.2.5.
Plaster-mold casting
8
1.2.6.
Permanent-mold casting
8
1.2.7.
Squeeze casting
8
1.3. Advantages & Disadvantages 9
2.
STEPS OF CASTING
2.1.3.2.
2.2.
2.3.
2.4.
2.5.
2.6.
Machining Allowances
11
2.1.3.3.
Distortion Allowances
12
2.1.3.4.
Rapping Allowances
12
Core Making
12
2.2.1.
Types of Core
12
2.2.1.1.
Green Sand Core
12
2.2.1.2.
Dry Sand Core
12
2.2.1.3.
Core Print
13
2.2.1.4.
Core Box
13
Molding
13
2.3.1.
Types of Mold
13
2.3.2.
Types of Temporary Mold
14
2.3.2.1.
Green Sand Mold
14
2.3.2.2.
Skin Dried Mold
14
2.3.2.3.
Dry Sand Mold
14
2.3.2.4.
No Bake Mold
14
2.3.2.5.
Molding Sand
14
Melting Furnaces
....15
2.4.1.
Cupola Furnace
15
2.4.2.
Induction Furnace
15
2.4.3.
Electric Arc Furnace
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2.4.4.
Crucible Furnace
16
Gating System
17
2.5.1.
Runner & Sprue
17
2.5.2.
Riser
18
Cleaning and Finishing
18
2.6.1.
IV.
V.
Cleaning
18
2.6.2.
Finishing
18
2.7. Casting Defects
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2.7.1.
Surface Defects
19
2.7.2.
Internal Defects
20
2.7.3.
Visual Defects
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CONCLUSION
BIBLIOGRAPHY
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VI.
ABSTRACT
This report discusses the summer technical internship program for a period of 30
days (1st July, 2015 to 30th July, 2015) in Saudi Cast Company located in Riyadh,
Saudi Arabia. It shows a brief background about the place of training. It also
mentions few facts about the department that was responsible for the internship
program. This report describes about the casting and the processes involved in
producing castings of various metals manufactured by Saudi Cast. The aim of my
training was to extrude the inner self to the environment of working area in
catastrophic periods and cope up with hurdles that are to be faced in future. It
also included the learning of modern techniques used in manufacturing
industries. It helped to bring the implementations of theoretical studies in
practical and real world. The main point that was observed without which none
can succeed was team work, every single individual had to coordinate with the
other for upgrading the job that has to be done.
INTRODUCTION
As part of the Bachelor degree for the Science Engineering students, a summer training
program is required to have a taste of the practical experience for engineers on the job.
The training program was supervised by the Plant Manager of Saudi Cast. The purpose
of this report is to show the experience at Saudi Cast during the summer training period.
Saudi Cast is a modern iron and steel foundry located in Riyadh, Saudi
Arabia. It was established in 1972. The production is of gray iron,
ductile iron, and steel castings.
Saudi Cast employs 200 professionals of 15 different nationalities. The
company is associated with a number of research and technology
institutions around the world, mainly World Foundry Organization, the
Casting Technology Institute of Sheffield UK, the American Foundry
men Association of Des Plains, Illinois, USA, and the Foundry
Association of Saudi Arabia.
Saudi Cast has two main product lines:
1. Drainage Castings
Indoor Drainage: Floor and Roof drainage, under the trade name:
FloDrain.
2. Industrial Castings
Heat and wear-resisting castings: Castings for the use in harsh and
Truck & Train: Precision castings to the truck and rail industries. We
TRAINING DESCRIPTION
A. CASTING
1.1. Definition
The casting may be defined as a metal object obtained by allowing
molten metal to solidify in a mold, the shape of the object being
determined by the shape of the mold cavity. Founding or casting is
the process forming metal objects by melting metal and pouring it
into molds. A foundry is a commercial establishment for founding, or
producing castings. Castings obtain their shape principally when
molten metal solidifies in the desired form. Wrought objects,
however are cast as ingots and
then plastically worked to
approximately the desired
shape.
and the instant contact of the molten metal with the die surface
produce a rapid heat transfer condition that yields a pore-free finegrain casting with mechanical properties approaching those of a
wrought product. The squeeze casting process is easily automated
to produce near-net to net shape high-quality components.
1.3.2. Disadvantages
1. Time required for the process of making casting is quite
long.
2. Metal casting involves melting of metal which is
high energy consuming process.
3. The working conditions in foundries are quite bad due to
heat, dust, fumes, slags etc. compared to other process.
4. Metal casting is still high labor-intensive compare to other
process.
5. Productivity is less than the other automatic process. E.g.:
Rolling.
B. STEPS OF CASTING
2.1.
Pattern Making
2.2.
Core Making
2.3.
Molding
2.4.
Melting &
Pouring
2.5.
Cleaning
Definition
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The pattern is the principal tool during the casting process. It is the
replica of the object to be made by the casting process, with some
modifications. The main modifications are the addition of pattern
allowances, and the provision of core prints. If the casting is to be
hollow, additional patterns called cores are used to create these
cavities in the finished product. The quality of the casting produced
depends upon the material of the pattern, its design, and
construction.
There are many types of pattern material used in industries as:
1.
2.
3.
4.
Wooden
Metal
Plastic
Quick setting material
2.1.2.
Types of Pattern
2.1.2.1. Solid or Single piece Pattern
2.1.2.2. Split pattern or two-piece Pattern
2.1.2.3. Cope and Drag Pattern
2.1.2.4. Match plate Pattern
2.1.2.5. Gated Pattern
2.1.2.6. Skeleton Pattern
2.1.2.1. Solid or single piece pattern
Pattern Allowances
Draft Allowances
Machining Allowances
Distortion Allowances
Rapping Allowances
Draft Allowances
Machining Allowances
The finish and accuracy achieved in sand casting are generally poor
and therefore when the casting is functionally required to be of good
surface finish or dimensionally accurate, it is generally achieved by
subsequent machining. Machining or finish allowances are therefore
added in the pattern dimension. The amount of machining allowance
to be provided for is affected by the method of moulding and casting
used viz. hand moulding or machine moulding, sand casting or
metal mould casting. The amount of machining allowance is also
affected by the size and shape of the casting; the casting
orientation; the metal; and the degree of accuracy and finish
required.
2.1.3.3.
Distortion Allowances
Rapping Allowance
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Before the withdrawal from the sand mold, the pattern is rapped all
around the vertical faces to enlarge the mold cavity slightly, which
facilitate its removal. Since it enlarges the final casting made, it is
desirable that the original pattern dimension should be reduced to
account for this increase. There is no sure way of quantifying this
allowance, since it is highly dependent on the foundry personnel
practice involved. It is a negative allowance and is to be applied only
to those dimensions that are parallel to the parting plane.
2.2. Core
A core is a device used in casting and moulding processes to
produce internal cavities and re-entrant angles. The core is normally
a disposable item that is destroyed to get it out of the piece. They
are most commonly used in sand casting, but are also used in
injection moulding.
2.2.1.
Types of Core
2.2.1.1.
Green-sand core
Green-sand cores are not a typical type of core in that it is part of
the cope and drag, but still form an internal feature. Their major
disadvantage is their lack of strength, which makes casting long
narrow features difficult or impossible. Even for long features that
can be cast it still leave much material to be machined. A typical
application is a through hole in a casting.
2.2.1.2.
Dry-sand cores
Dry-sand cores overcome some of the disadvantages of the greensand cores. They are formed independently of the mold and then
inserted into the core prints in the mold, which hold the core in
position. They are made by mixing sand with a binder in a wooden
or metal core box, which contains a cavity in the shape of the
desired core.
2.2.1.3.
Core Print
2.2.1.4.
Core Box
2.3. Molding
In sand casting, the primary piece of equipment is the mold, which
contains several components. The mold is divided into two halvesthe cope (upper half) and the drag (bottom half) which meet along a
parting line. Both mold halves are contained inside a box, called a
flask, which itself is divided along this parting line. The mold cavity
is formed by packing sand around the pattern in each half of the
flask. The sand can be packed by hand, but machines that use
pressure or impact ensure even packing of the sand and require far
less time, thus increasing the production rate. After the sand has
been packed and the pattern is removed, a cavity will remain that
forms the external shape of the casting. Some internal surfaces of
the casting may be formed by cores.
2.3.1.
Types of Molds
1. Permanent Mold Casting
Permanent mold casting is metal casting process that employs
reusable molds ("permanent molds"), usually made from metal. The
most common process uses gravity to fill the mold, however gas
pressure or a vacuum are also used. A variation on the typical
gravity casting process, called slush casting, produces hollow
castings. Common casting metals are aluminum, magnesium, and
copper alloys. Other materials include tin, zinc, and lead alloys and
iron and steel are also cast in graphite molds. Permanent molds,
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while lasting more than one casting still have a limited life before
wearing out.
2. Temporary Mold Casting
These molds are destroyed at the time of removing casting from
them. There are many type of temporary mold which are mentioned
below.
2.3.2.
Types of Temporary Mold
2.3.2.1.
Greensand Mold
Greensand molds use a mixture of sand, water, and a clay or binder.
Typical composition of the mixture is 90% sand, 3% water, and 7%
clay or binder. Greensand molds are the least expensive and
most widely used.
2.3.2.2.
Skin-dried Mold
In a dry sand mold, sometimes called a cold box mold, the sand
is mixed only with an organic binder. The mold is strengthened by
baking it in an oven. The resulting mold has high dimensional
accuracy, but is expensive and results in a lower production rate.
2.3.2.4.
No-bake mold
The sand in a no-bake mold is mixed with a liquid resin and hardens
at room temperature.
2.3.2.5.
Moulding Sand
be either silica or olivine. There are many recipes for the proportion
of clay, but these all strike different balances between moldability,
surface finish, and ability of the hot molten metal to degas. The coal
typically referred to in foundries as sea-coal, which is present at a
ratio of less than 5%, partially combusts in the surface of the molten
metal leading to off gassing of organic vapors.
Cupola Furnace
Induction furnace
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Electric Furnace
Induction heating furnaces and arc furnaces are beyond the scope of
this project profile. The scope of this project profile is confined to the
resistance heating furnace only. The heating elements used are
Nichrome wire, Kanthal wire or Graphite rods depending upon the
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Crucible furnace
Crucible furnaces are used for melting and holding small batches of
non-ferrous alloys. Crucible furnaces are the oldest type of melting
furnaces. A refractory crucible filled with the metal is heated
through the crucible wall.
There are two main types of crucible furnace:
mold; these vortices tend to suck gas and oxides into the mold. A
large sprue well is used to dissipate the kinetic energy of the liquid
material as it falls down the sprue, decreasing turbulence. The
choke, which is the smallest cross-sectional area in the gating
system used to control flow, can be placed near the sprue well to
slow down and smooth out the flow.
2.5.1.
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2.5.2.
Riser
Cleaning
Finishing
22
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Surface Defects
Due to design and quality of sand molds and general cause is poor
ramming.
1) Blow:
Blow is relatively large cavity produced by
gases which displace molten metal form.
2) Scar:
It occurs due to improper permeability or
venting. A scar is a shallow blow. It
generally occurs on flat surf; whereas a
blow occurs on a convex casting surface.
A blister is a shallow blow like a scar with
thin layer of metal covering it.
3) Scab:
This defect occurs when a portion of the face
of a mould lifts or breaks down and the
recess thus made is filled by metal. When
the metal is poured into the cavity, gas may
be disengaged with such violence as to
break up the sand which is then washed
away and the resulting cavity filled with
metal. The reasons can be: - to fine sand,
low permeability of sand, high moisture content of sand and uneven
moulds ramming.
4) Drop:
Drop or crush in a mould is an irregularly shaped projection on the
cope surface of a casting. This defect is caused by the break-away of
a part of mould sand as a result of weak packing of the mould, low
strength of the molding sand, malfunctioning of molding equipment,
strong jolts and strikes at the flask when assembling the mould.
The loose sand that falls into the cavity will also cause a dirty
casting surface, either on the top or bottom surface of the casting,
depending upon the relative densities of the sand and the liquid.
5) Penetration:
It is a strong crust of fused sand on the surface of a casting which
results from insufficient refractoriness of molding materials, a large
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Internal Defects
1) Blow Holes:
Blow holes, gas holes or gas cavities are well rounded cavities
having a clean and smooth surface. They appear either on the
casting surface or in the body of a casting.
These defects occur when an excessive evolved gas is not able to
flow through the mould. So, it collects into a bubble at the high
points of a mould cavity ad prevents the liquid metal from filling that
space.
2) Pin holes:
Pin holes are small gas holes either at the surface or just below the
surface. When these are present, they occur in large numbers and
are fairly uniformly dispersed over the surface. This defect occurs
due to gas dissolved in the alloy and the alloy not properly
degassed.
2.7.3.
Visible Defects
1) Wash:
A cut or wash is a low; projection on the drag
face of a casting that extends along the
surface, decreasing in height as it extends
from one side of the casting to the other end.
It usually occurs with bottom gating castings in which the molding
sand has insufficient hot strength, and when too much metal is
made to flow through one gate into the mold cavity.
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2) Shrinkage:
A shrinkage cavity is a depression or an internal void
in a casting that results from the volume contraction
that occurs during solidification.
3) Swell
A swell is a slight, smooth bulge usually found on
vertical faces of castings, resulting from liquid metal
pressure. It may be due to low strength of mould because
of too high a water content or when the mould is not
rammed sufficiently.
4) Shift
Mold shift refers to a defect caused by a
sidewise displacement of the mold cope
relative to the drag, the result of which
is a step in the cast product at the parting line.
Core shift is similar to mold shift, but it is the core that is displaced,
and (he dis-placement is usually vertical. Core shift and mold shift
are caused by buoyancy of the molten metal.
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CONCLUSION
As a student of Azad Institute of Engineering & Technology, I would say that this
training program was an excellent opportunity for me to get to the ground level and
experience the things that I would have never gained through going straight into a job.
I am grateful to Saudi Cast for giving me this wonderful opportunity. The main
objective of the training was to provide an opportunity to identify, observe and practice
how engineering is applicable in the real industry. It helps to observe management
practices and to interact with fellow workers. It is easy to work with sophisticated
machines, but not with people.
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