ST. ANNE’S COLLEGE OF ENGINEERING AND TECHNOLOGY (Approved by AICTE, New Delhi. Affiliated to Anna University, Chennai) ‘Accredited by NAC ANGUCHETTYPALAYAM, PANRUTI ~ 607 106, DEPARTMENT OF MECHANICAL ENGINEERING ME3393-MANUFACTURING PROCESSESUNIT-1 METAL CASTING PROCESS UNIT-I METAL CASTING PROCESS 1. Define foundry (AU MAY-JUNE 2006) ‘A plant where the castings are made is called foundry. 2. Define casting. (AU MAY-JUNE 2006, 2014) It is the process of producing metal parts by pouring molten metal into the mould cavity of the required shape and allowing the metal to solidity. The solidified metal piece is called as casting. 3. Define mould. Mould is the cavity of the required shape to be made in the molding sand or in other material, 4. Define pattern. (MAY/JUNE 2014) ‘The model of the required casting made in wood. Metal or plastics. 5. Name the various pattern materials. (AU MAY-JUNE 2006) Wood —teak wood, mahogany, white pine, etc, ‘Metal — cast iron, brass, aluminum, ete Plaster Plastics, Wax 6. What are the difference between shaking allowance and other allowance? (AU MAY- JUNE 2006) In shaking allowance, the extra size is subtracted from the pattern dimensions. In other allowance, the extra size is added with the pattern dimensions, 7. When do you make core or what is function of core in molding sand? To provide a hollow surface or recess on the casting. The core is made. PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS 8. What do you understand by core setting? Curing or heating the cores to obtain enough hardness is called as core setting. 9. What is a core point? Mention is its purpose? A core point is an extra projection on the patter. it supports the core. 10. What are the requirements of core sand? 11. Name the different types of core binders. Oil binders Water soluble binders Resin binders Inorganic binders 12. State the various types of core boxes. Half box dumps or slap core box Split core box Stickle core box Gang core box 13. State any two core dying ovens. Batch type ovens Continuous type ovens Dielectric baking oven 14, What are the different types of patterns used in foundries. Solid or single piece pattern split pattern Loose piece pattern Match plate pattern ‘Sweep pattern Skeleton pattern Segmental pattern Shell pattern 15. Define pattern allowances or what the main purpose of providing pattern is. ‘The amount of increase in size for compensating the reduction of dimensions due to PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS shrinkage, machining, drafting, shaking and distortion, effect. 16. When do you make core or what is function of core in molding sand? To provide a hollow surface or recess on the casting. The core is made. 19, What are the core making materials or core sand ingredients? *Core sand binders. *Additives *Moisture 20. Where the balanced core is generally used? This type of core is used when the blind holes along a horizontal axis are to be produced. 21. What is the final product of COzprocess?(AU MAY-JUNE 2007) Silica gel which binds the sand grains together in the final product of CO2 process. 22, Mention the specific advantages of CO process. (Nov/Dec-2018) Gives strength and hardness to core Process cost is less It saves time on heating It can be stored for long use. 23. What is the properties good molding sand? (AU MAY-JUNE 2007) Porosity or permeability Plasticity or flow ability Strength or cohesiveness Adhesivenes Refractoriness Collapsibility 24, What are the ingredients of molding sand? Binders ‘Additives: Moisture 25, State the purpose of adding ingredient to the molding sand.(AU NOV-DEC 2007) To increase the strength To ensure collapsibility To increase cohesiveness and adhesiveness PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS 26. What are the different types of molding sand? Green sand Dry sand Synthetic sand sand, Special sand Parting sand 27. Write the composition of good molding sand?(Nov/Dec-2018) Green sand: It contains 5 to 8% water and 15 to 20% clay. Loam sand: Loam sand is a mixture of fine sands, fine refectories, clay, graphite power and water. It contains more clay (50%) 28, What is meant by tempering of the sand? ‘The process of spraying and mixture adequate amount of water with the sand in the Muller is called a tempering 29, What are the various stages involved is sand conditioning? Removing foreign materials Distributing the binder uniformly Controlling the moisture ‘Aerating the sand and Delivering at proper temperature 30. List out any five molding tools. (AU NOV-DEC 2007) Shovel Riddle Rammer Trowel Slick Strike — off -bar Lifter 31. What is the use of swab and vent — wire? ‘Swab: the swab is used to apply water In the sand around to pattern, PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS Vent-wire It is used to make small holes on the mould after ramming. 32. What are the uses of runner and riser’? Runner: It is used to make a spree a hole in the cope. It receives the molten metal from the pouring basin and passes to the cavity Riser: It supplies excuses molten metal to the solidifying casting. It allows the escape of air. 33. What are chaplets? Sometimes, it is not possible to provide sufficient support for a core in the mould being poured, if the cores are bigger in size. In such cases, the core is supported with rigid metal pieces, called chaplets. 34, State the various methods for testing molding sand. Moisture content test Clay content test Grin fitness test Permeability test strength test deformation and toughness test hot strength test Refractoriness test Mould hardness test 35. Write down the formula for calculating the percentage of clay content. Percentage clay content = w1/w2*100 36. Define deformation. (AU MAY-JUNE 2010) Deformation is defined as the plasticity of sand that can be tested by reducing the length of specimen applying compressive force on it. 37. State the different types of molding processes. Green sand mould Dry sand mould Loam sand mould PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS 38. Mention any two differentials between green sand mould and dry sand mould. Green sand mould Dry sand mould Le for making mould Less surface finish Low strength Less permeability More time consuming Better surface finish Stronger than green sand mould More permeability 39. What are the different types of furnaces used for casting? Cupola furnace Open hearth furnace Crucible furnace Pot furnace Electric furnace 40. List the factors to be considered in the choice of metal melting furnaces. (AU MAY- JUNE 2010) Cupola furnace — for cast iron Open heath furnace — for steel Crucible furnace — for non-ferrous metal Electric furnace — for steel, alloy steel, brasses. 41, What are the types of Crucible furnace? Pit furnace Coke fired stationary furnace Oil fired tilting furnace 42, State the principle of thermocouple pyrometer? (AU MAY-JUNE 2011) When the two junctions are held at different temperatures a voltage is generated in the circuit. This voltage is measured by a galvanometer which is calibrated in degrees of temperature instead of electrical unit. 43. What does the different disappear in optical pyrometer? When the brightness of light of filament is equal to the rightness of light of molten metal, the filament disappears. 44. What is die casting? (AU MAY-JUNE 2011) The mould used for making a casting is permanent, called a die casting. PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS 45. What are the types of alloys cast in cold chamber die casting machines? (AU NOV-DEC 2010) Household equipments like washing machine parts, vacuum cleaner body, fan case, stove parts, etc. Automobile parts like fuel pump, carburetor body, horn , wiper, and crank case. ‘Components for telephones, television sets, speakers, microphones, record players and so on. Toys like pistols, electric trains modal aircrafts etc. 46. State any two limitations of full mould casting. Only small parts can be made Dimensional accuracy is less. 47. What are the reasons for the casting defects of cold shuts and misrun?(AU NOV-DEC 2010) Cold shuts - low pouring temperature and too small gate misrun - faulty molding and faulty molding box equipments. 48. Give four reasons for the casting defects hot tear’ Very hard ramming To low pouring temperature ‘Small gates Faulty design of pattern inclusion 49. Name four different casing defects (Nov/Dec-2013)(ApVMay-2019) Shifts - two halves mismatching of casting Hot fear - internal or external cracks Fins thin projection on parting line Inclusions - foreign material present in casting. 50. How casting defects are indentified? The casting defects are indentified by conducting various tested such as X-ray test. Magnetic particle test, liquid penetrate test and ultrasonic test. 51. State any four types of pattern. (May/June 2012) ‘The following types of pattern arc normally used Solid or single piece > Split pattem > Loose piece pattern PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS > Match plate pattern. 52. What are the causes for the formation of blow holes in the sand casting? (May/ June 2012) ‘The causes for the formation of blow holes in the sand casting are > Excess moisture > Hard ramming > Improper Venting > Using more binder. 53. What is meant by core print?[AU-NOV/DEC-2012}(Nov/Dec-2018) A core print is an extra projection on the pattern. Core print forms a seat in the mould. The core print is supported in the seat formed by the core print. 54. Name the different metal melting furnaces used in foundries . [AU-NOV/DEC-2012] 1. Cupola furnace-For cast Iron 2. Open hearth furnace-For steel 3. Crucible furnace-For non-ferrous metal a. Pit type furnace . Coke fired stationary furnace c. Oil fired tilting furnace 4. Pot furnace 5. Electric furnace a. Direct arc furnace b. Indirect arc furnace . Induction furnace 55. Compare the advantage of metal moulds over sand (expandable) moulds. (May/ June 2013) ‘Metal moulds ‘Sand moulds. Tehas accurate in size Tehas slightly variation in size It has smooth surface Tthas rough surface PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS 56. What are the function of flux in melting metals and alloy? (May/ June 2013) Fluxes for melting metals and alloy are solid substances (commonly mixtures of chloride and fluoride salts) used in metals and alloy foundries in order to reduce the melt oxidation, imize penetration of the atmospheric Hydrogen, absorb non-metallic inclusions suspended in the melt, keep the furnace/ladle wall clean from the built up oxides. 57. Differentiate shrinkage and porosity. (Now/Dec-2013) ‘SLNo- Shrinkage Porosity L The metal shrinks on solidification and contracts further on cooling to room temperature, To compensate this, the pattern is made larger than the required casting Porosiy is a measure of molding sand by which the sand allows the steam and gases to pass through it This extra size provided on the pattern for metal shrinkage is called shrinkage allowance. To escape these gases, the molding sand should have good gas permeability or porosity. 38. Name the steps involved in making a casting. Steps involved in making a casting are (1)Pattern making (3)Core making (S)Pouring (Testing (Melting (6)Finishing (8)Heat treatment (9)Re-testing 59. What are the applications of casting? ‘Transportation vehicles (in automobile engine and tractors) Machine tool structures ‘Turbine vanes and power generators Mill housing pump filter and valve 60. Define pattern. A pattern is defined asa model or replica of the object to be cast. PREPARED BY RJAYAKUMAR AP/MECH (2)Sand mixing and preparation ‘A pattem exactly resembles the casting to be made except for the various allowances. Page 9UNIT-1 METAL CASTING PROCESS 61. Define mould making. It is a model or form around which sand is packed to give rise to a cavity called as mould cavity, in which molten metal is poured and the casting is produced. 62. Why is a pattern larger than casting? A pattern is slightly larger than the casting because a pattern carries allowance compensate for metal shrinkage. 63. What do you mean by core prints in pattern? To produce seats for the cores in the mould in which cores can be placed, for producing cavity in the casting. Such seats in the mould are called as core prints. 64, Name the functions of pattern. (1) Prepare a mould cavity (2) To produce seats for the cores (3) To establish the parting line (4) To minimize casting defects. 65. Name the materials for making patterns ‘The common materials of which the pattems are made are as follows: (1)Wood (2) Metal (3) Plastic (Plaster (5) Wax 66. List the various alloys and metal used in pattern. ‘The various metals and alloys employed for making patterns ate : (a) Aluminium and its alloys (b) Steel (©) Brass () Cast icon (e) White metal 67. Explain wax mol After being molded, the wax pattern is not taken out; rather the mould is inverted and heated and the molten wax comes out or gets evaporated, hence there is no chance of the mould cavity getting damaged while removing the pattern. 68. List the allowances of pattern. The following allowances are provided on the pattern (a) Shrinkage or contraction allowance (b) Machining allowance (©) Draft or taper allowance (d) Distortion allowance (e) Rapping or shake allowance 69. List the three forms of contraction. Contraction takes place in three forms (J) Liquid contraction (2) Solidifying contraction (3) Solid contraction PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS 70. Shrinkage of metal depends on what factors?(Apl/May-2019) ‘The shrinkage of metal depends on the following factors (2) The metal to be cast (2) Pouring temperature of the molien metal (3) Dimensions of the casting (4) Method of molding, 71. What do you mean by finish allowance? Machining allowance or finish allowance is the amount of dimension on a casting which is made oversized to provide stock for machining. 72. What are the factors on which amount of machining depends? Factors affecting machining are (1) Metal of casting (2) Machining method used (3) Casting method used (4) Shape and size of the casting (5) Amount of finish required on the machined portion 73. Why isa taper allowance used? Draft allowance or taper allowance is given to all vertical faces of a pattern for their easy. Removal of sand without damaging the mould. 74. When does war page occur? War page occurs when (1) Itis of irregular shape. (2) It is of U or V-shape (3) The arms having unequal thickness. (4) One portion of the casting cools at a faster rate than the other. 75. How do you eliminate war page? To eliminate this defect, an opposite distortion is provided on the pattern, so that the effect is balanced and correct shape of the casting is produced 76. Enlist the factors affecting selection of types of pattern. ‘The type of pattern to be used for a particular casting will depend on following factors : (1) Quantity of casting to be produced (2) Size and shape of the casting (3) Type of molding method (4) Design of casting 77. Name any four types of pattern. ‘The various types of patterns which are commonly used are as follows : (U)Single piece or solid pattern (2) Two piece or split pattern (3) Loose piece pattern (4) Cope and drag pattern (5)Gated pattem PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS 78. Write the significance of loose molding. Some patterns embedded in the molding sand cannot be withdrawn; hence such patterns are made with one or more loose pieces for their easy removal from the molding box. 79. Name and give use of the pattern in which number of casting are made at a time Gated pattern by using gated patterns number of casting can be made at a time, hence they are used in ‘mass production system. 80. Piston rings are made by ......pattern Match plate pattern ‘These pattems are made in two pieces i.e. one piece mounted on one side and the other on the other side of the plate, called as match plate. 81. What is the difference between sweep and segmental pattern? ‘The main difference between them is that, a sweep is given a continuous revolving motion to generate the required shape, whereas a segmental pattem is a portion of the solid pattern itself and the mould is prepared in parts by it. 82. Why are patterns colored? Patterns are provided with certain colors and shade for following reasons: (i) To identify quickly the main pattern body and different pattern parts. (ii) To indicate the type of the metal to be cast. (iii) To identify loose pieces, core prints, ete. (iv) To visualize machined surfaces, etc. 83. Selection of mould materials depends on..... Selection depends on following factors cn) cost of the material (ii) Quality of casting required (iii) Number of casting required (iv) Shape and size of the casting Material to be cast, etc. ‘What are the types of molding sand? All types of sands used in the foundry can be grouped as: 1. Natural sand 2. Synthetic sand 3. Special sands 85. Why is synthetic sand better than natural sand? (1) Itrequires less proportion of binder. (2) Higher refractoriness and permeabi (3) Properties can be easily controlled. (4) Refractory grain size is more uniform, 86 Name the different types of special sand. ‘Types of special sand are (1) Greensand = (2) Loamsand (3) Core sand (4) Parting sand (5) Facing sand (6) Backing sand PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS 87 Define black sand It is the sand which backs up the facing sand and does not come in direct contact with the pattern. This sand has black color and hence, sometimes called as black sand. 88. Define green strength. A mould which has adequate green strength will retains its shape and does not distort or collapse, even afier the pattern has been removed from the molding box. 89. Define permeability. The sand must be porous to allow the gases and steam generated within the moulds to be removed freely. This property of sand is known as permeability or porosity. 90 Name the constituents of molding sand. ‘The main constituents of molding sand are : (1) Sand 2) (3) Additives (4) 91. Classify binders and name the typesin it 1) Organic binders (a) Linseed oil (©) (b) Molasses (d) 2) Inorganic binders @ Clay, ) (c) Portland cement 92. Name the types of clay binders Clay binder which is most widely used have following types: (a) Bentonite (b) Fire clay (© — Limonite @ 2) To develop certain other properties like resistance to sand expansion defects, etc. 94 What do you mean by coal dust? It reacts chemically with the oxygen preseat in the sand pores and thus, produces a teducing atmosphere at the mould metal interface and prevents oxidation of the metal. 95. Functions of sand preparation are. . (1) To develop optimum properties in the molding sand. (2) To obtain even distribution of sand grains throughout the bond. (3) To add suitable amount of water to activate clay binder. (4) To deliver sand at the suitable temperature. 96. Define Muller. It is a mechanical mixer used for mixing sand ingredients in dry state. PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS 97. Name various methods of sand testing. (1) Moisture content test (2) Clay content test (3) Permeability test (4) Grain fineness test 98. Name the factors affecting permeability test. Permeability depends on the following factors: Grain shape and size Grain distribution Binder and its contents Water amount in the molding sand Degree of ramming Enlist the functions of core. Core provides a means of forming the main internal cavity for hollow casting. Core provides external undercut feature. Cores can be inserted to obtain deep recesses in the casting. Cores can be used to increase the strength of the mould. 100 Define Core. Core is a sand shape or form which makes the contour of a casting for which no provision has been made in the pattern for molding. 101. Difference between core sand and mould sand. ‘The main difference is that core sand has very low clay content and larger grain size. Core sand mixture consists of .. Core sand mixture consists of sand, 1% core oil, 1% cereal and 2.5 to 6% of water. Name the core sand ingredients. Ingredients are (1) Granular refractoriness (2) Core binders (3) Water (4) Additives ‘What does core making consists of ? Core making basically consists of following steps: (1) Core sand preparation (2) Core making @) Core baking (4) Core finishing or dressing (5) Setting the cores 105. Define core driers. The special shapes. which support the green sand cores having curved surfaces, are known as core driers. 106 List various types of core. Their main types are as follows (1) Horizontal core (2) Vertical core (3) Hanging core PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS (4) Balanced core (5) Ramup core (©) Kiss core Drop core 107. What is core box? Core box isa pattern for making cores. They are employed for ramming cores in them. Core boxes provide the required shape to the core sand. 108. Name the types of core boxes. (1) Half core box (2) Dump core box (3) Split core box (4) Stickle core box (5) Gang core box (©) Loose piece core box (7) Leftand right hand core boxes 109. Why do we use a core prints? Core prints are basically extra projections provided on the pattern. They form core seats in the mould when pattern is embedded in the sand for mould making. Core seats are provided to support all the types of cores. 110 Name the types of core prints. : Core prints are of the following type: (i) Horizontal core print Gi) Vertical core print (ii) Balanced core print (iv) Cover core print 111. Define mould. When the pattem is removed, a cavity corresponding to the shape of the pattern remains in the sand which is known as mould or mould cavity 112. What is loam molding? In this, a rough structure of component is made by hand using bricks and loam sand. The sand used is known as loam sand or loam mortar. 113 _ Explain in short shell molding. Shell molding is suitable for thin walled articles. It consists of making a mould that has two or more thin shell like parts consisting of thermoseiting resin bonded sand, 114 Name any six hand mould tools A number of hand tools are (1) Shovel 2) Hand riddle 3) Rammers (4) Lifters or cleaners (5) Drawspike (6) Bellow 115 Functions of molding machine. The main functions of molding machines are: Ramming of molding sand. Rolling over or inverting the mould through 180° Rapping of pattern. Removing the pattern from the mould. PREPARED BY RJAYAKUMAR AP/MECHUNIT-1 METAL CASTING PROCESS 116 Name the types of molding machine. Following are the types of molding machines: (a) Squeeze molding machines (b) Jolt molding machines (©) _Jolt-squeezing machines (© Sand stinger 117 _ Difference between permanent mould casting and sand casting. The main difference between permanent mould casting and sand casting is that, in this, the mould is permanent which is neither destroyed nor remade after each cast. 118. Name the type of die casting machine. ‘The main types of die-casting machines are: (a) Hot chamber die-casting () Cold chamber die-casting 119 Classify centrifugal casting, Centrifugal casting processes can be classified as: (a) Truecentrifugal casting (b)_-—-Semi-centrifugal casting (©) Centrifuging 120. What do you mean by shaking out operation ? After solidification of casting, the mould are broken to obtain the final casting. This operation is known as shake out operation, which may be performed manually or mechanically. 121. Operations performed after shaking are.. ‘The various operations which are performed afier shake out are as follows : (a) Removal of dry sand cores. (b) Removal of gates, risers, runners, etc. (©) Removal of unwanted metal projections, fins, etc. (d) _ Removal of adhering sand and oxide, scale from the casting surface. 122. Define snagging. ‘The operation of removal of unwanted metal projections and fins is called as snagging. 123. Name defects occurring in casting. Blow holes (2) Porosity (3) Shrinkage Inclusions (5) Hot tears or hot cracks Misrun and cold shuts Name the inspection methods of casting. Pressure test (2) Magnetic particle test Dye penetrant test (4) Radiographic inspection Ultrasonic inspection (6) Visual inspection 125 What is the difference between magnetic and dye penetrate testing ? Magnetic testing is used for magnetic materials and dyes are used for non-magnetic materials. PREPARED BY RJAYAKUMAR AP/MECHUNIT-I METAL CASTING PROCESS Unit -1 Metal casting processes Sand Casting : Sand Mould - Type of patterns - Pattern Materials — Pattern allowances Molding sand Properties and testing — Cores ~Types and applications — Molding machines~ Types and applications; Melting furnaces : Blast and Cupola Furnaces; Principle of special casting processes : Shell - investment - Ceramic mould ~ Pressure die casting - Centrifugal Casting - CO2 process - Stir easting; Defects in Sand casting Metal Casting Process, Manufacturing Manufacturing in its broadest sense i§ the process of converting aw — materials into useful products. It includes i) Design of the product ii) Selection of raw materials and iii) The sequence of proces8es through Which the product will be manufactured. Casting Casting is the process of préducing metal parts by pouring molten metal into the mould cavity of the Fequired shape “and allowing the metal to solidify. The solidified metal picce is called as “casting”. Advantages Y Design flexibility Y Reduced costs Y¥ Dimensional accuracy Y Versatility in production Disadvantages Y Lot of molten metal is wasted in riser & gating ¥ Casting may require machining to remove rough surfaces Sand Casting 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 UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS remove casting. In sand casting expandable molds are used. So for each casting operation you have to form a new mold. Y Most widely used casting process. ¥ Parts ranging in size from small to very large ¥ Production quantities from one to millions ¥ Sand mold is used. ¥ Patterns and Cores Solid, Split, Match-plate and Cope-and-drag Patterns Cores - achieve the internal surface of the part Molds ¥ Sand witha mixture of water and bonding clay ¥ Typical mix: 90% sand, 3% water, and 7%, clay Y To enhance strength and/or permeability’ind Refractory for hightemperature Size and shape of sand Y Small grain size > better surface finish V Large grain size -> to allow es€ape of gases during pouring v Irregular grain shapes ->” strengthen inolds due to interlocking but to reduce permeability ‘Types of sand a) Green-sand molds - Thixture of Sand) clay, and water; “Green” means mold contains moisture at time of pouring. ) Dry-sand méld- organic binders rather than clay and mold is baked to improve strength ) Skin-dried mold - drying tiold’cavity surface of a green-sand Mold to'a depth of 10 to 25 mm, using torches or heating Steps in Sand Casting The cavity in the sand)inold is formed by packing sand around a pattern, separating the mold into two halves The ‘mold mist 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 UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS 5. Heat treatment of casting is sometimes required to improve metallurgical properties 2. Describe briefly about the various types of molding tools used with sketch. (AU MAY —JUNE 2010) Molding tools: The following tools are used in a hand molding process. # Shovel # sprue pin # Riddle #riser pin # Rammer # gate cutter # Trowel #draw spike # Slick #swal # Strike-off-bar # bellows # Lifter # mallet # Vent wire # molding boxés 1. Shovel It isa steel pan with long’wooden handle. It is used to mix and‘temper the molding sand with clay, moisture and other additives before pouring ini6:the motild, Fig)Shovel This also usédifor carrying the molding sand from the sand pit or pill to the molding box. NOW aay, a casviron handle is also used. Steel wire mesh (screen) fitted into a circular or square frame is called riddle. It is sed for removing foreign materials such as stones, nails, etc. It is also used to separate various sizes of sand grains. 3. Rammer: * It is used to ram or pack the sand in the box. * It is normally made of wood or metal. UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS Fig: Rammer ‘Rammer has two ends. Such that One end is in wedge shaped and is known as peenénd. The other end is cylindrical in shaped is knowns butt end. It has a metal pan with a short wooden handle, The pan may be in different shapes? oe Ee Fig: Trowel + It is used t)smoothen the Surfaces of mould and repair the damaged portions of mould, + Iisa spoon Shaped doubled-ended trowel. Fig: Double — ender or slick * It is used for repairing and finishing small curved or straight surfaces and round corners of the mould. 6. Strike-off-bar: * It is made of wood or metal UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS + Ithas a straight edge * It is used to remove excess sand from the mould after ramming. 7. Lifter + It isa bend and twisted blade as shown in figure. Fig: Lifter * It is used to lift dirt or loose and from the deep mould. * It is also used for repairing and finished the cavity’and gates. 8. Vent wire: + Itisa thin steel wire with handles + Itis used to make small holes in the mould after ramming, 9. Sprue pin: + Itisa tapered cylindrical wooden piece. + Ibis used to make a sprue hold in the cope. + The sizes of sprue pin dependhupon the)size, ofthe mould. + The molten métal passes through this sprue hole to the cavity. 10. Riser pin. + It is also a tapered wooden rod. [/ Fig: Riser pin * Its size is smaller than the sprue pin. It is used to make a riser in the cope. 11. Gate cutter: * It isa bend type of metal which is used to cut gates. \) y Fig: Gate cutter UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS + The gate is a passage between mould cavity and runner. 12. Draw spike: + It isa pointed or threaded steel rod with a ring at one end as shown in fig. £0) wed Fig: Draw spike * It is used to remove the pattern from the mould, 13. Swab: + Itisa small brush * It is used to apply water on the sand,around the pattern Fig: Swab + It may,be used for sweep away the dust from the pattern or excessive sand from the Biould joint or to give coating on the pattern. 14, Bellows: a) is used t0,below off loose sand particles from the mould and pattern. Kh Fig: Bellows 15. Mallet: + Itis wooden hammer which is used to drive the draw spike into the pattem and then lifts from the mould WYEAR/ III SEMESTER |_| EC! MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS Fig: Mallet 16. Molding boxes: * Molding box or flask is a frame or box of wood or metal Which is used to hold molding sand. = A molding box may be in two or three parts. = The top part is cope = The middle part is check + The lower part is drag. The main types of boxes are + Snap flask + Tight or box flask (a) Snap flask + Itis generally made of Wood. + Ithas hinges on one comehopposite comers have latches to lock the flask in position. ‘rst the flasks 1o8K€djto make mould. After making the mould, the latches are unlocked and flask is opened out, The flask is removed ffom the mould, number of moulds can be made with the help of o8@)box in this wa (b) Tight or box flask; box Shaped container without top or bottom. This made of metal or wood. It is used for making small and medium size moulds. The top part (copé) and bottom part (drag) are held in position by dowel pins or bolt and nut. 3. Describe briefly the various pattern material used for making pattern. Pattern materials: (AU MAY — JUNE 2010) The following factors to be considered for selecting pattern materials Y Design of casting ¥ Number of casting to be produced UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS ¥ Degree of accuracy and surface Y Finish required ¥ Shape, complexity and size of the castings ¥ Castings or molding method adopted patterns are made by different materials which have their own advantages, limitations and their filed of applications. Commonly used pattern making materials are given below. ¥ Wood-teak wood, mahogany, white pine, etc. Metal-cast iron, brass, aluminum, white metal etcy Plaster Plastics Wax ¥v ¥v ¥v v Wood is a material commonly used’forepattern Making. Generally, teak wood, mahogalty, white pine, 10s€ wood aré used for making pattern, Laminated wooden sheets are also used for getting accuracy, surface finish and long life. These woods should not contain more than.10% moisture to avoid wrapping and distortion @using Subsequentdrying. ‘Metal spray coating’up to 0.25mi thick may be given on wooden pattern. Zine and aluminum aréused for coating the metals and the wooden surface to avoid moisture absorption and good surface finish, Advantages: Yule is light in\weight, chBapyand easily available. Y IRs easy to Work, easy-to cut and easy to fabricate. Y It can be easily, repaired Y It can be Basily smoothened by varnishes and paints. Limitations: ¥ Itabsorbswater from sand and changes its shapes. ¥ Ithas non uniform structure. ¥ Ithas high wear and tear by sand. Hence, it cannot be used for mass production. ¥ It cannot be used in machine molding. Metal: Y Metal pattern is used when a larger number of castings are to be made. UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS v Metal pattern can be either cast from a masterpiece or may be macl usual method of machining. Y These patterns are usually used in machine molding. Advantages: ¥ It has long life and accurate in size. ¥ It has smooth surface mass production is possible. ¥ It does not absorbs moisture and deform in size. ¥ It can be used for rough handling and its resistance’to wear, tear abrasion and corrosion. Disadvantages: ¥ It is costlier and heavier than wood. ¥ It cannot be easily repaired. ¥ Ferrous patterns can get rusted, ¥ Itis difficult to make the required shape. The materials commonly used foF'pattern making are, Cast-iron Brass Aluminiuiy Cast iron haying fine gfain‘can be used as a pattern material. Tehas high resistance to sand abrasion and smooth surface, but it is heavier and difficult to work. Tt cast is less and’nore durable than other metals. Its brittle and can be easily broken. Ie will getfusted by moisture unless it is protected. It may be easily worked and built up by soldering or brazing. It is used only for small size pattern because of high cost. It is very strong and not affected by moisture. It takes very good surface finish and with sands wear and tear. It can make very high accuracy. UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS Aluminium: ¥ Aluminium is the best material because it is light in weight, strong and easily machined. ¥ It can be made with high accuracy and good surface finish. _It will not be affected by moisture and get rusted and also melt low temperature. It is a very soft and easily damage by rough surfaces. A plastics pattern has many advantages over other materials, Plastics pattern is cast from a wooden pattern galled master pattern. Itis light in weight but strong. It is not affected by moisture and more reSistance to,wear. It has very smooth glassy surface. It does not shrink much and has high dimensional accuracy and more economical than other metals, The following plastics are widely used for patte¢n making with the composition based on epoxy, phenol formaldehyde and polyestePresins. Y Poly acrylates Y Poly ethylene Y Poly vinyl chloride ete) ‘Wax pattern is primarily used/in investment castings. The commonly ised Waxes are paraffin wax, shellac wax and microcrystalline wax . It has_good sutface finish and high dimensional accuracy. It will nobabsorb moisture and easy to work. Cost is very less, but it can be used for making small patterns only. 4. Explain the types of pattern in details. (AU NOV-DEC 2010) Pattern: A pattern is one of the important tools used for making cavities in the mould into which molten metal is poured to produce a casting. Types of patterns: 1. Solid or single piece pattern UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS Split pattern . Loose piece pattern . Match plate pattern . Sweep pattern . Skeleton pattern . Segmental pattern 8. Shall pattern 1. Solid or single piece patter + These types of pattern are made of single solidpiece without joints, partings or loose piece, it is called solid or one-piece pattern. BS ing « géd with some allowances. 4 It is used for making a fewllarge size simple castings. 4 Removal of pattern from the Sand is ea8ye 2. Split pattern: + One pattern whith is having Complex geometry cannot be removed from mould if they are made by single piece. + Genefilly. split pattern is, made into to parts. 4 One part is u8ed.to produgé'the lower half of the mould. 4 Other part is/tsed t6)produce the upper half of the mould. “P\These tw0 parts are assembled together in correct position by pins called dowel pins, % The litte separating the two parts is called parting line. (TOS fap | TR met oe Lad cont go Stes eee caer CBee UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS Fig: Three piece pattern ‘ If the split pattern are made of three pieces. Then it is called three piece patterns. 3. Loose piece pattern: ‘ Ifa pattern is made from a single piece having projections On back parting plane is lie above or below, it is impossible to with draw it from the mould. ‘ In such cases, the pattem is built up into solid pattern and loose pieces. fa | — ref Fig: Loose piece pattern After making tne mouig, rst tne s6lid\pattern i§ removed and then the loose pieces are removed without bréaking mould. Is called loose piece pattern. Loose pieces are attached to the main body of the pattént by pins. 4. Match plate pattern: % This pattern is made in tw,halves mounted on both sides of a plate called match plate which is made bYaluminuin or wood. + The match plate i$ aCurately plated between the cope and the drag flasks by means of locating pins. pol sre Fig?Match plate pattern “ Match plate patterns are used in machine molding. “ This type of pattern is used for small, accurate size and large number of castings. Piston rings of I.C engine are produced by this process. 5. Sweep pattern: + Sweep patterns are mainly used to generate surfaces of revolution like cylinder, cone, sphere in large castings. UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS eptnce Sweap pattern Fig: Sweep pattern A half of the board is fitted in the centre Spindle. ‘The sand is approximately rammed around the mould cavity. The sweep is rotated to form the ant6uldcavity it the sand. ‘Sweep patterns are used for making large and cireular castings in loam molding. 6. Skeleton pattern: For larger casting of simple shape, Ifa solid pattern is made of wood. + Ibis very expensive. A skeleton pattera isiuised.instcathof a full pattern. A skeleton pattern iia ribbed framelof a desired casting. > > sbyickle 7. Segmental pattern: + A segmental pattern is a segment of whole pattern as shown in fig UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS A poten of would mace Haat ae — Se riaX > Se paren segmental pattern ‘% This pattem is also called part pattern ‘ The pattern is used for forming circular moulds. ‘© This pattem is used for casting circular components such as rings, Wheel rims, gear blanks, etc. 8. Shell pattern: 4 Shell pattern is a hollow patter its outer shape is uSed for making the mould. The core is prepared using the inner surface of the pattern itself. Itis also known as block patterng Fig? Shell pattern Thesespatterns are usually made of metal. These patterns are mainly used for making drainage fittings and pipe work like short bends. 5. What are the types of molding process? And briefly explain. Molding processes (AU,NOV-DEC 2010) Define the process of making a cavity similar to the product required in sand is called molding. There are different types of moulds given below. > Green sand mould > Dry sand mould > Loam mould 1. Green sand mould: > Green sand mould contains 10 to 15% clay,4 to 6% of water and remaining UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS percentage of silica sand. > Itis porous. > Itis that mould in which the molten metal is poured immediately after the mould is prepared. > These moulds are preferred for making small and medium size castings. > Itis specially used for non-ferrous metals and alloy castings» Advantages: > The process is less expensive > It can be used for all metals > Mould distortion is less > It does not restrict the free contraction of metal. > Itneeds lesser time for making mould since Urying/is not required. Limitations: > Surface finish is less > Strength of the mould is low > Defects like blow holesfnay oteur. 2. Dry sand mould: > If the green saftd mOulldis dried after making the mould, it is called dry sand mould. > It isa mixture of silica Sand, coal dust, and binders like clay, betonies and molasses\éte. > The step-by ~ st@p,procedure 6f making dry sand mould is the same as that of green sand molding. Advantages: © kis stronger thai green sand mould. > It has better dimensional accuracy > Permeability is more > It can be stored for long time. Limitations: > It isa more time consuming process, since, it requires heating. > Cost is high. > It is subjected to hot tear. UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS 3. Loam molding: > Loam sand is a mixture of silica sand, water, graphite powder and more amount of clay. > The mould made by using loam sand is called Joam molding. > This is made by using pit molding method. > Initially, rough frame work is made by bricks. The loam,sand is applied over the brick work. > Loam molding is made also by skeleton pattern. Applications: > It is used for large cylinders large bells, wheels, Kettles, gear wheels, pans and other large machine parts. Advantages: > Large castings can be made with/eSs Cost . singé no pattern & mould boxed are required. > Ithas good surface finish. Accurate casting can belproduced, Limitations: > Itisa time consuming process, > Skilled labour‘are Feguired, > 6. Describe about the good properties needed for molding sand. A good casting Gan.be produced nly with the use of good quality molding sand. These properties are ) Porosity or permeability . Plasticity or flow ability . Adhesiveness Strength 6r cohesiveness . Refractoriness 6. Collapsibility Porosity or permeabil Permeability is a measure of molding sand by which the sand allows the steam and gases to pass through it. Permeability of molding sand depends on the following factors. 1. Quality and quantity of clays and quarty. 2. Moisture content UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS 3. Degree of compactnes: ‘The following parameters which affect the permeability of molding sand. 1. If the clay content is less the permeability will be more and vice-versa. 2. If the grain size is layer, the permeability will be more and vice versa. 3. Soft ramming (ie, less density) improves the permeability! 4. Higher the silica content on sand lower will be the permeability. 2. Plasticity or flow abilit 1. The property of molding san by which the molding sand flows around and over the pattern, and uniformly fills the flask. 2. It gives the shape of the pattern and retaifis the shape after removijg'thé pattern, 3. This property may be improved by“adding clay and water to silica sand. 3. Adhesiveness: 1. The property of molding sand by which it sticks or adhefes to another body. . The molding sand should cling o& stick to the sides of the molding boxes. . It does not fall out when the flasks ue lifted and turned over. This property depends on the type and amount of binder used in the sand mix. 4. Addition of clay aid moisture intreases the adhesiveness. 4. Strength or cohesiveness: 1. It is property of molding sand by which it sticks together. 2. A molding)sand should have sufficient strength so that the mould does not collapse Or get partially damaged during shifting, turning or pouring the molten metal. Strength ofthe molding sand depends on 1. Grain size and\shape 2. Moisture content 3. Density of sand after ramming strength is increased with increasing density, clay content and decreased size of sand grains. 5. Refractoriness: 1. The property of molding sand to resist high temperature of molten metal This property mainly depends on the purity of the sand particles and size. Rough and larger grain, and quarty content in molding sand increase the refractoriness. 4. Poor refractoriness will result in rough surface in casting. UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS 6. Collapsibility: 1. The property of the molding sand to decrease in volume to some extend under the compressive forces developed by the shrinkage of metal during freezing and subsequent cooling. ‘This property permits the molding sand to collapse easily after the casting solidifies. |. If the mould or core does not collapse, it may restrictthe free contraction of the solidifying material and causes crack on the casting. |. This property depends on the amount of quartyand binders. 7. Enumerate the various casting defects and suggest suitable remits.(AU MAY-JUNE 2011, Now/Dec-2012, 2013, May/June 2014) . Defects ‘Remedies 1Shrinkage: * Proper solidification, It is a depression on the casting surface | ® Pour at correct temperattre formed if these gases could not comé | * Modify gating runner and riser system out; blow holes are formed on the interior of the cas + Control moisture content * Ramproperty + Provides sufficient vent holes + Control bitter content It is the erosion or breakingdown a + Provide uniform ramming. portion of tha =~ + Pour with correct velocity. filled with n + Ram property UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS 5. Hard spots: Some spots on the surface become hard. LZ | LF. 6. Honey combing: Number of small cavities pres casting surface. 7. Shift: matching of casting sections. oe 8. Cold shut: s the incomplete filling of the mould * Pour with correct velocity * Provide adequate support to the mould. * Provide uniform coding » Pour—at cofrect temperature * Provide comect famming + Provide comect gating system. * Pour at\voreet temperature. + Repair or replace the pins and dowel pins in the pattern, + Assembly the molding boxes properly. + Provide proper box locating of core. + Pour at correct temperature « Provide correct gating system. MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS » Pour at correct temperature * Modify gating system. 9. Fins: This projection on parting line. > ) = + Pour at correctitemperature. * Use sufficient molten metal. 10. Blister: The scar covered by the thin layer of a 8. a Figure shows the cross section of a control component ( having a flange and an axial hole). UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS 9. Describe briefly, with sketches, the steps involved/in making a sand)mould to cast this component. Sketch also the shape of the casting as soon as it removed,from the mould.(AU MAY-JUNE 2012, 2014) The procedure for making green sand mould (floor or bench molding method) is explained below: 1. Here , we are using single piece pattern. The single piece pattem is placed at center of the molding board as shown in figure (a) YEAR / Ill SEMESTER R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS .. The drag box is placed around the pattern. Dowel pins are connected on the drag box 20 mm layer of facing sand is first placed around the pattern and then the drag box is filled up with green sand . Sufficient ramming is done by the peen end of the hand rammer. Excess sand is removed by strike off bar. . Vent holes are made by vent wire which is used to@@scape the steam and gases produced during pouring. The top surface is made smooth by trowel. . Then the drag is tilted upside down as shown in fig(b) . The parting sand is sprinkled over thé surface of green sand to ayoid sticking of sand on cope with the sand on drag. 10. Cope box is placed correctly positionion the drag using the dowel pins as shown in fig (c) 11. Raiser pin and sprue*pin feyplaced in Correct position. 12. The operation of filling, rafiming and venting of the sand on cope are done similar to that of drag. 13, Sprue pin or raiser pinlire removed 14. Cope and drag box are separated. 15. Then pattern piece afe withdrawn slowly. 16. A gate is cut on the top surface of the drag. It should be exactly below the sprue on the cope. 17. Finally, the eope an drag are assembled. Weight is placed on the cope to prevent the cope from floating up when the molten metal is poured. Now, the mould is ready for pouring. 10. Explain the steps involved in “Lost wax process “,with suitable sketches. (May/ June 2012, Nov/Dec-2013) UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS The molten metal is poured in already made mould cavity by melting the mould pattern in the mould itself. When the wax pattern is heated, it will be melted and disposed of from the mould called “Lost wax process” . Before making the mould, first the wax pattern has to prepare from the master pattern. Various steps involved in lost wax proces 1. The master pattern is prepared by casting process. Itgmay be made of brass, aluminium alloy or steel metal shrinkage and wax allowances)are provided on the master pattern. . A composite die is used for making master pattefn. The die is made Of low-melting alloy such as bismuth alloys, aluminium, Cl efe, Master pattern die cavityyis formed by machining process. Generally split type.cavities)are formed. . First, halves of die cavities are clamped" together. Molten wax isjinjected under the pressure of about 4 bar to the die cavity. Die cavities areypreheated to avoid immediate solidification of wax. If it is like this, partial filling of die cavity take place. Polystyrene, polythenes/patterns are made at 3Sbar with higher temperature. . If the size of the wax pattern is large several small wax patterns are first prepared and assembled together with a gating\system alongswith central spure. Assembling various small wax patterns af welded by using heated tools known as cluster. 5. The assembled wax pattems have to be Smoothened/ super finished before putting into operation, This is done intwo stages. Stage 1: First, slimy is made by ahixing fine’silica either with water or ethyl silicate. Thea wax pattern are dipped in this prepared slurry to give primary coating of about 1mm thickness. It provides the improved surface quality to wax patterns. Then wax pattern is dried. Stage 2: In this stage, first ceramic slurry is prepared by using refractory material like silica and binder like gypsum. The gypsum is purely water-based sodium silicate. Wax, a solid type mould is placed over the assembled wax patterns. Then the ceramic slurry is poured over these assembled patterns UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS 2 fp 4 Stury Assembied wax pattems or clustor Solid mould type Sprue Fig 1.73 . After applying coating, the mould is prepared using assembled wax pattern called cluster. Next, the mould made along with)waxspattern dried in air for about 2 to 3hus. then baking of pattemsis. done in an oven for Zhours for melting the wax patterns, When the heating temperatureyreaches about 100 t0 120°C, the wax will start to melt. Finally, the ‘melted wax will flow out through the sprue in molten form. . Again, the entire mould is transferred to heating furnace. First the mould is held at 150°C for further,drying. NeXt, the heating is continued about 800 to 900°C to vapotize remaining wax inside the mould cavity. This preheated mould is used to fill mould cavity Without partial filling due to solidification of molten metal, while pouring throtigh the Sprue. Then, it is allowed to solidify by cooling. . After solidification is over, the casting are removed from the mould by shaking out. At.that.time, the fragile material of mould will break. Then gates and sprue called runner are removed usually by machining. . Finally, the casting are cleaned and inspected to detect casting defects. 11. Write short notes on following: (May/ June 2012, Nov/Dec-2013)(Nov/Dec-2018) (@) Ceramic mould UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS In this method, first the ceramic slurry is prepared by mixing fine grained refractory powders of zircon (ZrSio,) alumina (Aloo), fused silica (SiO2) and patented bending agents. ‘Then this slurry is applied over the pattern surfaces to form thin coating around it. After applying coating on the pattern, it is baked in a less expensive fire clay. After this, the pattern is remoyed"out from the mould and it is transferred to an oven for further heating mould about 1000°C. Then the molten metal is poured in the mould cavityithrough the sprue to produce castings. In this case also, the preheated mould is used during pouting of molten metal. As a result, the partial filling of molding is completelyjetiminated due to solidification of molten metal. This type of mould castingmethied is maifily used forall materials using better ingredients in slurry. (2) Centrifugal casting. (Now/Dec-2013)(Nov/Dec-2018) Centrifugal casting is primarily used for making hollow castings like pipe without using coresIn this process, the Tiétal mould is made to rotate. The rotating mould is mounted 6fijaytrolley as shown in fig. The trolley move over rails. The end of the mould is closed by end cores to prevent the flow of metal. The métahis poured intO\mould through a long spout. The mould rotate by electric motor ommechanical ‘means as well as moves axially on the rails. Due to centrifugal force, thélmolten metal is thrown to walls of the mould. The outside Ofithe mould is water-cooled. So, the molten metal solidifies immediately. UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS Molten metal Pouring Spot Metal mould Water jacket Pipe being Cast Fig 1.77 Centrifugal casting Centrifugal casting method is used for producing cylindrical and symmetrical objects. Applications ‘Components like water pipe, gears, bush bearings, fly wheel, piston rings, brake drums, Gun barrels etc. Advantages . Core is not required to produiée}hollow tomponents. . Rate of production is high: |. Pattern, runner, riser are not required. . Thin castings ealbe made. Castings have uniform physical properties. Limitations 1. Ibis suitablevonly for cylindrical and symmetrical shaped castings. 2. Cost of equipment is high. 12, Describe the various pattern allowances which can be quantitatively specified. [AU-NOV/DEC-2012;May/JUNE-2013](Nov/Dec-2018) © Patterns are not made into the exact size of the castings to be produced. © patterns are made slightly larger than the required castings. YEAR / Ill SEMESTER R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS + This extra size given on the pattern is called pattern allowance + Pattern allowances are given for the purpose of compensating the metal shrinkage to provide extra metal which is to be removed in machining, to avoid metal distortion, for easy withdrawal of pattern from mould and for rapping. + If allowances are not given on the pattern, the casting will become smaller than the required size. The various types of allowances are Shrinkage allowance Machining or finish allowance Draft or taper allowance Distortion or camber allowance * Rapping or shake allowance SHRINKAGE ALLOWANCE ‘The metal shrinks on solidification‘and contracts further on\cooling to room temperature. To compensate this, the pattern is made\larger than the required casting. This extra size providedeon the pattern for metal shrinkage is called shrinkage allowance. If it is not given, the casting willbecome smaller. Materials’ Shrinkage allowance (mm/min) CL 10.4 Aluminium 17 Brass 15.3 Steel 20.8 Zinc, lead, 25 MACHINING OR FINISH ALLOWANCE All the castings are to be machined to get the required surface finish on the metal. During machining, some of the metal is removed from the casting. For this purpose, the pattern is made larger than the required casting. UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS This extra size given to the pattern for machining purpose is called machining or finishing allowance. The amount of finish allowance depends on the material of the casting, ize of casting, volume of production, method of molding, configuration of the casting, method of machining and degree of finishing etc. Machining allowance is always larger for hand molding when compared to machine molding. The machining allowance for various materials is shown bélow. Materials Machining allowance 0-300mm 0-600mm Cast Iron 2.5mm 4.0mm Aluminium 1.6mm 3.2mm, Bronze 1.6mm 3.2mm Brass 1.6mm. 3.2mm Cast steel 3mm 45mm DRAFT OR TAPER ALLOWANCE, ALLOWANCE allowance Fig 1.10 Draft allowance If the verticabrfaces of pattern are perpendicular to parting line, the edges of mould may damaged when the pattern is removed from the sand. Hence, the vertical faces are made into taper for as removal of pattern. This slight taper provided on the vertical sides of pattern is called draft allowance. ‘The amount of taper depends upon the following factors a. Height and size of pattern lI YEAR // Ill SEMESTER RJAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS b. molding method c. Mould materials The common draft provided on the pattern is 1° to 3° Otherwise, For taper on external surface,10 to 25 mm/m is provided. For taper on internal surface,40 to 65 mm/m is provided DISTORTION OR CAMBER ALLOWANCE Fig 1.11 Distortion allowance The casting may distort or wrap ditring cooling if'it is an irregular shape, flat long casting furnace and U or V Shape. All surfacés do not shrink uniformly. The arms having unequal thickness are also the reasoiiifor distortion Due to. distortion, the’casting Will not get the required shape. It may bend. To avoid this, the shape Of the pattem is slightly bent into the opposite direction. Sollthé Castin@ neutralizes the initial distortion given on the pattern and gets the correct shape after cooling. For example, a casting of U shape may distort and legs become divergent, instead of being parallel. To avoid this, the legs are made convergent instead of being parallel. So, the legs are become parallel after cooling. RAPPING OR SHAKE ALLOWANCE To remove the pattern out of mould cavity, it is slightly rapped or shaked to detach it from the mould cavity. This is called rapping. So the mould cavity may become larger. YEAR / Ill SEMESTER R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS To avoid this, the pattern is made slightly smaller than the required casting. This allowance given in the pattern is called Rapping or shakes allowance. As the allowance is subtracted from pattern dimensions, this is known as negative allowance 13.What are the desirable properties of molding sand for sand casting? Explain briefly each one[AU-NOV/DEC-2012] ‘A good casting can be produced only with the use of good quality molding sand. These properties are 7. Porosity or permeability 8. Plasticity or flow ability 9. Adhesiveness 10.Strength or cohesiveness 11 Refractoriness 12.Collapsibility 1. Porosity or permeability: Permeability is 2 measure of molding sand by which the sand allows the steam and gases to pass through it. When molten metal is poured intothe mould, steam and gases are formed due to moisture, binderand additiveS\present in the sand. If the gases are not removed, casting defects such as blowholes will occur. Even though we provide vent holes and fiser, all of these'gases will not escape through it. To escape théSegases, the molding sand should have good gas permeability Permeability-of molding sand depends on the following factors. 1. Quality and quantity of clays and quartz. 2 Moisture content 3. Degree of compactness. The following parameters which affect the permeability of molding sand. 1. If thélelay content is less the permeability will be more and vice-versa. 2. If the grain size is larger, the permeability will be more and vice versa. 3. Soft ramming (ie, less density) improves the permeability. 4. Higher the silica content on sand, lower will be the permeability. 2. Plasticity or flow ability: 1. The property of molding san by which the molding sand flows around and over UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS the pattern, and uniformly fills the flask. 2. It gives the shape of the pattern and retains the shape after removing the pattern. 3. This property may be improved by adding clay and water to silica sand. 3. Adhesiveness: 1. The property of molding sand by which it sticks or adheres'to another body. 2. The molding sand should cling or stick to the sides oftthe molding boxes. 3. It does not fall out when the flasks are lifted and turnedbover. This property depends on the type and amount of binder used,in the sand mix, Addition of clay and moisture increases the@dhesiveness. 4, Strength or cohesiveness: 1. Itis property of molding sand by which it sticks together. 2. A molding sand should have sufficient strength so that the mould does not collapse or get partially damaged during shifting, turning of pouring the molten metal. Strength of the molding sand depends om, 1. Grain size and shape 2. Moisture content 3. Density of safid afi ramming strength is increased with increasing density, clay content and detreased size Of sand grains. 5. Refractoriness:, 1. The propéity,of molding stnd to resist high temperature of molten metal. 2. This property mainly depends¥n the purity of the sand particles and size. 3)Rough and larger geainyyand quartz content in molding sand increase the refractoriness, 4. Poor refractoriness will result in rough surface in casting. 6. Collapsibility: 1. The propeity of the molding sand to decrease in volume to some extend under the compressive forces developed by the shrinkage of metal during freezing and subsequent cooling. This property permits the molding sand to collapse easily after the casting solidifies. 14.With illustrative sketches, explain the various casting defects indicating, their causes and remedies. [AU-NOW/DEC-2012] UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS 13.Explain the stages of preparing shell mould, with suitable sketches. List the unique advantages of making castings in shell moulds. [AU-NOV/DEC-2012, 2013)] The shell mould casting is a semi-precise method for producing small castings in large numbers. The process involves the use of match plate pattern similar to cope and drag patterns which are used in green sand mould casting. Initially the patterns are machined from copper alloys, aluminium or CI depending upon the lift of the pattern. They are made with usual allowances afid polished surfaces. Then it is attached to the metal match plate. Loose sand Tlot pattern @ l—Flask | __Refractory materials Fig 1.69 Shell moulding The mould contaifis)S to 10% of phenolic resin mixed with fine dry silica. These are mixed with either dry oil or in)the presence of alcohol. It should be noted that there is no. water used. The pattern is heated to about 230-600°C.Then the sand-resin mixture is either dumped of blown ovenits surface. Sometimes, to prevent the sticking of sand with pattern, a release agent silicone is sprayed over the hot pattern. The heated pattern melts and hardens the resin. This results in bonding the sand grains closely together and forms a shell around the pattern. After Specified time of 20-30 sec, the pattern and sand are inverted as shown in fig. 1.69 (b).The thickness of the shell can be accurately controlled by the time of contact of the mixture with the heated pattern. In about 20-30 sec, we can get a normal shell thickness of 6mm.The extra sand which is not adhered to the shell is removed off. The thickness of the shell is depending on the required strength and rigidity to hold the weight of the liquid metal to be poured into the mould. UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS Then the mould is heated in an oven at 300°C for 15-60 sec. This curing makes the shell rigid when it can be stripped off by means of ejector pins mounted on the pattern. Thus, the formed shell constitutes one half of the mould. Two such halves, placed one over the other, make the complete mould as shown in fig.1.69(c ) While pouring the molten metal, the two halves are clamped. down together by clamps or springs. After cooling and solidification, the shells are¢brokeit or shaken away from the castings. Applications; 1. Used for making brake drums and bushings. 2. Cams, cam shaft, piston and piston rings can be made. 3. Used for making small pulleys, motor hadising, fen blade 4. Air compressor, crankcases and cylinders, conveyors, rollers can be made. Advantages: 1. A high accuracy castings With tolerances“6f 0.002 to 0.005 mm/min is possible. 2. Good/Stirface finish canbe obtained. 3. Complex parts can be made by this method. 4. Less sand is used compared to other methods 5. Moulds can be stored for long time. Limitations: 1. Only small size of the castings can be made. 2. Serious dust and fume problem during sand and resin mixing will occur. 3. Cost is more. UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS 4. Carbon pickup may occur in the case of steels. 5. Describe the process of Investment casting. What process controls are needed in this case? (May/ June 2013) The castings obtained by this method have very smooth surfaces and possesses high dimensional accuracy. Hence, it is called as precision investment casting Here, the term “ Investment “ means the layer of refractory matétial with which the pattern is covered to make the mould. Like sand casting method, we can't use the mould again and again. The method involves the use of expendable (heat disposable)pattern surrouded with a shell of refractory material to form the casting mould, Casting are“formed by pouring the molten metal in the mould cavities created by melting Gut pattern. Sifteé the pattern made of wax is melted out and gets destroyed, that is, why the name i§ealled‘as “ Last-wax method”. Fig 1.71 tnvesiment casting UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS ially, the master pattern which is equal to the part to be cast is made by metal that can be easily machined, such as, brass, aluminium alloy or a fusible alloy ( tin, lead and bismuth). The dimension of the pattern is slightly larger than the actual size of the part to be made to compensate the adjustments in the die, in the wax, in the investment material Determination of pattern dimension is very difficult job. This makes thepattern very costly. Fg 1.72 Investment casting This pattern is used to.make a die out of a soft/material e.g. aluminium. Therefore, wax or plastic is injected’ under pressiifesinto\the die to form an expendable pattern. The molten wax is slightly above its melting point andhinjection pressure is above 4 bars. If it a plastic material like polystyrene, polythenes etc. the injection pressure is of the order of 35 bars with higher temperature. This\expendable pattern is rifised.in alcohol to remove grease and dirt. After drying, a thin coftting of.primary investment slurry is made around the wax pattern by dipping these in the slurry. Investment slarry consists of silica flour, water and some bonding agent. Then, the pattern is taken ouitof the’Slurry and rotated to produce a uniform coating, to fill inside corners and to drain out the excessive slurry. This slurry coating being in direct contact with the surfaces of the wax patterns will determine the surface quality of the casting. Sometimes. a number of expendable patterns are assembled as a ‘tree’ for economy as shown in fig. Finally, fine-grain silica sand is sprinkled over the wet slurry surface. Thus the produced coating on the expendable pattern after drying is called pre-coat. UU YEAR / Ill SEMESTER, R JAYAKUMAR AP/MECH MANUFACTURING PROCESSUNIT-I METAL CASTING PROCESS ‘The pattern with the pre coat is then placed in a metal container type flask. Both the pattern and flask are secured to the base by molten wax. Then, the can is filled with slurry of heavy, self-hardening refractory material. This material sets in after a lapse of 24 hrs when the flask is placed in an oven. Thus, most of the wax or plastic melts and flows out of the mould by leaving a cavity with the shape of the intended casting. 16. Briefly explain the Principle, operation, advantages, disadvantages and application of CO: molding. (May/ June 2013)(Nov/Dec-2018) Principle: Co2 Casting is a kind of sand casting process. In this/process:the sand molding. mixture is hardened by blowing gas over over the mold. This process is favoured by hobby metal casters because a lot of cost cutting can be don@,In addition. one canbe sure of getting dimensionally accurate castings with fine sufface finish. But. this process is not economical than green sand casting process. Operation: ‘The Mold for Co2 Casting, is made of a’mixture of sand and liquid silicate binder which is hardenedyby passing Co2 gas over the mold. The equipment of the molding process include Co2 e¥linder, regulator, hoses and hand held applicator gun or nozzle. Carbon di oxide molding delivéngreat accuracy in production. Ay existing pattet/ can be used for the molding purpose which can be placed in the mold before the mold is hardened. This method helps in producing strong mold and cores that can Bejued forlhigh endiapplications. If the process is carefully executed then casting can be as precise as produced by the shell casting method. Carbon di oxide €asting is favored both by the commercial foundry men and hobbyist for a number of reasons. In commercial operations, foundry men can assure customers of affordable castings which require less machining. The molding process which can be fully automated is generally used for casting process that require speed, high production runs and flexibility. In home foundries this is one of the simplest process that improves the casting quality . YEAR / Ill SEMESTER R JAYAKUMAR AP/MECH MANUFACTURING PROCESS