Metal Casting Processes
Metal Casting Processes
Metal Casting Processes
PEMP EMM2512
Session Objectives
At the end of the session students should have understood
Fundamentals of metal casting Metal casting processes
Sand casting Die casting Investment casting Continuous casting
Case studies
Cylinder block Piston
M.S Ramaiah School of Advanced Studies - Bangalore
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Manufacturing Processes
Manufacturing Processes
Casting:
Expendable mold Permanent mold
Machining:
Turning Milling Drilling Boring Grinding Shaping broaching
Joining:
Welding Brazing Soldering Bonding assembly
Finishing:
Lapping Polishing Deburring Surface treating coating
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What is casting?
Processing methods affect material properties differentially (and therefore the final component) Casting
Mostly Metals
Casting involves pouring/injecting molten material into a prepared cavity. On solidification the metal takes the form of the cavity. Cavity is formed within a Mould. Choice of manufacturing technique dependant upon required properties of component Suitability cost
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Applicability of Casting
Excellent for large and complex shapes, particularly with internal features Can produce net shape or near net shape components Used where mechanical properties are not of paramount importance Used where solid state processing is difficult or uneconomical
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Large, complex sand casting by rigid mould technology meeting stringent radiographic and penetrant NDT stds.
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Large surface area with wall thickness of 5 mm. As- cast internal oil passages, 5-12 mm dia, running to a total length of 500 mm. Casting weight : 50 kgs, Process : Rigid mould
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Large diameter, large surface area, thin walled casting for missile applications
Reduction gear cover casting for a helicopter engine with as -cast internal oil passages
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Casting processes
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Expendable mold
Permanent mold
Single-crystal growing
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Solidification of metals
Encourage smaller dendrites via mixing using convection currents or physical mixing (vibration) Innoculants -nucleating agents, form equiaxed dendrites with uniform distribution Quick cooling desirable Heat metal just enough Methods to ensure rapid cooling
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PEMP CASTING PROCESSES OPERATIONS - FLOW CHART COMPONENT DRAWING ESTIMATES & QUOTATION RECEIPT OF ORDER EMM2512
CASTING DRG DRAFT; M/C ALLOWANCE; CORNER & FILLET RADII; PARTING LINE.
TOOL DRG. PATTERN & CORE BOX /DIE DESIGN; CONTRACTION ALLOWANCE; AUXILLIARY TOOLS LIKE CHILLS, TEMPLATES, MOULD BOXES Etc.
METHODS DRG. POURING & FEEDING SYSTEM MFG. PROCESS DETAILS MOULD MEDIA METAL TEMP. Etc.
TOOL MFG. INCLUDING AUXILLIARY TOOLS SAND MIXING AND TESTING MOULD AND CORE PREPERATION OR DIE PREPERATION ASSEMBLY CASTING KNOCK OUT FETTLING AND CLEANING HEAT TREATMENT NDT AND INSPECTION SHIPPING FURNACES MELT AND REFINE REJECTION
RECLAIMED SAND
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- Metallic 2-piece pattern, 175C-370C - coated with a lubricant (silicone) - mixture of sand, thermoset resin/epoxyurea formaldehyde - cure (baking) -remove patterns, join half-shells mold - pour metal - solidify (cooling) - break shell part
Applications: small mechanical parts requiring high precision such as gear housings, cylinder heads and connecting rods etc
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Ceramic-mold:
good finish high mp metals (steel, ) => impeller blades, turbines, cutters for machining operations, dies for metal working and molds for making plastics or rubber components
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(d) dry ceramic melt out the wax fire ceramic (burn wax)
(c) Shell built immerse into ceramic slurry immerse into fine sand (few layers)
(e) Pour molten metal (gravity) cool, solidify [Hollow casting: pouring excess metal before solidification
(g) Cut off parts (high-speed friction saw) finishing (polish) M.S Ramaiah School of Advanced Studies - Bangalore
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Investment casting for instrument frame M.S Ramaiah School of Advanced Studies - Bangalore
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Permanent mold casting MOLD: made of metal (cast iron, steel, refractory alloys) CORE: (hollow parts) - metal: core can be extracted from the part - sand-bonded: core must be destroyed to remove Mold-surface: coated with refractory material - Spray with lubricant (graphite, silica) - improve flow, increase life - good tolerance, good surface finish - low mp metals (Cu, Bronze, Al, Mg)
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Two part permanent mould mounted on moulding machine, with centre core designed to pull down for casting removal
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Liquid metal injected into steel die at high velocity solidifies under Injection Pressure : 7 MPa to 140 MPa Locking force - 2000 ton Casting rate: 5 10 pieces / minute Die material: 0.3 C; 5.0 Si; 1.3 Mo; 1.0V. hardened to 420 460 BHN Die life: 50,000 to 2 lakh pieces Excellent surface finish / reproducibility Excellent dimensional accuracy: 0.05mm Castability 1mm (Al alloy) Alloy restriction / shape & size restriction Prone to gas porosity (finely dispersed N)-can be avoided by O2 purging
producing Al2O3 surface
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Used for lower melting point alloys (zinc and magnesium) Mold pressures usually 7 MPa to 14 MPa but can be up to 35 MPa.
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Used for higher melting point alloys aluminum and copper based Die pressures from 35 to 140 MPa
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Centrifugal casting
- permanent mold - rotated about its axis at 300 ~ 3000 rpm - molten metal is poured
- Surface finish: better along outer diameter than inner, - Impurities, inclusions, closer to the inner diameter
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Centrifugal casting
Eg. Cylinder Liners, Piston rings etc.
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Advantages
many metals, sizes, shapes, cheap better accuracy, finish, higher production rate Wide range of metals, sizes, shapes complex shapes, good surface finish complex shapes, high accuracy, good finish complex shapes, excellent finish good finish, low porosity, high production rate Excellent dimensional accuracy, high production rate Large cylindrical parts, good quality
Disadvantages
poor finish & tolerance limited part size patterns have low strength non-ferrous metals, low production rate small sizes small parts, expensive Costly mold, simpler shapes only costly dies, small parts, non-ferrous metals Expensive, few shapes
Examples
engine blocks, cylinder heads connecting rods, gear housings cylinder heads, brake components prototypes of mechanical parts impellers, injection mold tooling jewellery gears, gear housings gears, camera bodies, car wheels pipes, boilers, flywheels
Centrifugal
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Casting Defects
Discontinuities in castings
that exhibit a size, shape, orientation, or location that makes them detrimental to the useful service life of the casting
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Water quenching
Ageing
Air cooling
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Summary
Fundamentals of metal casting and different methods of casting have been studied Casting defects, design considerations were discussed Case studies such as casting of Cylinder block and Piston have been discussed
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