Casting

• Manufacturing Process – liquid metal is going to solidify in given

shape and size to get the desired product.
 Casting Term ology
• Mould / Mold – A void created in compact sand / metal / wax mass
• Filled with molten metal to produce the casting.
• Moulding / Molding – the process of producing the mould.
 Pattern
• Replica / model of desired casting
• Packed in moulding material to produce the a cavity.
 Flask

• Hold the sand the intact.

• Material – upper moulding flask
• Cope – upper moulding flask
• Drag- lower
• Runner – is the passage trough which molten metal reach up to
cavity.
• Parting Line – drag cope surface meet each other.
• Riser – Reservoir of molten metal – to compensate the reduction in
volume of liquid metal due to contraction.
 Mould
•M
 Mould making Procedure

•M
 Pattern Allowance
• The difference in dimension of pattern to final dimension of casting.
• Reason
• 1. Shrinkage or contraction allowance– cooling from pouring temp to
room temp.
• Liquid Contraction of riser – compensated by riser
• Solidifying Contraction - compensated by riser
• Solid Contraction --- compensated by pattern
• Influencing Factor - pouring temp
• Design and dimension of casting
• Type of metal
 Machining Allowance
•M
 Draft allowance
• Purpose – to facilitate easy withdrawal of pattern from the mould without
damaging the surface and edge.
 Distortion allowance
•D
 Rapping or shake allowance
•R
 Pattern Material
• Number of casting
• Dimensional accuracy required
• Surface Finishing
• Casting method
 Pattern Material
• Wood – cheap and abundance
• Shaped in different shape
• Light in weight
• Good surface finishing
• Wear out quickly
• Susceptible to moisture
 Metals
• Casting – large in number
• Closer dimensional accuracy
• Longer life
• Costlier
• Machining required
• Heavy in weight
• Rusted
• Ex- cast iron, brass, Al etc.
 plastics
• Lightness in weight
• High strength
• Resistance to wear
• Fine surface finish
• Resistance to corrosion
• Reasonable cost
 plaster
• Plaster of paris or gypsum cement
• Easily shaped
• Carries high compression strength
• Closer dimensional accuracy.
 wax
• Used in investment casting
• For complicated shape
 Master pattern
• Used for preparing the moulds for metal castings which are later used
as metal pattern for further moulding work.
• Carry double shrinkage allowance.
 Type of pattern
• Solid and single piece pattern
• Simplest in all type , made in one piece and carries no joint , partition
or loose pieces.
• Cheapest
 Two piece or split pattern
• Difficulty in mould making and withdrawn of pattern
• Made in two parts joint at the parting line
• Can be multiple piece
 Match plate pattern
• Objective – rapid production of small and accurate casting on large scale.
• Greater dimensional accuracy
• Construction cost is high but compensated by high production.
• Pattern made in two parts.
• One piece is mounted one side and other on the side of plate called
match plate.
 Match plate pattern
•M
 Gated Pattern
Objective – mass production of small casting
Multi cavity moulds are prepared
Patterns are connected to each other by gate former which provide
suitable channels.
 Sweep pattern
• Used for preparing mould of large symmetrical casting.
• Large saving in time, labour and material.
• Consists – base, spindle, wooden template
• Sweep rotated about the spindle to form the
cavity.
 Pattern with loose piece
• Have loose piece in order to enables their easy withdrawal from the
mold.
 Segmental pattern
• Used for large circular casting
• Avoiding the use of solid pattern of exact size.
• Segment is moved from one position to second in mold
.
Skeleton pattern- casting size very large and
heavy, hollow pattern
Only out side features
Cope and drag pattern- riser, runner and
ingate are integral part of pattern
 Properties required in the Foundry sand
• Refractoriness – with stand high temp. of molten temp. without
fusing.
• Depend upon – silicon oxide quantity in sand (melting temp. 1710 C)
• Shape and size of sand grain
• Presence of iron oxide, calcium, potassium and sodium.
 Permeability
• Allows the gases and steam to escape
• Reason – casting unsound or blast
• Depend upon – grain size and shape, proportion of water and clay,
ramming of sand.
• Increase by venting
 Adhesiveness and Cohesiveness
• Ad. – capability of adhering to the surface of other material
• Objective- adhering to the moulding flask.
• Coh.- rammed grain particle bind together
• Depends upon- grain size, clay, and moisture content.
 collapsibility
• Sand mould automatically collapses after solidification of casting.
• Reason – tear and cracking in casting.
 Sand term ology- Green sand
• Freshly prepared mould sand in which there is enough moisture to
give it sufficient bond.
• Composition – 70-85% silica, 10- 20% clay, 3-6% water, 1-6% additives
Effect of ramming on the moulding sand
• Increase the density of mould
• Increase the mould hardness and strength.
• Decrease the permeability.
 Other sand term ology
•O
 Gating system
•G
 Solidification of liquid metal
• Skim forming
• Dendritic growth
 Chills
• To provide unidirectional solidification in casting.
 Gating system
variable – Temp. Gradient, unidirectional solidification, erosion of
sand, absorption of air
* Top * Bottom * Side
 Core
• A solid body of sand used to form a cavity of desired shape and size in
casting
Investment casting
 Investment casting
•I
 Permanent Mould
• Mould is not destroyed after each casting.
• Economical –High production rate
• Used for low melting point material
• Better dimensional accuracy , surface finishing
• Less skilled labour
• 2.4 mm thickness
 Gravity Die casting
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 Die casting or pressure die casting
• Liquid metal injected in to permanent mould under pressure.
 Cold chamber die casting
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 Hot Chamber die casting
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 Centrifugal casting
• Rotating the mould at a high speed with molten metal.
• Adv. – impurities separation
• Better dimensional accuracy
• Proper directional solidification
•
True Centrifugal casting
True Centrifugal casting
Semi Centrifugal casting
Centrifuging casting
 casting defect
•I
Blow holes and cold shut
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 Mould Shift
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 Cupola

• Furnace used for melting of cast iron.

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