Professional Documents
Culture Documents
Casting: Forming Sheet Metal Processing Powder-And Ceramics Processing Plastics Processing
Casting: Forming Sheet Metal Processing Powder-And Ceramics Processing Plastics Processing
Casting: Forming Sheet Metal Processing Powder-And Ceramics Processing Plastics Processing
Casting
Forming
Plastics processing
Cutting
Joining
Surface treatment
Sand Casting
Pattern
Pattern Basics Completed
Pattern
materialsTypes of
patterns Pattern
allowances
Mould design &
Preparation Molding Materials
Molding sand
( types, quality , testing)
Mould preparation
Melting Cast metal pouring system
furnace
Casting
1. Function of mould arising to different sands ( e.g moulding
sand , facing sand etc.)
1. Moulding sand
2. Backing (system) sand
3. Facing sand
4. Mould wash
5. Parting sand
6. Core sand
Types of Sand
Facing Sand
• used next to pattern for easy removal and increasing
smoothnes.
• coal dust 2-8% is mixed with the system sand.
• coal dust burns resulting into gas pressure thus
protecting molten metal entering into sand.
Mould wash
• similar sand like facing sand but used after pattern is
taken out ( through spraying, painting etc.).
• water/ alcohol is used to mix the sand. Alcohol is
preferred because of faster evaporation.
Types of Sand
Backing Sand
• reconditioned sand ( after the sand mould is broken).
• used as cost effective requirement.
• facing / mould wash sand is used in conjunction.
Parting sand
• used at the parting line of the pattern.
• avoids adherence of the pattern with the moulding
sand.
• washed silica sand helps for it’s non-stickiness
properties.
Mould design &
Preparation
Molding Materials
a. Natural sand
b. Synthetic
c. Special
Important to understand for design of mould, runner
system, casting defects
Moulding Materials
Major part of Moulding material in sand casting
are
1. 70-85% silica sand (SiO2)
2. 10-12% bonding material e.g., clay , cereal
etc.
3. 3-6% water
Advantages Disadvantages
1. Less costly 1. Get fused with metal
2. Easily available 2. High coefficient of expansion
3. Wide range of grain sizes
and shapes
These sands are got from river and can withstand upto 1550 deg C
sed in case of :
. Mechanised production ( high volume)
. Machine molding
. High pressure molding
Molding sand
Special sand ( are available in specific
area or made from minerals)
1. Zircon sand - better properties
2. Chromite sand - but costlier
3. Olivine sand - need special preparation
P= V. 5.08 cm
p.HA. T
P= 501.28
p. T
3.0- Green compression strength
- sand specimen prepared ( as per standard) is immediately
tested under compression loading .
- value (30-160 kPa)
4.0- Green shear strength
-test specimen preparation same as earlier.
- testing is for shearing test in UTM
- value is lower ( 10-50 kPa)
Tensile strength
preparation core box
7. Sand Grain Size (GFN)
GFN :
41 - steel castings 50 kg+
67 - small steel casting
105 - light cast iron/ cu- casting
150 – aluminium alloy casting
GFN testing set-up
Sizes and example
Sizes and example
Moulding sand properties
metal - value differs for different types (0.073 N/cm3 for Cast iro
Design of Core
Vertical core Weight of core
Wc=Volume x ρ core
D Volume=π/4 x (Di2-D2) x H
+
π/4 x (D2) x 2a
Design of Core
P≤ 350 A
Locations :
1. Horizontal simply supported core
2. Horizontal overhanging or side core
3. Vertical double supported core
4. Vertical hanging core
5. Vertical bottom core
Design of Core
1. Laddle
2. Pouring cup/ basin
3. Sprue (down-gate) (1)
4. Gate (in-gate)
5. Runner (cross-gate) (6)
6. Riser (6)
(2)
(3)
(5) (4)
Gating System- Design
One of the most important design criteria of gate design is to
ensure that metal reaches all cross sections in a streamline flow.
Mass continuity =
QAv
11=A
2v
2
A1 h
Sprue design = 2
A2 h1
Reynolds number
V olu
me n
Chvorinov’s Rule S
olid
ific
atio
ntim
e =C
Su
rfa
ceAre
a
Hydraulic Principles used in the Gating Syste
Reynold's Number
Nature of flow in the gating system can be established by
calculating Reynold's number
RN = Reynold's number
V = Mean Velocity of flow
D = diameter of tubular flow
µ = kinematics Viscosity = Dynamic
viscosity / Density
ρ = Fluid density
RN< 2000, then streamline flow. Otherwise turbulent flow.
Turbulent flow can result in :
V=√2gh
If h=0.1 m, g=10 m/s2,then
V=1.4 m/sec h
D 2.5 D
Tapered sprue
Straight sprue
At “B”, h=h1
h2-h1
p=0, v1=√2gh1
C PL
Sprue tapered downward ?
p v2
h+ + =c
A ρg 2 g
B h1
=
QA
v
1=
1 A
v
22
h2-h1
to maintain constant
head ( otherwise
C PL vortex), then Bernoulli’s
theorem will be
√h1/h2=v1/v2
hence,
A1 h2
=
A2 h1
Sprue Well
slug
Top Gate
- to have a strainer core to
reduce velocity of flow
- perpendicular to PL Top gate
- symmetrical geometry part
- good for flat casting (low
height)
- problem of turbulence
- NG for non-ferrous matl
Design of Gating system
Bottom Gate
- for parts where major portion remains in the drag, tall casting
-Turbulence problem is avoided
- directional solidification problem
Bottom gate
Design of Gating system
Parting Gate
-easy to dismantle/ fettle
Parting gate
Parting line
Design of Gating system
Step Gate
- for parts where uneven geometrical shapes and
large parts
Step gate
Types of Gating System
Increasing
cross sect
area
Liquid Liquid
Liquid
Void
V o
lu
me
n
S
o
lid
if
ic
a
tio
ntim
e
=C
S
ur
f
ac
eAr
e
a
n =1 for die casting C=constant for a metal
=2 for sand casting
Fastest
Risers
V o
lu
me n
Chvorinov’s Rule S
olid
ific
atio
ntim
e =C
S
urfa
ce
Are
a
How to solve problem of solidification ?
Risers can
help to avoid
this void
Risers
Risers
Pouring time
- too fast pouring causes turbulence
Where,
K is fluidity in inches/ 40
T is average section thickness ( V/A) in mm
W is mass of casting in kg
A ( in mm2)=W/ (d t C √2gH)
W is mass of casting in kg
d is density of casting metal in kg/mm3
C is efficiency factor dependent on gating design
H is total metal head in mm
t is pouring time in seconds
Choke Area
H=h
H=h-c/2
Choke Area
H=h-p2/2c
Calculate the gating requirement for the cast iron in C30 steel
Solution
Step -1 : calculate the total volume in mm3
Step-4 : take casting yield around 0.6 and calculate input weight
2
V
ts ≈
A
• Cooling for Sand Mold
Tw
TEMPERATUR
METAL - MOLD
∆T
INTERFACE
E
MOLD - AIR
∆ T INTERFACE
T0
DISTANCE
Heat transfer- Die casting
1
V
≈
ts
A
Thermal Conductivity “k” of Various Materials
for Parts and Molds (W/m °K)
Copper 394
Aluminum 222
Iron 29
Sand 0.61
PMMA 0.20
PVC 0.16
dT
q = −k
dx
Cooling Time; thin slab
Cooling Time; intersection
V h 1 1
= 1 +
A 2 2 L − 1
h
Fluidity of Metals
Casting parameters
•Mold Design
•Degree of Super Heat
•Mold Material
- Thermal Conductivity
- Surface Roughness
•Heat Transfer
• Rate of pouring
Heat Transfer
– - Pouring
– - Solidification
– - Cooling rate
• - Rate is a function of
Volume and surface
area
Hydraulic Principles used in the Gating System