Metal Casting

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Metal Castingto CCG :
Congratulations

1. Casting process
2. Sand Casting
3. Design consideration

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What is casting?
Schedule

A 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.

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Types of Casting

 Sand Casting
 Die Casting
 Injection Molding
 Centrifugal Casting
 And More

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Sand Casting

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Tooling

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Terminology
 The casting process uses the following specialized terminology :-

 Pattern :- An approximate duplicate part of the final casting used to

form the mold cavity.

 Molding material :- The material that is packed around the pattern and
then the pattern is removed to leave the cavity where the casting
material will be poured.

 Flask :- The rigid wood or metal frame that holds the molding material.
 Cope :- The top half of the pattern, flask, mold, or core.
 Drag :- The bottom half of the pattern, flask, mold, or core.

 Core :- An insert in the mold that produces internal features in the

casting, such as holes.

 Mold cavity :- The combined open area of the molding material and
core, there the metal is poured to produce the casting.

 Riser :- An extra cavity in the mold that fills with molten material to
compensate for shrinkage during solidification.

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Terminology
 Gating system :- The network of connected channels that deliver the
molten material to the mold cavities.
 Pouring cup or pouring basin :- The part of the gating system that
receives the molten material from the pouring vessel.
 Sprue :- The pouring cup attaches to the sprue, which is the
vertical part of the gating system. The other end of the sprue
attaches to the runners.
 Runners :- The horizontal portion of the gating system that
connects the sprues to the gates.
 Gates :- The controlled entrances from the runners into the mold
cavities.

 Parting line or parting surface :- The interface between the cope and
drag halves of the mold, flask, or pattern.

 Draft :- The taper on the casting or pattern that allow it to be

withdrawn from the mold.

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Solid Pattern

 A solid pattern is a model of

a part as a single piece.

 The parting line and runner

system must be determined
separately.

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Split Pattern

 A split pattern means cut the

Pattern in two separate pieces
that meet along the parting line
of the mold.

 Split patterns are typically used

for parts that are geometrically
complex.

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Match-Plate Pattern

 A match-plate pattern is similar to

a split pattern, except that each
half of the pattern is attached to
opposite sides of a single plate.
 The plate is usually made from
wood or metal.
 This pattern design ensures proper
alignment of the mold cavities in
the cope and drag.
 The runner system can be
included on the match plate.
 Match-plate patterns are used for
larger production quantities.

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Cope and Drag Pattern

 A cope and drag pattern is

similar to a match plate
pattern, except that each half
of the pattern is attached to a
separate plate.

 The mold halves are made

independently.

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Core Part

 If the casting requires sand

cores, the cores are formed in
Core boxes.
 It can be made of wood,
plastic, or metal just like the
pattern.
 The core-boxes can also
contain multiple cavities to
produce several identical cores

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Applications

 Engine blocks and manifolds.

 Machine bases.

 Gears.

 Pulleys.

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Possible Defects
Support

Defect Causes
 Insufficient material
Unfilled sections
 Low pouring temperature

 Melt temperature is too high

Porosity  Non-uniform cooling rate
 Sand has low permeability

Hot tearing  Non-uniform cooling rate

 Erosion of sand mold interior
Surface projections  A crack in the sand mold
 Mold halves shift

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Advantages

 Can produce very large parts.

 Can form complex shapes.

 Many material options.

 Low tooling and equipment cost.

 Scrap can be recycled.

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Disadvantages

 Poor material strength.

 High porosity possible.

 Poor surface finish and tolerance.

 Secondary machining often required.

 Low production rate.

 High labor cost.

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Design Considerations

 Maximum wall thickness

 Uniform wall thickness
 Corners
 Fillet
 Draft

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Maximum Wall Thickness

• Decrease the maximum wall thickness of a part to shorten the cycle time (cooling time
specifically) and reduce the part volume.

INCORRECT CORRECT

Part with thick walls Part redesigned with thin walls

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Uniform Wall Thickness
 Uniform wall thickness will ensure uniform cooling and reduce defects. A thick
section, often referred to as a hot spot, causes uneven cooling and can result in
shrinkage, porosity or cracking.
INCORRECT CORRECT

Non-uniform wall thickness (t1 ≠ t2) Uniform wall thickness (t1 = t2)

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Corners

 Round corners to reduce stress concentrations and fracture.

 Inner radius should be at least the thickness of the walls.

INCORRECT CORRECT

Sharp corner Rounded corner

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Fillets

CORRECT
INCORRECT

POOR CORRECT

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Draft

 Apply a draft angle of 2° - 3° to all walls parallel to the parting direction to facilitate
removing the pattern from the mold.
INCORRECT CORRCT

No draft angle Draft angle (q)

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Design Consideration for Parting Line
 The parting line is in the largest cross-sectional plane of the casting.
 The component face with the greatest surface detail is in the drag, because fluid fill is better in
the drag and low-density, non-metallic inclusions tend to segregate in the cope at the top of the
casting.

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Undercuts
 Minimize the number of external undercuts.

 External undercuts require side-cores which add to the tooling cost .

 Some simple external undercuts can be cast by relocating the parting line.

Die cannot separate

cc
Simple external undercut New parting line allows undercut

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External Undercuts
 Redesigning a feature can remove an external undercut.

cc

Part with hinge Hinge requires side-core

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 cc

Redesigned hinge New hinge can be cast

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 Redesigning a part can remove an internal undercut.

cc
cc

Part with internal undercut Die cannot separate

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 cc

cc
Part redesigned with slot New part can be cast

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 Minimize number of side-action directions.

4 side-actions in 2 directions

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Ribs

 Add ribs for structural support, rather than increasing the wall thickness.

INCORRECT CORRECT

Thick wall of thickness t Thin wall of thickness t with ribs

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 Orient ribs perpendicular to the axis about which bending may occur.

INCORRECT CORRECT

Incorrect rib direction under load F Correct rib direction under load F

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 Thickness of ribs should be 50-60% of the walls to which they are
attached.

 Height of ribs should be less than three times the wall thickness.

 Round the corners at the point of attachment.

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 Apply a draft angle of at least 0.25°.

CORRECT

INCORRECT

Thin rib of thickness t

Thick rib of thickness t

Close up of ribs

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Bosses
 Wall thickness of bosses should be no more than 60% of the main wall
thickness.
 Radius at the base should be at least 25% of the main wall thickness.
 Should be supported by ribs that connect to adjacent walls or by gussets at
the base.
INCORRECT CORRECT

Isolated boss Isolated boss with ribs (left) or gussets (right)

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 If a boss must be placed near a corner, it should be isolated using ribs.

INCORRECT CORRECT

Boss in corner Ribbed boss in corner

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Pulley: Machined

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Pulley: Casting

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Pulley: Pattern

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Pulley: Core

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Mold Cavity & Core

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