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Casting: Definition, Types, Steps Involved in Casting, Advantages, Disadvantages, Importance (PDF)
Casting: Definition, Types, Steps Involved in Casting, Advantages, Disadvantages, Importance (PDF)
Casting: Definition, Types, Steps Involved in Casting, Advantages, Disadvantages, Importance (PDF)
Definition of Casting:
Casting is a process in which the liquid molten metal is poured into the casting cavity
whose shape is same as that of the shape of the casting to be produced, allowing to
solidify and after solidification, the casting will be taken out by breaking the mould called
as Casting Process.
The parts of the Sand casting process are Cope and drag, Sprue, Pouring Basin, Runner,
Ingate, Casting Cavity, Riser, Parting Line, Chaplets, etc.
With the help of sand casting process, cylinder blocks, machine tool beds, pistons, etc.
can be produced.
In Sand Casting Process, the Mould is made up of Sand whereas, in Die Casting
Process, the mold is made up of Metal.
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Gravity Die Casting
Pressure Die Casting
If the flow of molten metal into the mold cavity is due to the gravitational force, then it is
called Gravity Die Casting.
If the flow of molten metal into the mold cavity is due to the external pressure, then it is
called Gravity Die Casting.
The material used for mold is a Phenolic resin (Thermosetting Plastic) has the viscosity of
(Dynamic Viscosity equal to 1500 to 2000 Centipoise). You can dip the pattern into
phenolic resin for 1 to 2 minutes and take the pattern out.
This method is used for producing the symmetrical and circular shape of castings only.
Because of Cement concrete mold, the same mold can be used for producing a few
numbers of castings. Therefore, it is also called a Semi-Permanent Mould Casting
Process.
1. Pattern making
2. Mold and Core making
3. Pouring and Solidification
4. Fetling
5. Inspection
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By Krzysiulek, sand casting working principle
1.Pattern Making:
The pattern is the replica of the casting to be produced. Replica means the shape of the
pattern is same as the shape of the casting to be produced.
By Glenn McKechnie,Two sets of castings (bronze and aluminium) from the above
sand mold
Types of Allowances:
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Shrinkage allowance
Machining allowance
Draft allowance
Shake allowance
Distortion allowance
Solid pattern
Split pattern
Match plate pattern
Cope Pattern and Drag Pattern
The different types of pattern materials used in the casting process are as follows.
Wood Pattern:
Except for moisture absorption, the wood is possessing all other properties which are
required as pattern material, and out of all the different woods, the wood which is
absorbing less moisture will be used as pattern material.
Metal Pattern:
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In the case of metal patterns, the density is high and it is difficult to manufacture the metal
patterns.
Ex: Aluminium, white metal, Titanium has low density, but they are very costly.
When wooden parts are used for producing metal patterns, the double shrinkage
allowance must be provided on the wooden pattern.
Plastic Pattern:
They are processing all the properties which are required for pattern material.hence in
today's manufacturing industry, plastics are the most commonly used pattern materials.
Polystyrene: It is used for producing very large castings where the removal of the pattern
is not possible.
Wax Pattern:
It will be selected as pattern material for producing the complex shape of the pattern, to
produce the complex shape of the casting i.e. because of the highest softness of the wax
material, it is possible to produce the Complex shape of the pattern easily.
After creating a pattern with any of the material mentioned above, we need to create sand
mould.
For creating a sand mould, the properties of green sand has to be known.
Let's understand what is mold, what is a molding, and what are the different molding
materials in detail...
It is described as a void or cavity created in a compact sand mass with the help of a
pattern which (mold), when filled with molten metal produces a casting.
The mold is made by using the molding sand consists of basic elements such as
Silica Sand Particles: They are used for producing the required strength of the
molding sand. (75-80%) of sand is filled with Silica sand Particles.
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Clay: It is used for producing the bond between the sand particles. (15-20%) of clay
is filled in molding sand.
Water or Sodium Silicate: It is used for initiating the bond formation between the
sand particles(6-8%).
Green Sand or Dry Sand with 50% Clay is called as Loam Sand.
What is a molding?
The process of making a cavity or mold in the compact sand is called as Moulding.
A material which possesses high refractoriness can be used for mold making. Thus,
the mold making material can be metallic or non-metallic(sand).
For Metallic Moulds, the common materials are Cast iron, mild steel, and alloy
steels.
For Non-Metallic Moulds: Materials used are molding sand, Plaster of Paris, silicon
carbide, graphite, and ceramics.
Note:
Out of all materials, the molding sand is the most commonly utilized non-metallic
molding material because of its certain inherent properties namely refractoriness,
high permeability, and workability along with good strength. Moreover, it is also
highly cheap and it is easily available.
Core making:
When the molten metal is poured, it will not move to each and every corner. Therefore,
chills are provided at the corners to do the solidification fastly.
4.Fetling:
Fetling is nothing but, breaking of the mould after production of a component so as to
take it out from the sand mould.
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5.Inspection:
After production of component, it is inspected under the guidance of quality engineers
and further it is sent to the machining shop where the surface finish of the component is
to be done.
Advantages of Casting:
The Advantages of Casting Process are as follows.
High complexity shapes: Casting processes can create any complex structures
economically.
Short lead time: Short lead time compared to others and hence, ideal for short
production runs.
Low-cost tooling: Tooling and equipment costs are low compared to some other
metal manufacturing processes.
Design flexibility: The size of an object doesn’t matter for casting.
Wider material choice: all types of engineering alloys can be cast.
Disadvantages of Casting:
The disadvantages of Casting Process are as follows.
References:
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