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Casting: Workshop Practice ME-105

The document provides an overview of casting processes and terminology. It discusses the main types of casting which include (1) sand casting, (2) die casting, and (3) centrifugal casting. For sand casting, it describes the sand mold, green sand and air set methods. For die casting, it notes the reusable mold and high pressure injection of molten metal. Centrifugal casting involves spinning a mold to distribute molten metal along its walls. The document also covers casting allowances for shrinkage and draft, and common defects such as blow holes, cold shuts and shrinkage cavities.

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Mazahir habib
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396 views

Casting: Workshop Practice ME-105

The document provides an overview of casting processes and terminology. It discusses the main types of casting which include (1) sand casting, (2) die casting, and (3) centrifugal casting. For sand casting, it describes the sand mold, green sand and air set methods. For die casting, it notes the reusable mold and high pressure injection of molten metal. Centrifugal casting involves spinning a mold to distribute molten metal along its walls. The document also covers casting allowances for shrinkage and draft, and common defects such as blow holes, cold shuts and shrinkage cavities.

Uploaded by

Mazahir habib
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Casting

Workshop Practice
ME-105

Department of Mechanical Engineering


College of E&ME, NUST Pakistan
Contents
• Definition of Casting

• Types of Casting

• Sand Casting & Associated Terminologies

• Permanent Mold Casting

• Die Casting

• Casting Allowances

• Properties of Castings

• Casting Defects
CASTING & ITS TYPES
Casting
• A manufacturing process that involves pouring molten material into
a mold and then allowing it to cool and solidify.

• Mold contains a hollow cavity of the desired part shape and can be
either permanent or temporary.

• After solidification, the part is ejected or broken out of the mold.


The solidified part is also called “casting.”

• Casting is mainly categorized into two types, based on nature of


mold. Other sub-categorizes are based on mold material, pattern
type and molten material injection process.
Types of Casting
Sand Casting
Permanent
Pattern Casting
Plaster Mold
Casting
Expendable
Mold Casting
Evaporative
Casting
Temporary
Pattern Casting
Investment
Casting
Casting
Die Casting

Non-expendable Centrifugal
Mold Casting Casting

Pressure Casting
EXPANDABLE MOLD CASTING

SAND CASTING
Sand Casting
• Sand casting is a metal casting process that uses various types of
sand as the mold material. Over 70% of all metal casting are
produced via sand casting.

• The sand mold is enclosed is a box frame called flask and is held
together by a bonding agent.

• Sand Casting is performed by either:


– Green Sand Method (CHECK THE COMPOSITION OF GREEN SAND)
– Or Air Set Method

STUDY INVESTMENT CASTING !


Sand Casting - Illustrated
Sand Casting Mold

Cope Drag

Core

The top and bottom halves of the sand casting mold known as cope and drag
respectively. The wooden items are the core used to create hollow internal
features.
Sand Casting Terminologies

CHECK CORE & ITS


PURPOSE IN
CASTING.
Core
Non-expendable Mold Castings

DIE AND CENTRIFUGAL CASTING


Die Casting
• It is part of an array of casting processes known as injection molding.

• The process is characterized by forcing molten metal under pressure into a


mold.

• The mold cavity is created by the assembly of two steel halves which are
machined to produce desired cavity shape.

• Unlike sand casting, the mold is reusable in die casting. Die casting is used
for mass producing high-accuracy and good finished parts.

• Die casting differs from permanent casting (low-pressure & vacuum


casting) on the basis of pressure used to inject molten material into the
mold cavity.
Die Casting - Illustrated
Centrifugal Casting
• In this casting process, a permanent mold is rapidly spun around its
axis (300-3000 rpm) while molten metal is being poured into it.

• The molten metal is thrown outwards along the mold walls under
centrifugal force, where it solidifies to form cylinders.

• Centrifugal castings can be generated in all lengths and diameters


and thickness. The process is used to create semi-finished castings
which are subsequently machined.
Centrifugal Casting - Illustrated
CASTING ALLOWANCES
Casting Allowances
• Since dimensional changes occur when a material solidifies,
appropriate allowance is introduced into the pattern.

• To prevent shrinkage of casting, the pattern is over sized based on a


set of so called “shrink rules”.

• For example aluminum has a solidification shrinkage of ~6.6 % and


low carbon steel has a shrinkage of ~2.5-3.0 %.

• Apart from shrinkage allowance, a draft is introduced into the


pattern as well. The draft is a slight taper in the pattern that allows
for easy retrieval of the pattern from the mold.
Draft - Illustrated
Casting Defects
• Blow: A relatively large cavity produced by gases that prevent the molten
metal from filling the mould completely.

• Cold Shuts: A defect produced when two fronts of molten metal do not
fuse properly therefore creating an area of weak strength.

• Shrinkage Cavity: This defect is produced if inadequate shrinkage


allowance is given to the pattern.

• Misrun: Is created when the molten metal does not completely fill the
mould either due to high viscosity or absence of a riser.

• Inclusion: Contamination of the casting by external materials such as slag


or chips broken off from the ladle.
THE END

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