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Casting Unit 3

Casting is important in manufactuing

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Nagasuresh Babu
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18 views5 pages

Casting Unit 3

Casting is important in manufactuing

Uploaded by

Nagasuresh Babu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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a.

Casting:
In casting process, the molten metal is poured into a mould cavity and is allowed to
solidify after solidification, the casting is removed from the mould and cleaned, finally
machined to the required shape and size and inspected before use. They are further
classified into 2 types
1. Expandable mould
2. Permanent mould

1. Expandable mould
Here, the mould is prepared from sand, plaster or any other similar material which can
break easily to remove the solidified part, in other words a new mould has to be prepared
for each new casting. Eg: Green sand, dry sand, plaster, etc.

2. Permanent mould
Here, the mould is fabricated out of steel and can be used repeatedly to produce many
castings. Eg: Gravity die casting, continuous casting, pressure die casting, centrifugal
casting.
Expandable mould a. Sand casting (green sand, dry sand)
b. Shell casting
a) CASTING c. Foam casting
d. Investment casting
Permanent mould a. Gravity die casting
b. Pressure Die casting
c. Centrifugal casting
Steps involved in making a casting
1. Pattern
2. Mould preparation
3. Core making
4. Melting and pouring
5. Cleaning and Inspection

1. Pattern
A pattern is a replica of the object is to be cast. It is used to prepare a cavity into which the
molten metal is poured. A skilled pattern maker prepares the pattern using wood, metal,
plastic or any other material. Many factors like durability, allowance for shrinkage and
machining, etc., are considered when making a pattern.

2. Mould preparation
It involves for making a cavity by packing sand around a pattern enclosed in a supporting
metallic frame. When the pattern is removed from the mould an exact shaped cavity
remains into which the molten metal is poured. Gating and risering are provided at suitable
locations in the mould.

3. Core making
In some cases a hole or a cavity is required in the casting. This is obtained by placing a core
in the mould cavity. The shape of the core corresponds to the shape of the hole required.
The mould is cleaned & finished before metal pouring.

4. Melting and pouring


Metals or alloys of the required composition are melted in a furnace and poured in to the
mould cavity. Many factors like temperature of molten metal, pouring time, turbulence, etc
should be considered while making & pouring.

5. Cleaning and Inspection


After the molten metal is solidified and cooled, the rough casting is removed from the
mould, cleaned and dressed (removing cores, adhered sand particles, gating, risering
system, fins, blisters, etc from the casting surface) and then sent for inspection to check for
dimensions or defects like blow holes, crakes, etc.

Procedure for making a casting

a. Mould box
It is usually a metallic frame used for making for holding a sand mould. The mould box has
two parts. The upper part is called “Cope” and the lower part is called “Drag”.
b. Parting line
It is the zone of separation between a cope & drag position of the mould in sand casting.
c. Sprue/Runner
It is a vertical passage through which the molten metal will enter the gate.
d. Pouring basin
The enlarge position of the sprue with its top into which the molten metal is poured.
e. Gate
It is a short passage way which carries the molten metal from the runner sprue in to the
mould cavity.
f. Riser
A riser or a feed head is a vertical passage that stores the molten metal ands supplies the
same to the casting as it solidifies.
g. Mould cavity
The space in a mould that is filled with molten metal to form the casting upon solidification.
h. Core
A core is performed by using a mass of sand placed in the mould cavity to form hollow
cavity in the castings.
i. Core print
It is a projection attached to the pattern to help for support and correct location of core in
the mould cavity.

Following are a few advantages and limitations of casting process.

Advantages:
 Casting is the basic and versatile (flexible) manufacturing process.
 Difficult shapes can be easily cast.
 Large, hollow & intricate shapes can be easily cast.
 Casting provides freedom of design with respect to shape, size and quality of the
product.
 Some metals that cannot be machined can be produced by casting to the required shape.
 Heavy objects can be produced only by casting process.
 Controlled mechanical & metallurgical properties can be obtained.
 Casting process is most suitable for mass production.
 A large variety of alloying composition & properties can be obtained.
 Directional properties can be obtained in certain cases by controlled cooling.
 Parts with close dimensional tolerance & ready to use can be produced by special
casting methods.
Disadvantages OR Limitations

 Casting process is an elaborate process and involves operations.


 It requires large infrastructure like casting section, melting, pattern, core section,
cleaning, finishing, and inspection.
 Very high investment is required.
 Casting process is not economical & viable for small scale operations.
 The man power requirement is large.
 High care is required in handling chemicals and molten metal.
 The actual casting operation cannot be automated.
 Generally most operations may be casting or one of type i.e. mould has to be
prepared for each casting.
 Great care is required in controlling the cooling rate to obtain defect free casting.
 Very difficult to cast thin sections.

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