Unit 1

Metal casting processes

(Casting)
Introduction to Manufacturing Science, various manufacturing processes and

Organizing the required manufacturing processes ––Introduction to casting –

Fluidity and Solidification time of molten metals – Sand casting - Properties of

refractory sand –Shell moulding- Investment casting –Plaster moulding –

Advantages, Disadvantages and applications of Die casting and Centrifugal

casting–Casting defects – Testing and inspection of casting.

1
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
• Inspection of casting

2
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
• Inspection of casting

3
 M

Introduction to casting

4
Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand

5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop
5
Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand
Metallic CUBE
5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop
6
 Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand
Metallic CUBE
5. Cope Box

6. Pouring basin and runner

7. Riser

Wooden CUBE 8. Mould cavity

9. Foundry Shop
7
Pattern
Mould Box
Mould Box

Flat Surface - Ground

8
Pattern
Mould Box
Mould Box

Pattern

Mould Box

Ground

Flat Surface - Ground

9
Mould box filled with
Moulding SAND

12
Rammer

13
 Again add
Moulding SAND

14
Rammer

15
Invert the Mould
Box with pattern

16
Inverted Mould Box
with pattern

17
Another Mould BOX

Inverted Mould Box

with pattern

18
Conical Shaped
Wooden pieces

Inverted Mould Box

with pattern

19
Inverted Mould Box
with pattern

20
Moulding
Sand

Inverted Mould Box

with pattern

21
Rammers

Inverted Mould Box

with pattern

22
Rammers

Inverted Mould Box

with pattern

Sand

23
Sand

Inverted Mould Box

with pattern

Sand

24
 Inverted Mould Box
with pattern
Sand

25
Mould Box – 2 Sand

Mould Box – 1

26
Remove (Pull up) the
pattern with care
Sand

Cavity
Pattern
(Mould cavity)
Align the two mould boxes

Sand

Cavity
Pattern
(Mould cavity)

28
 Remove the Conical
Shaped Wooden pieces

Sand

29
Sand Mould Box – 2

Mould Box – 1

30
Sand Mould Box – 2

Mould Box – 1
(Drag BOX)

31
Sand Mould Box – 2
(Cope BOX)

Mould Box – 1
(Drag BOX)

32
 COPE
Sand

DRAG

33
 COPE
Sand

DRAG

34
 COPE
Sand

Mould
Cavity

DRAG

35
 Pouring basin and runner

COPE
Sand

Mould
Cavity

DRAG

36
RISER Pouring basin and runner

COPE
Sand

Mould
Cavity

DRAG

37
 Molten metal is poured through
the Pouring basin and runner

Sand

38
 Molten metal is poured through
the Pouring basin and runner

Sand

39
 Molten metal is poured through
the Pouring basin and runner

Sand

40
When the mould cavity is
full, excess molten metal Molten metal is poured through
rises through the RISER the Pouring basin and runner

Sand

41
When the mould cavity is
full, excess molten metal Molten metal is poured through
rises through the RISER the Pouring basin and runner

Sand
Allowed to
solidify

42
Solidification
complete

Break the
mould

44
Solidified
Metal

45
 Final Product

Solidified
Metal

46
 Remove the unwanted
projections by machining

Final Product

47
 Final Product

Final Product or
CASTING

48
Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand

5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop
49
Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand

5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop
50
Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand

5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop
51
Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand

5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop
52
Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand

5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop
53
Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand

5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop
54
Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand

5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop
55
Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand

5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop
56
Introduction to casting
1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand

5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop
57
Mould Making - Movie

Sand Casting - Movie

58
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
• Inspection of casting

59
Introduction to casting

1. Cast Product or Final product

2. Pattern

3. Drag Box

4. Moulding Sand

5. Cope Box

6. Pouring basin and runner

7. Riser

8. Mould cavity

9. Foundry Shop

60
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
• Inspection of casting

61
 Fluidity of molten metal

Ability of the molten metal to completely

fill the mould cavities

62
Fluidity of molten metal

Cope

Drag

Mould cavity
63
Fluidity of molten metal

Cope

Drag

Mould cavity
64
 Fluidity of molten metal

Ability of the molten metal to completely

fill the mould cavities

65
 Fluidity of molten metal

Factors affecting Fluidity:-

» Viscosity

» Surface Tension

» Impurities in molten metal

» Freezing Point

» Solidification Time

66
 Fluidity of molten metal

Factors affecting Fluidity:-

» Viscosity

» Surface Tension

» Impurities in molten metal

» Freezing Point

» Solidification Time

67
 Fluidity of molten metal

Factors affecting Fluidity:-

» Viscosity

» Surface Tension
Inversely
Proportional
» Impurities in molten metal

» Freezing Point

» Solidification Time

68
 Fluidity of molten metal

Factors affecting Fluidity:-

» Viscosity

» Surface Tension
Inversely
Proportional
» Impurities in molten metal

» Freezing Point

» Solidification Time

69
 Fluidity of molten metal

Factors affecting Fluidity:-

» Viscosity

» Surface Tension
Inversely
Proportional
» Impurities in molten metal

» Freezing Point

» Solidification Time Directly

Proportional

70
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
• Inspection of casting

71
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
• Inspection of casting

72
 Solidification Time
Define:-

Time between the pouring of molten

metal & the end of solidification

73
 Solidification Time
Define:-

Time between the pouring of molten

metal & the end of solidification

Pouring of
molten metal

74
 Solidification Time
Define:-

Time between the pouring of molten

metal & the end of solidification

End of
Pouring of solidification
molten metal

75
 Solidification Time
Define:-

Time between the pouring of molten

metal & the end of solidification

End of
Pouring of solidification
molten metal

Solidification Time
76
 Solidification Time
Chvorinov’s Rule:-
Total Solidification Time

V n
T
A

77
 Solidification Time
Chvorinov’s Rule:-
Total Solidification Time

V 2
n
T
Where; A
V = Volume of the casting

A = Total Surface Area of the casting

n = 1.5 to 2.0 (selected from standard tables)

(usually assumed to be as 2)

78
 Solidification Time
Chvorinov’s Rule:-
Total Solidification Time
2
V
T = C
Where; A
V = Volume of the casting

A = Surface Area of the casting

n = 1.5 to 2.0 (selected from standard tables)

(usually assumed to be as 2)
c = A constant depending on mould material, metal
79
properties and temperature (selected from standard tables)
 Solidification Time
For more details on

“fluidity of molten metal Solidification time….”

Refer

Page number 266 - 272

Manufacturing Engineering and Technology

(4th edition)

Authors: Kalpakjian & Schmid

80
 Chvorinov’s Rule:-

Significance of Chvorinov’s rule

It ensures that…
• The casting solidifies first and then the
Pouring basin, runner and riser
• Thus eliminates the volume shrinkage
81
Cope

Drag

82
 Cope

Volume = V Drag

83
 Cope

Volume = V Drag

84
 Cope

Volume = V Drag

85
 Cope

Volume = V Drag

86
 Solidification starts

Assume that the Pouring basin and runner

and riser are not present
Cope

Volume = V Drag

87
Assume that the Pouring basin and runner
and riser are not present
Cope

Drag

Solidification under progress

88
Assume that the Pouring basin and runner
and riser are not present
Cope

Drag

Solidification under progress

89
Assume that the Pouring basin and runner
and riser are not present
Cope

Drag

Solidification under progress

90
Assume that the Pouring basin and runner
and riser are not present
Cope

Drag

Solidification under progress

91
Assume that the Pouring basin and runner
and riser are not present
Cope

Drag

Solidification under progress

92
Assume that the Pouring basin and runner
and riser are not present
Cope

Drag

Solidification under progress

93
Assume that the Pouring basin and runner
and riser are not present
Cope

Drag

Solidification under progress

94
Assume that the Pouring basin and runner
and riser are not present
Cope

Drag

Solidification under progress

95
Assume that the Pouring basin and runner
and riser are not present
Cope
Volume shrinkage during solidification

∆V

Volume = V - ∆V Drag

After solidification ends

- it cools to room temperature 96

 Cope

∆V

Volume = V - ∆V Drag

This volume shrinkage can be nullified if both the Pouring

basin, runner & riser feeds the mould cavity during 97
solidification
 Chvorinov’s Rule:-

Therefore the main significance

(ultimate aim) of Chvorinov’s rule

* To eliminate volume shrinkage during

solidification.
98
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
• Inspection of casting

99
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
• Inspection of casting

100
Properties of a good moulding sand
1. Refractoriness

2. Permeability

3. Adhesiveness

4. Cohesiveness

5. Green strength

6. Dry strength

7. Collapsibility

101
Properties of a good moulding sand
It’s the ability of the moulding sand to
1. Refractoriness
withstand the high temperature of the
2. Permeability molten metal

3. Adhesiveness

4. Cohesiveness

5. Green strength

6. Dry strength

7. Collapsibility

102
Properties of a good moulding sand
1. Refractoriness
It’s the ability of the moulding sand to
2. Permeability
allow the free passage of waste gasses
3. Adhesiveness from the mould cavity

4. Cohesiveness

5. Green strength

6. Dry strength

7. Collapsibility

103
Properties of a good moulding sand
1. Refractoriness

2. Permeability
It’s the ability of the moulding sand to stick
3. Adhesiveness
to the walls of the mould box
4. Cohesiveness

5. Green strength

6. Dry strength

7. Collapsibility

104
Properties of a good moulding sand
1. Refractoriness

2. Permeability

3. Adhesiveness
It’s the ability of the moulding sand to stick
4. Cohesiveness
to one another
5. Green strength

6. Dry strength

7. Collapsibility

105
Properties of a good moulding sand
1. Refractoriness

2. Permeability

3. Adhesiveness

4. Cohesiveness
It’s the strength of the sand in the moist
5. Green strength
state
6. Dry strength

7. Collapsibility

106
Properties of a good moulding sand
1. Refractoriness

2. Permeability

3. Adhesiveness

4. Cohesiveness

5. Green strength
It’s the strength of the sand in the dry
6. Dry strength
state
7. Collapsibility

107
Properties of a good moulding sand
1. Refractoriness

2. Permeability

3. Adhesiveness

4. Cohesiveness

5. Green strength

6. Dry strength
It’s the ease with which casting can be
7. Collapsibility
withdrawn after solidification by breaking
the mould
108
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
• Inspection of casting

109
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
• Inspection of casting

110
Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting

111
 Shell Moulding

Pattern Required Final Product

2-D View of the product

112
 Shell Moulding

Pattern

113
Dump Box
 Shell Moulding

Pattern

SAND + BINDER

114
Dump Box
 Shell Moulding

Pattern

SAND + BINDER

Phenol formaldehyde
resin

115
Dump Box
 Shell Moulding

Heating the pattern

Pattern in an oven

SAND + BINDER

Phenol formaldehyde
resin

116
Dump Box
 Shell Moulding

Heated pattern
Pattern taken out from the
oven

117
Dump Box
 Shell Moulding

Heated pattern
aligned over the
dump box

118
Dump Box
 Shell Moulding

Heated pattern
clamped over the
dump box

119
Dump Box
Shell Moulding
Sand + resin
mixture falls on the
heated pattern

Inverted Mould box

Invert the dump box 120

Shell Moulding
Sand + resin
mixture falls on the
heated pattern

Inverted Mould box

121
 Shell Moulding

Remaining
sand falls
back to
dump box
Keep as such for a few minutes

122
 Shell Moulding

Remaining
sand falls
back to
dump box

123
 Shell Moulding

Pattern &
sand Shell

Unclamp and take the pattern & sand shell

124
 Shell Moulding

Kept in an Oven to
complete curing

125
Shell Moulding
Shell

Shell mould is
stripped from the
pattern

126
 Shell Moulding
Shell Shell

Shell
One mould
more is prepared in the
shell same
Shell wayis
mould
stripped from the stripped from the
pattern pattern

127
 Shell Moulding

TWO shells are clamped together inside a mould box

128
Shell Moulding
Molten metal
poured

129
Shell Moulding
Molten
Metal

130
Shell Moulding
Solidified

131
Shell Moulding

Break the mould

132
Shell Moulding

Take the casting out side

133
Shell Moulding
Remove the
unwanted
projections

134
Shell Moulding

The final product is ready

135
 Shell Moulding
For more details on SHELL MOULDING

Page Number: 292 & 293

136
Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting

137
Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting

138
Investment Moulding

139
Investment Moulding

Final product

140
Investment Moulding

X 5 nos.

Final product

141
Investment Moulding

X 5 nos.

Final product

WAX Pattern (5 Nos.)

142
 Investment Moulding

WAX tree
143
 Investment Moulding

WAX tree
144
 Investment Moulding

WAX tree
145
 Investment Moulding

WAX tree
146
 Investment Moulding

WAX tree
147
 Investment Moulding

WAX tree
148
 Investment Moulding

plaster of Paris
+ 2 Dimensional
plaster of Paris
view of Dump
binder box +
+ binder
powdered silica +
powdered silica

Dip the Wax tree in to the Cylindrical Dump

Box filled with Investment slurry 149
 Investment Moulding
Heated

Heated

Thin shell of
investment

Heated
Heated

WAX drains
WAX tree is coated with aoff…
very thin shell of
150
investmentcoating
The thin investment coatingleft behind
 Investment Moulding

WAX drains off…

151
The thin investment coating left behind
 Investment Moulding
Heated

Heated

Heated
Heated

Again heated to strengthen the investment coating

152
and remove all the remaining traces of wax
 Investment Moulding

Inverted investment coating is ready for

153
pouring molten metal
Investment Moulding

Molten metal poured

154
Investment Moulding

Allow to solidify
155
 Investment Moulding

Break the investment coating by mechanical vibration,

156
or water blasting
 Investment Moulding

Break the investment coating by mechanical vibration,

157
or water blasting
 Investment Moulding

Cut the required part from the metal tree

158
Investment Moulding

Final product (5 Nos.)

159
Investment Moulding
is also known as

160
 Investment Moulding
is also known as

“LOST WAX” process

For more details on
INVESTMENT MOULDING

MOVIE -1

MOVIE -2
Page Number: 298, 299 & 300
161
Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting

162
Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting

163
 Plaster Moulding

Materials with low melting point can be

cast with plaster moulding process

164
Plaster Moulding

Final product

165
Plaster Moulding

Final product

Wooden Pattern

166
 Plaster Moulding

Wooden pattern kept on a flat surface 167

 Plaster Moulding

Mould box also is positioned properly 168

 Plaster Moulding

Plaster of
Paris Mixture

Plaster of Paris mixture is poured 169

 Plaster Moulding

Allowed to settle for 15 – 20 minutes 170

Plaster Moulding

Mould box is inverted 171

 Plaster Moulding

Pattern

Pattern removed 172

 Plaster Moulding

Heated

Heated to 120 to 260 degree Celsius – to remove excess

173
moisture content
Plaster Moulding

Mould cavity

Mould cavity is ready 174

Plaster Moulding

Molten metal is
poured

Allow to solidify 175

 Plaster Moulding

Final Product

After solidification, break the mould and take the casting

176
 Plaster Moulding

Refer page Number 296 and 297

177
Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting

178
Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting

179
 Ceramic Moulding

The process is exactly similar to plaster moulding

180
 Ceramic Moulding

The process is exactly similar to plaster moulding

Instead of Plaster of Paris, a ceramic slurry is used here

181
 Ceramic Moulding

The process is exactly similar to plaster moulding

Instead of Plaster of Paris, a ceramic slurry is used here

182
 Ceramic Moulding

The process is exactly similar to plaster moulding

Instead of Plaster of Paris, a ceramic slurry is used here

Zircon
+
Fused silica
+
Bonding agent
183
 Ceramic Moulding

Refer page Number 296 and 297

184
Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting

185
Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting

186
 Die Casting
It comes under the category of

“Permanent Mould Casting”

The mould can be used again and again

Re-usable moulds are known as

“Permanent Moulds”
or
“Metal moulds”
or
“DIE” 187
 “Permanent Mould Casting”
Molten metal is poured into the DIE cavity.

(Molten metal flows inside the DIE cavity by gravitational force)

“Die Casting”
Molten metal is forced into the DIE cavity.

(Molten metal is injected in to the DIE cavity)

188
 Permanent Mould Casting
Molten Metal
DIEPoured
cavity and
solidified

• After solidification, DIE is opened.

• The final product taken out

• Again the DIE is closed for another pouring

Movable DIE Fixed DIE

189
 Re – usable mould casting

Permanent DIE Casting

Mould Casting (metal injected)
(metal poured)

HOT chamber Process M1

(Molten metal Injected directly in to the die cavity)

COLD chamber Process M2

(Molten metal Poured in to a secondary chamber and
then injected in to the die cavity) M3
190
 Die Casting

Refer page Number 301, 302, 303, 304 & 305

191
Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting

192
Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting -

193
 Centrifugal Casting

• Used for casting AXI - SYMETRICAL components.

• The Inertial force of rotation plays the major role.

(Centrifugal force)

• Hence the name; “Centrifugal Castings”

194
Centrifugal Casting

Molten metal poured

Molten metal is thrown to the
walls of mould cavity

Rotating Mould Box

Axis of rotation
(Vertical) 195
Centrifugal Casting
Rotation
Solidification
maintained
Complete
until
complete Casting
Centrifugal solidification
Process

Rotating Mould Box

Axis of rotation
(Vertical) 196
 Centrifugal Casting
Solidification Complete

Axis of rotation
(Horizontal)

Rotating Mould Box

Axis of rotation
Rotating Mould Box (Vertical) 197
 Centrifugal Casting
Solidification Complete

Axis of rotation
(Horizontal) Mainly for castings with
Uniform diameter

Rotating Mould Box 198

 Centrifugal Casting

199
Movie

Centrifugal casting is a method of casting parts
having axial symmetry. The method involves pouring
molten metal into a cylindrical mold spinning about
its axis of symmetry.
The mold is kept rotating till the metal has solidified.
As the mold material steels, Cast irons, Graphite or
sand may be used.
The rotation speed of centrifugal mold is commonly
about 1000 RPM (may vary from 250 RPM to 3600
RPM).
Centrifugal casting is carried out as follows:
The mold wall is coated by a refractory
ceramic coating (applying ceramic slurry,
spinning, drying and baking).
Starting rotation of the mold at a
predetermined speed.
Pouring a molten metal directly into the
mold (no gating system is employed).
The mold is stopped after the casting has
solidified.
Extraction of the casting from the mold.
The casting solidifies from the outside fed
by the inner liquid metal.
Non-metallic and slag inclusions and gas
bubbles being less dense than the melt are
forced to the inner surface of the casting by
the centrifugal forces. This impure zone is
then removed by machining.
Resulted structure of the centrifugal
castings is sound.
Centrifugal casting technology is widely
used for manufacturing of iron pipes,
bushings, wheels, pulleys bi-metal steel-
bronze bearings and other parts possessing
axial symmetry.
200
 Centrifugal Casting
Various types are…
• TRUE Centrifugal casting
• Mainly horizontal axis of rotation.
• Through holes - pipes, gun barrels….etc…..

• SEMI Centrifugal casting

• Mainly for manufacturing wheels with spokes.

• CENTRIFUGE casting

201
 Centrifugal Casting
Various types are…

• TRUE Centrifugal casting

• Mainly Horizontal axis of rotation

• Castings of Uniform inner and outer diameter

• Castings having through holes

202
 Centrifugal Casting
Various types are…

• SEMI Centrifugal casting

• Mainly Vertical axis of rotation

• Castings of Uniform / Varying inner and outer diameter

• Castings having Blind holes / through holes

203
 Centrifugal Casting
Various types are…

• CENTRIFUGE casting

• Mainly Vertical axis of rotation

Mould cavity Mould cavity204

 Centrifugal Casting
Various types are…
• TRUE Centrifugal casting
• Mainly horizontal axis of rotation.
• pipes, gun barrels….etc…..

• SEMI Centrifugal casting

• Mainly for manufacturing wheels with spokes.

• CENTRIFUGE casting

Refer page number 306, 307 and 308 205

Different Casting Methods

1. Shell Moulding

2. Investment Moulding

3. Plaster Moulding

4. Ceramic Moulding

5. Die casting

6. Centrifugal casting

206
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
• Inspection of casting

207
 Unit I Casting
• Introduction to manufacturing processes
• Introduction to casting
• Fluidity of Molten metal
• Solidification Time
• Properties of a good moulding sand
• Different casting methods
• Defects in casting
Self learning
• Inspection of casting

208
 Unit 1
Metal casting processes
(Casting)
Introduction to Manufacturing Science, various manufacturing processes and

Organizing the required manufacturing processes ––Introduction to casting –

Fluidity and Solidification time of molten metals – Sand casting - Properties of

refractory sand –Shell moulding- Investment casting –Plaster moulding –

Advantages, Disadvantages and applications of Die casting and Centrifugal

casting–Casting defects – Testing and inspection of casting.

209
 Unit -1

THE END

210