Metal casting process

NAME : ARINDAM MAJUMDER

DATE : 17-08-2023

COLLAGE : JADAVPUR UNIVERSITY

ROLL : 002011201115

SEC : A3

Under guidance of : TAPAN KUMAR BARMAN

 Contents

1. Introduction to casting.

2. Steps in casting

3. Advantages of casting.

4. Limitations of casting.

5. Types of casting
5.1 expandable mould casting.
5.2 Permanent mould casting.

6. Casting terminology
6.1 pattern
6.1.1 pattern materials
6.1.2 types of pattern
6.1.3 pattern allowances

6.1.3.1 Shrinkage allowances

6.1.3.2 Machining allowances
6.1.3.3 Draft or taper allowances
6.1.3.4 Shake allowances
6.1.3.5 Distortion allowances
Abstract :

Casting is a versatile manufacturing process which is

used from 3700 BC , but even today importance of this
mfg. process is not decreases it is the first step of
making the product.
Some steps are followed to do casting, mould and
pattern making then melting and pouring of hot molten
metal into the cavity through riser , solidification and
cooling of molten metal and last inspection of the final
casted product.
Like other mfg. processes it also have some advantages
and limitations.
There also different casting process to get the best
desired product.
Casting:
1. Introduction to casting:
It is the oldest (7000 year old) manufacturing process & even today it is the first
step of making the product.
Casting is basically melting a solid material , heating to a temperature above
the melting temperature & and pour it to a mould or cavity to get a desired
shape.
However as with other manufacturing processes, best results and economy can
be achieved by using casting.

2. Steps in casting :

 Mould and pattern making - a mould is an assembly of two or

more metal blocks , consisting of a primary cavity . the mould
cavity hold the liquid material and essentially acts as a negative of
the desired product.
A pattern is the replica of the part to be cast and is used to
prepare the mould cavity. They are made of either wood or metal.

 Melting & pouring (liq. Metal) – the solid material is heated to a

temperature greater than its melting temperature , and the
poured or injected to the mould cavity through the gating system
for solidifying.

 Solidification & cooling - to get the desired product the liquid

metal needed to be solidified , which is done by cooling and
solidification.

 Defects inspection – after all the procedures if the cast product

have some defects , then some non-destructive techniques are
used to identify them. Eg- visual inspection for rough surfaces ,
pressure test for to be used as a pressure vessel and ultrasonic
inspection.
3. Advantages of casting :

 Large size objects are made by casting only.

 Complex shape can be obtain by casting.

 Both ductile and brittle material can be cast easily.

eg- as we know brittle materials are hard in nature , so to get a
desired shape from a solid brittle material by machining is difficult
because during cutting the tool can be damaged , where as if we
use casting process we can easily achieve the desired shape.

 Tools and equipment used in casting process is less expensive

when compare to the other manufacturing processes. We can say
it is the most economic manufacturing process when compare to
others.
4. Limitations of casting :

 Surface finish of sand casting object is not good.

 Casting process is laborious process.

 Sand mould casting objects are subjected to gaseous defects.

Moulding sand have moisture contents in it ,when hot molten
metal enters in it these moisture contents get vaporised and
create gaseous defects in casted product.

 Casting objects do not have same properties throughout the

volume of casting.
A simple diagram is shown of mould wall and different structure of
casting objects.
Heat transfer rate nearer to the mould wall is higher than the
centre of the casting object, three different temperature are
shown in the diagram where T1<T2<T3.
The area under T1 is called chilled zone , fine grain structures
formed here which is brittle and hard in nature.
Coarse grain structure formed in T2 temperature which is little
higher than T1.
Columnar grain structure formed in the area under T3
temperature.

In different temperature formed structures are different because

of nucleation (liquid to solid transformation) rate and growth rate
which is directly proportional to the temperature.
At low temperature nucleation
rate is high and growth rate is low(nucleation rate > growth rate).
So the grains are more in number but small in size.So the formed
structures in T1 temperature are fine grain.
At high temperature growth rate is high than the
nucleation rate(nucleation rate < growth rate). Here, the grains are
less in number but comparatively big in size. So the structures in
T2 and T3 are coarse and columnar in nature.
5. Types of casting :

Casting is classified into two categories,

5.1 Expendable casting(temporary mould) -

expandable mould casting is a generic classification which
includes,
 Sand mould casting
 Dry sand mould casting
 Shell mould casting
 Investment casting
 Vacuum mould casting
 Ceramic mould casting

5.2 Permanent mould casting(metalic mould) -

Permanent mould casting is a process for producing a large
number of castings using a single reusable mould.
The casting process simply involves
pouring molten metal into a mould where it cools and solidifies. The
mould is then opened, the casting removed, and the mould is
reused. The mould is made from a high-temperature metallic
material, such as cast iron or hot work die steel, which can withstand
the repeated heating and cooling involved with large volume
production.
Some of the permanent mould casting is
 Centrifugal casting
 Die casting
 Slush casting

6. Casting terminology :

6.1. pattern –
it is the replica of final product to be produced with some changes
or modifications in terms of allowances or core print.
 6.1.1. pattern materials –
Patterns are made of wood, metals , plastic , rubber , wax &
foam etc.
In mass production metallic patterns are used and these metallic
patterns are made by wooden pattern & that is why wooden patterns are
also called master pattern.

6.1.2. Types of pattern –

 Solid piece or single piece pattern

 Split piece pattern
 Loose piece pattern
 Sweep pattern
 Skeleton pattern
 Cope and drag pattern
 Gated pattern

6.1.3. pattern allowances –

A pattern is always made somewhat larger than the final job
to be produced. This excess to dimension are referred to as the pattern
allowances. There are mainly two allowances
6.1.3.1 Shrinkage allowances
6.1.3.2 Machining allowances
Some other allowances are also there like,
6.1.3.3 Draft or taper allowance
6.1.3.4 Shake or rapping allowance
6.1.3.5 Distortion allowance

6.1.3.1 shrinkage allowance -

Provided to take care of the contraction of
casting , contraction of casting happen in three stages
 Contraction of liquid from pouring temperature to freezing
temperature.
 Contraction associated with change in phase from liquid to solid.
  Contraction of solid casting from freezing temperature to room
temperature.

NOTE :

 Liquid and solidification shrinkage are compensated by

using riser.
 Solid shrinkage is compensated by increasing the size of
pattern & this increment in dimension in pattern is called
shrinkage allowance.

6.1.3.2 Machining allowance –

will take care of the extra material that will be
removed to obtain a finished product. In this the rough surface in the cast
product will be removed. The machining allowance depends on the size of the
casting, material properties, material distortion, finishing accuracy and
machining method

6.1.3.3 Draft allowance –

 Given on vertical surfaces of pattern for easy removal
of pattern and to prevent breakage of mould cavity.

Conclusion :
Casting is an important mfg. process that helps
to the manufacturing industries to produce a
different variety of products. There are
different methods of casting like sand casting ,
die casting , full mould casting, investment
casting.

References :
 Youtube lec on metal casting by Gaurav babu.
 Ghosh , Mallik manufacturing process.