2. METAL CASTING PROCESSES
Sand casting – Sand moulds - Type of patterns – Pattern
materials – Pattern allowances – Types of Moulding
sand – Properties – Core making – Methods of Sand
testing – Moulding machines – Types of moulding
machines - Melting furnaces – Working principle of
Special casting processes – Shell, investment casting –
Ceramic mould – Lost Wax process – Pressure die
casting – Centrifugal casting – CO2 process– Sand
Casting defects – Inspection methods
3. 1.Manufacturing
Manufacturing in its broadest sense is the process of converting raw
materials into useful products.
• IT Includes
i) Design of the product
ii) Selection of raw materials and
iii) The sequence of processes through which the product will be
manufactured. Casting.
Any Product in the engineering industry will be manufactured in the below
methods
1. By totally deforming the metal to the required shape. (Casting
/Forming)
1. By joining two metals. (Welding)
2. By removing the excess material from the raw stock.(Machining)
4. Casting.
Casting is the process of producing metal parts by
pouring molten metal into the mould cavity of the
required shape and allowing the metal to solidify. The
solidified metal piece is called as "casting".
Sand Casting /Sand Moulding.
Sand Casting is simply melting the metal and pouring it
into a preformed cavity, called mold, allowing (the metal
to solidify and then breaking up the mold to remove
casting.
In sand casting expandable molds are used. So for each
casting operation you have to form a new mold.
5. Types of sand
a) Green-sand - mixture of sand, clay, and water,Binders
(Molases, Linseed oil); "Green” means mold contains
moisture at time of pouring.
b) Dry-sand - organic binders rather than clay and mold
is baked to improve strength
c) Skin-dried - drying mold cavity surface of a green-sand
- mold to a depth of u p t o 25 mm, using torches or
heating
d)Core Sand
e)Baking sand
f)Loam Sand
g)Parting sand, Etc
6. Patterns
Patterns are the replica or physical models of the final
required shape of the casting, made by wood
(teak,magony,pine), plastics, Metals, Plaster of paris etc.,
Types of patterns.
1.Solid pattern
2.Split piece pattern
3.Three piece pattern
4.Loose piece pattern
5.Match plate pattern
6.Segmental pattern
7.Sweep patten
8.skeleton Pattern
9.shell Pattern.
7. Pattern Allowance.
Allowance are the extra dimensional compensation
give to the pattern in order to attain the correct shape
and size of the final solidified metal casting.Five types
of allowances were taken into consideration for various
reasons.
Allowance types – refer PDF pg.no 8
8. Steps in Sand Casting
The cavity in the sand mold is formed by packing sand
around a pattern, separating themold into two halves •
The mold must also contain gating and riser system For
internal cavity, a core must be included in mold A new
sand mold must be made for each part.
1. Pour molten metal into sand mold
2. Allow metal to solidify
3. Break up the mold to remove casting
4. Clean and inspect casting
5. Heat treatment of casting is sometimes required to
improve metallurgical properties.
24. Pattern Allowances
Rapping Allowances or Shake Allowances
Negative Allowance
To rap the pattern from the sand
It creates some space around the pattern
25. Moulding Sand
Constituents of Moulding Sand
Silica sand grains
80-90% Silicon dioxide
Quartz rock
Imparts refractoriness, chemical resistivity, permeability.
Clay
5-20%
Bonding Strength
Moisture
2-8%
Miscellaneous materials
Limestone, magnesia, soda and potash.
26. Types of Moulding Sand
Green Sand
18-30% Silica
6-8% water
Soft, light and porous
Dry Sand
Green sand dried and baked
Large castings
Loam Sand
50% of clay
Large Castings
27. Types of Moulding Sand
Facing Sand
Face of mould
Surface of pattern
20-30 mm
Backing Sand
Back up facing sand
System Sand
No facing sand
Reactivated sands
Parting Sand
Avoids sticking of pattern to mould sand
Avoids sticking of cope and drag
Core Sand
Silica and core oil, to prepare core
28. Properties of Moulding Sand
Porosity or Permeability (gas holes and pores)
Flowability
Collapsibility
Adhesiveness (should cling or stick to sides of box)
Cohesiveness or strength
Refractoriness (withstand high temp.)
34. Core
A core is a device used in casting process to
produce internal cavities and reentrant angles. The
core is normally a disposable item that is destroyed to
get it out of the piece. They are most commonly used
in sand casting.