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    Metal Casting Design - Life of A Casting - Reliance Foundry

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    Sailakshmi
    This document discusses metal casting design and the factors that must be considered to create high quality castings. It explains that casting design requires understanding how metals behave during the liquid, cooling, and solidification stages. Characteristics like fluidity, shrinkage rates, slag formation, and pouring temperature must be accounted for in the design. The document also discusses heat transfer in castings, solidification patterns, shaping thicknesses, junctions, drafts, cores, parting lines and other mold design considerations that engineers must evaluate to minimize defects and create durable, well-designed castings. Understanding the relationship between materials and casting methods is essential for excellence in casting design.

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    Metal Casting Design - Life of A Casting - Reliance Foundry

    Uploaded by

    Sailakshmi
    12 views7 pages
    This document discusses metal casting design and the factors that must be considered to create high quality castings. It explains that casting design requires understanding how metals behave during the liquid, cooling, and solidification stages. Characteristics like fluidity, shrinkage rates, slag formation, and pouring temperature must be accounted for in the design. The document also discusses heat transfer in castings, solidification patterns, shaping thicknesses, junctions, drafts, cores, parting lines and other mold design considerations that engineers must evaluate to minimize defects and create durable, well-designed castings. Understanding the relationship between materials and casting methods is essential for excellence in casting design.

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    Metal Casting Design_ Life of a Casting _ Reliance Foundry

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    This document discusses metal casting design and the factors that must be considered to create high quality castings. It explains that casting design requires understanding how metals behave during the liquid, cooling, and solidification stages. Characteristics like fluidity, shrinkage rates, slag formation, and pouring temperature must be accounted for in the design. The document also discusses heat transfer in castings, solidification patterns, shaping thicknesses, junctions, drafts, cores, parting lines and other mold design considerations that engineers must evaluate to minimize defects and create durable, well-designed castings. Understanding the relationship between materials and casting methods is essential for excellence in casting design.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    12 views7 pages

    Metal Casting Design - Life of A Casting - Reliance Foundry

    Uploaded by

    Sailakshmi
    This document discusses metal casting design and the factors that must be considered to create high quality castings. It explains that casting design requires understanding how metals behave during the liquid, cooling, and solidification stages. Characteristics like fluidity, shrinkage rates, slag formation, and pouring temperature must be accounted for in the design. The document also discusses heat transfer in castings, solidification patterns, shaping thicknesses, junctions, drafts, cores, parting lines and other mold design considerations that engineers must evaluate to minimize defects and create durable, well-designed castings. Understanding the relationship between materials and casting methods is essential for excellence in casting design.

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    © All Rights Reserved
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    Download as pdf or txt
    of 7

     QUOTE 

    CASTING SERVICES

    Metal Casting Design—Life of A Casting


    Engineering metal castings for quality and value
    Good metal casting design means creating the simplest mold that will produce a desired shape.
    This process requires expert knowledge of metals and casting methods to find the best value in
    a quality casting.

    End-users often need to know how a cast metal object will behave when struck, in different
    heat conditions—and most importantly, under load. Will it warp, crack, or deform over time?
    These mechanical requirements determine what kind of metal is best for a product. Metal
    designs may also require a certain grade of finishing for aesthetic or mechanical reasons. An
    engineer or designer chooses metals and casting methods to answer these needs, and creates
    a design using their experience of how material and method influence each other in the
    foundry. Knowing the behavior of metal in liquid, cooling, and solid states is important when
    creating a design that will minimize problems on the production floor.

    Variables in metal casting design

    Slag is the dark layer floating on this titanium as it flows


    from an arc furnace during de-slagging.
    Metal castability

    There are four main metal characteristics that affect the outcome of a casting design:
    QUOTE 

    Fluidity is the ease with which various metals flow in a molten state. The more fluid a
    metal is when liquid, the better it can capture small details within a mold.
    Shrinkage is the contraction rate of molten metal as it cools from a liquid state. Liquid
    shrinkage describes the contraction rate when the metal first begins to cool,
    solidification shrinkage describes the point in time when the metal starts freezing from
    liquid to solid, and solid shrinkage when the metal has set. These rates can predict
    strains and defects that might occur during cooling. If parts of the design freeze much
    faster than others it can challenge the integrity of the casting.
    Slag or Dross formation describes the presence of non-metallic inclusions in a
    casting, and where they are acceptable (surface) or detrimental (sub-surface).
    Pouring temperature is the temperature at which a given alloy can be poured; the
    hotter the metal, the more production challenges present themselves.

    Heat transfer
    Two different heat transfer rates affect how quickly a metal solidifies within a mold. One is the
    dispersion of heat of the metal through itself, and the other the rate of heat transfer from
    where the casting touches the mold. These rates help determine the overall temperature
    differential through the casting, as well as the differential cooling that can happen as sections
    of the casting change state first.

    Solidification patterns
    Usually, a casting cools more quickly where it is touching the mold, crystallizing from the edge
    inward. Knowing the crystallization, heat transfer, and shrinkage rates of a given metal allows
    an engineer or metallurgist to predict the pattern of crystallization through the casting. When
    looking to minimize problems with shrinkage, molds are designed with these solidification
    patterns in mind. Parts of the mold may be cooled with chills to create more rapid shrinkage in
    a section. Other parts of the casting might be connected to reservoirs, called risers, which
    slowly feed liquid metal into a cooling casting to prevent cavities forming as the solidifying
    metal shrinks.

    Shape and section size changes


    Hot spots in cooling castings can be formed where there is increased thickness in material.
    Where possible, it’s helpful to design castings of uniform thickness, but when this is not
    possible designs can minimize strain by gradually changing the slope of walls and to make sure
     thickness is preserved.
    that in all places the minimum metal QUOTE 

    Metal castings with large diameter changes should be tapered slowly to prevent cooling strain.

    By smoothing sharp angles and adding cores, engineers prevent high-volume hotspots from
    forming.
    Junctions between sections
    Sharp angles in junctions between sections are an area engineers are mindful of when
    considering casting thickness. Unless a designer is careful, two or more sections of a casting
    that come together can create a larger volume of metal at the point the sections meet. If the
    designer smooths these corners rounding them away from sharp angles, this volume can be
    made more consistent with themetal volumes on either side. QUOTE 

    Mold stability
    The casting mold must be able to handle the behavior of metal while it cools. Expansion,
    contraction, and off-gassing (gasses evolving from the mold during pouring that get trapped in
    the solidifying casting) are all possibilities, depending on the metal being used. The materials
    used in the mold must be able to withstand the metal in all states, without fracture or collapse.

    Surface finish capability


    Different molding methods produce different finishes. If a product needs a fine finish, the
    molding processes tend to be more expensive. In some cases, precision finishes are only
    needed for some of the product, and part of the casting can be machined after being
    unmolded: in these cases, the metal needs to be easily machinable. Very smooth finishes tend
    to come from more intensive and therefore more expensive molding processes, but for large
    objects this is less expensive than machining the whole surface.

    Other mold design considerations

    A sand mold with a core. Where the halves of the mold


    come together is the parting line.

    To produce an excellent casting at a good price, the designer should minimize or eliminate
    expensive cores, deep drafts, and irregular parting.

    Drafts
    Drafts refer to the taper on the vertical walls of a casting. These are necessary so that a
     of the object being designed, can be removedQUOTE
    pattern, which is the “positive” image without 
    disturbing the walls of the mold.

    Cores
    Cores are used to create intentional holes or voids inside a casting. They are designed to burn
    up during molding or shake out afterwards. They are often expensive to produce, and in some
    designs can be avoided by changing the “parting line” of the mold or the orientation of the
    casting.

    Parting Lines
    Parting lines are created where the two halves of a mold come together. Risers and gates are
    often placed along the parting line, and because of this there can be extra metalwork needed
    after the casting is removed, to take off extra material. There may also be metal leaks into the
    parting line, usually thin and flat: this is called flash, and removal of flash is a common step
    after casting.

    Excellence in casting design


    When designing a metal casting, understanding the relationship between materials and
    methods is key to making a product of quality and value. The dependencies between metal and
    mold are complex. Knowing the mechanical properties necessary for the final product will
    influence what metal is needed; the behavior of the metal in liquid, cooling, and solid states will
    determine some of the needs of the mold. For example, metals with less fluidity may do better
    in molds with less small detail: metals that are very brittle upon cooling may be less suited to
    designs with sharp edges that are prone to chipping. The melting temperature required will
    also determine the challenges of the process on the foundry floor—for example, the high
    melting point of steel requires a higher level of monitoring and precision throughout the
    casting process. Experience and communication between designers, engineers, and
    metalworkers can help create a superior product at the lowest price.

    PREVIOUS POST:
    INTRODUCTION

    METAL CASTING PROCESS

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