Académique Documents
Professionnel Documents
Culture Documents
Casting
Session Overview
Sand Casting
Investment Casting
Die casting
1/31
2009.02.24
Process
Equipment
Materials
Design guides
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Casting
ME 455/655
Casting
Basic Process
Advantages:
2/31
2009.02.24
Many alloys
Complex shapes
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ME 455/655
Casting
Casting Processes
3/31
2009.02.24
Sand Casting
Die Casting
Investment Casting
Centrifugal Casting
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Sand Casting
ME 455/655
Casting
4/31
2009.02.24
Natural Sand
Synthetic Sand
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Sand casting
ME 455/655
Casting
5/31
2009.02.24
Pattern Making
Molding
Core Making
Gating System
Sand
Melting of metal
Pouring into
molds &Solidification
Shakeout &
Removal of gating
system
Cleaning and
Finishing
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ME 455/655
Casting
Sand Casting
6/31
2009.02.24
joshua.summers@ces.cle mson.edu
http://aid.ces.cle mson.edu
Sand Casting
ME 455/655
Casting
Advantages
7/31
2009.02.24
Disadvantages
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Sand Casting
ME 455/655
Casting
Gating system
Sprues
Runners
Gates
Risers
8/31
2009.02.24
Vents
ME 455/655
Casting
Sand casting
9/31
2009.02.24
joshua.summers@ces.cle mson.edu
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ME 455/655
Casting
Sand Casting
10/31
2009.02.24
Consideration
Runner Patterns
Cores
Drafts
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ME 455/655
Casting
Guidelines
11/31
2009.02.24
joshua.summers@ces.cle mson.edu
http://aid.ces.cle mson.edu
ME 455/655
Casting
Investment Casting
12/31
2009.02.24
joshua.summers@ces.cle mson.edu
http://aid.ces.cle mson.edu
ME 455/655
Casting
Investment Casting
13/31
2009.02.24
joshua.summers@ces.cle mson.edu
http://aid.ces.cle mson.edu
ME 455/655
Casting
Investment Casting
14/31
2009.02.24
turbine blades
airplane parts
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ME 455/655
Casting
15/31
2009.02.24
Centrifugal Casting
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ME 455/655
Casting
16/31
2009.02.24
Ceramic Casting
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ME 455/655
Casting
Die Cast
Costs
17/31
2009.02.24
Parts
Complex geometry
Thin walls
High dimensional accuracy
Good surface finish (post-machining
can be totally eliminated
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ME 455/655
Casting
Example
18/31
2009.02.24
Metal: Aluminum
Process: Die Cast
Weight: 20 lb
Size: Large(over 12X12)
Market: Automotive
Description: Rear Sub-frame
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Example
ME 455/655
Casting
19/31
2009.02.24
Metal: Zinc
Process: Die Cast
Weight: xx
Size: Large(over 12X12)
Market: Automotive
Description: 1974 Pontiac radiator grill
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Example
ME 455/655
Casting
20/31
2009.02.24
Metal: Aluminum
Process: Die Cast
Weight: 0.35 lb
Size: Medium(3X3 to 12X12)
Market: Sports/Recreation
Description: Pistol frame
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Example
ME 455/655
Casting
21/31
2009.02.24
Metal: Aluminum
Process: Die Cast
Weight: 10.29 lb.
Size: Large(over 12X12)
Market: Industrial/Commercial
Description: Impeller for Industrial and Commercial Blowers
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Example
ME 455/655
Casting
22/31
2009.02.24
Metal: Aluminum
Process: Die Cast
Weight: 0.2 lbs
Size: Very Small(1X1)
Market: Automotive
Description: Starter Switch Housing
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Die Casting
ME 455/655
Casting
23/31
2009.02.24
Two types
Cold chamber
Hot chamber
Typical Pressures
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ME 455/655
Casting
Mold
Machine
24/31
2009.02.24
joshua.summers@ces.cle mson.edu
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ME 455/655
Casting
25/31
2009.02.24
Aluminum
Copper
Zinc
Effect
Silicon
Copper
ME 455/655
Casting
26/31
2009.02.24
Tensile
Strength
MPa (ksi)
Properties
3.5 %
324
(47)
Fairly easy to
fill
11 %
4%
331
(48)
Easy to fill
Automotive
engines
AA 386
(UNS A03860)
9.5 %
0.6 %
317
(46)
Good
corrosion
resistance
Marine
Environments
AA 390
(UNS A03900)
17 %
4.5 %
283
(41)
Good wear
resistance
Material
Silicon
Copper
AA 380
(UNS A03800)
8.5 %
AA 384
(UNS A03840)
Application
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ME 455/655
Casting
27/31
2009.02.24
ME 455/655
Casting
28/31
2009.02.24
joshua.summers@ces.cle mson.edu
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Guidelines
ME 455/655
Casting
Basic functions
29/31
2009.02.24
Flow
Solidification
Ejection (either from permanent mold or by destroying mold)
Flow is smooth
Fill cavity evenly
Cooling should be rapid to reduce cycle time
Cooling should be rapid to reduce warpage
For ejection, keep tooling to a minimum
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ME 455/655
Casting
Guideline
Avoid undercuts
Even flow
Cool Rapidly
30/31
2009.02.24
Fusion lines (areas where flows between gate filling) will weaken
region
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10
Guideline
ME 455/655
Casting
31/31
2009.02.24
Min. Thickness
mm (in)
Aluminum alloys
0.9 mm
(0.035 in)
0.5
Zinc alloys
0.6 mm
(0.025 in)
0.25
Material
1.25 mm
(0.050 in)
0.7
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11