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Steps in Making Sand Castings Steps in Making Sand Castings Steps in Making Sand Castings
Pattern making: The pattern is a physical model of Core making: Cores are forms, usually made of Melting and Pouring: The preparation of molten
the casting used to make the mold. The mold is sand, which are placed into a mold cavity to form metal for casting is referred to simply as melting.
made by packing some readily formed aggregate the interior surfaces of castings. Thus the void Melting is usually done in a specifically designated
material, such as molding sand, around the pattern. space between the core and mold-cavity surface is area of the foundry, and the molten metal is
When the pattern is withdrawn, its imprint provides what eventually becomes the casting. transferred to the pouring area where the molds are
the mold cavity, which is ultimately filled with metal Molding: Molding consists of all operations filled.
to become the casting. If the casting is to be hollow, necessary to prepare a mold for receiving molten Cleaning: Cleaning refers to all operations
as in the case of pipe fittings, additional patterns, metal. Molding usually involves placing a molding necessary to the removal of sand, scale, and excess
referred to as cores, are used to form these cavities. aggregate around a pattern held with a supporting metal from the casting. Burned-on sand and scale
frame, withdrawing the pattern to leave the mold are removed to improved the surface appearance of
cavity, setting the cores in the mold cavity and the casting. Excess metal, in the form of fins, wires,
finishing and closing the mold. parting line fins, and gates, is removed. Inspection
of the casting for defects and general quality is
performed.
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Pattern material - Metal Pattern material - Plastics Pattern material – Plaster & Wax
Advantage Disadvantage Advantage Disadvantage Plaster - Advantage Wax - Advantage
More strength & accurate. Relatively expensive. Durable. Fragile, hence lighter Made up of plaster of paris Provide good surface finish
Don't absorb moisture, Tendency to get rusted. Provide a smooth surface. section needs or gypsum cement in water Higher accuracy of casting
hence retain their shape. reinforcement. High compression strength.
Not easily repaired. Moisture resistance. Mould cavity doesn't
Long life. Heavier than wooden. Doesn't change in shape / May not appreciable in Gypsum cement expands damage, since the pattern
Don't warp. size. jolting and molding on solidification; hence is removed by melting the
Aluminum cannot machine.
Greater resistance to withstand rough handling. Light weight, good strength. shrinkage of casting can be wax
abrasion. completely set off Application in investment
Cast iron is hard, brittle & Easy to make.
Rapid production in large hence easily breaks. Smooth surface finish, casting process
Wear and corrosion hence reproduce clearly
quantity. resistance. defined contours
Good surface finish.
High strength is achieved
by reinforcement
Easily machinable in wood
working tools
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Core and Core Prints Core and Core Prints Classification of casting Processes
Castings are often required to have holes, recesses, etc. of 1. Conventional Molding Processes
various sizes and shapes. These impressions can be obtained 1. Green Sand Molding
by using cores. So where coring is required, provision should 2. Dry Sand Molding
be made to support the core inside the mold cavity. Core prints 3. Flask less Molding
are used to serve this purpose. The core print is an added 2. Chemical Sand Molding Processes
projection on the pattern and it forms a seat in the mold on 1. Shell Molding
which the sand core rests during pouring of the mold. The core 2. Sodium Silicate Molding
print must be of adequate size and shape so that it can 3. No-Bake Molding
support the weight of the core during the casting operation. 3. Permanent Mold Processes
Depending upon the requirement a core can be placed 1. Gravity Die casting
horizontal, vertical and can be hanged inside the mold cavity. 2. Low and High Pressure Die Casting
A typical job, its pattern and the mold cavity with core and 4. Special Casting Processes
core print is shown in Figure. 1. Lost Wax
2. Ceramics Shell Molding
3. Evaporative Pattern Casting
4. Vacuum Sealed Molding
5. Centrifugal Casting
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Green Sand Molding Sand Mold Making Procedure Sand Mold Making Procedure
Green sand is the most diversified molding method used in The first step in making mold is to place the pattern on the molding Cope half of the pattern is then placed over the drag pattern with the
metal casting operations. The process utilizes a mold made of board. help of locating pins. The cope flask on the drag is located aligning
compressed or compacted moist sand. The term "green" The drag is placed on the board (Figure (a)). again with the help of pins (Figure (b)).
denotes the presence of moisture in the molding sand. The Dry facing sand is sprinkled over the board and pattern to provide a The dry parting sand is sprinkled all over the drag and on the
mold material consists of silica sand mixed with a suitable non sticky layer. pattern.
bonding agent (usually clay) and moisture. Molding sand is then riddled in to cover the pattern with the fingers; A sprue pin for making the sprue passage is located at a small
then the drag is completely filled. distance from the pattern. Also, riser pin, if required, is placed at an
Advantages appropriate place.
The sand is then firmly packed in the drag by means of hand
Most metals can be cast by this method. The operation of filling, ramming and venting of the cope proceed in
rammers. The ramming must be proper i.e. it must neither be too
Pattern costs and material costs are relatively low. hard or soft. the same manner as performed in the drag.
No Limitation with respect to size of casting and type of After the ramming is over, the excess sand is leveled off with a The sprue and riser pins are removed first and a pouring basin is
metal or alloy used straight bar known as a strike rod. scooped out at the top to pour the liquid metal.
Disadvantages With the help of vent rod, vent holes are made in the drag to the full Then pattern from the cope and drag is removed and facing sand in
depth of the flask as well as to the pattern to facilitate the removal of the form of paste is applied all over the mold cavity and runners
Surface Finish of the castings obtained by this process is gases during pouring and solidification. which would give the finished casting a good surface finish.
not good and machining is often required to achieve the The mold is now assembled. The mold now is ready for pouring (see
The finished drag flask is now rolled over to the bottom board
finished product. exposing the pattern. (Figure (c))
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Molding Material and Properties Molding Sand Composition Molding Sand Composition
Dry Strength: When the molten metal is poured in the mold, The main ingredients of any molding sand Binder
the sand around the mold cavity is quickly converted into dry
sand as the moisture in the sand evaporates due to the heat of are: Base sand, Binder, and Moisture Binders are of many types such as:
the molten metal. At this stage the molding sand must posses • Clay binders,
the sufficient strength to retain the exact shape of the mold
• Organic binders and
cavity and at the same time it must be able to withstand the Base Sand: Silica sand is most commonly • Inorganic binders
metallostatic pressure of the liquid material.
used base sand. Other base sands that are Clay binders are most commonly used binding
Hot Strength: As soon as the moisture is eliminated, the sand
would reach at a high temperature when the metal in the mold also used for making mold are zircon sand, agents mixed with the molding sands to provide
is still in liquid state. The strength of the sand that is required Chromite sand, and olivine sand. Silica sand the strength. The most popular clay types are:
to hold the shape of the cavity is called hot strength.
is cheapest among all types of base sand Kaolinite or fire clay (Al2O3 2 SiO2 2 H2O) and
Collapsibility: The molding sand should also have
collapsibility so that during the contraction of the solidified and it is easily available. Bentonite (Al2O3 4 SiO2 nH2O)
casting it does not provide any resistance, which may result in Of the two the Bentonite can absorb more water
cracks in the castings. Besides these specific properties the which increases its bonding power.
molding material should be cheap, reusable and should have
good thermal conductivity.
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MULTIPLE CAVITY DIES Single Cavity and Multiple Cavity Die HOT CHAMBER DIE CASTING
Advantages In hot chamber die casting manufacture, the supply of molten metal
Production rate is high. is attached to the die casting machine and is an integral part of the
casting apparatus for this manufacturing operation. The metal for
Unit cost per component is less. casting is maintained at an appropriate temperature in a holding
Edged gated components can also be placed symmetrically furnace adjacent to, if not part of, the machine. The injection
around the injection center line mechanism is located within the holding furnace and a substantial
part of it is therefore in constant contact with the molten metal.
Disadvantages Pressure is transmitted to the metal by the injection piston, which
Initial investment of the is more. forces it through the gooseneck and into the die. On the return stroke
With increase in number of cavities, the feed balancing and metal is drawn into the gooseneck for the next shot. In this process
thermal balancing becomes more complicated. there is minimum contact between air and the metal to be injected,
thus minimizing the tendency for turbulent entrainment of air in the
With increase in number of cavities, the design and metal during injection. Due to the prolonged contact between the
manufacturing becomes more complex. metal and parts of the injection system hot chamber is restricted to
These require larger capacity machines which reduces the zincbase alloys. The Zinc alloys are the most widely used in the die
number shots per hour. This is because the operating casting process. They have very desirable physical, mechanical and
speed in larger capacity machines is less compared to that casting properties. They also have the ability to be readily finished
of smaller capacity machines. with commercial electroplated or organic coatings.
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HOT CHAMBER DIE CASTING COLD CHAMBER DIE CASTING COLD CHAMBER DIE CASTING
The essential feature of this process is the independent holding and injection
units. In the cold chamber process metal is transferred by ladle, manually or
automatically, to the shot sleeve. Actuation of the injection piston forces the
metal into the die. This is a single-shot operation. This procedure minimizes
the contact time between the hot metal and the injector components, thus
extending their operating life. However, the turbulence associated with
highspeed injection is likely to entrain air in the metal, which can cause gas
porosity in the castings. The cold chamber process is used for the production
of aluminum and copper base alloys and has been extended to the production
of steel castings. Next to zinc aluminum is the most widely used die-casting
alloy. The primary advantage is it light weight and its high resistance to
corrosion. Magnesium alloy die-castings are also produced and are used where
a high strength–to–weight ratio is desirable.
The mold has sections, which include the “cover” or hot side and the
“movable” or ejector side. The die may also have additional moveable segments
called slides or pulls, which are used to create features such as undercuts or
holes which are parallel to the parting line. The machines run at required
temperatures and pressures to produce a quality part to near netshape.
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LOW PRESSURE DIE CASTING LOW PRESSURE DIE CASTING LOW PRESSURE DIE CASTING
The process works like this, first a metal die is positioned Low pressure die casting is a metal casting process generally
above a sealed furnace containing molten metal. A refractory used in situations that require high quality manufacturing. In
lined riser extends from the bottom of the die into the molten low pressure casting, molten aluminum is slowly drawn into a
metal. Low pressure air (15 - 100 kPa, 2- 15 psi) is then metal mold or die through a riser tube while kept under
introduced into the furnace. This makes the molten metal rise constant and controlled pressure. This process helps avoid
up the tube and enter the die cavity with low turbulence. After oxidation, cold currents, and air inclusions, generally
the metal has solidified, the air pressure is released . This producing excellent surface finish and highly accurate
makes the metal still in the molten state in the riser tube to dimensions. However, it is much slower and therefore more
fall back into the furnace. After subsequent cooling, the die is costly than high pressure die casting.
opened and the casting extracted.
With correct die design it is possible to eliminate the need of
the riser also. This is because of the directional freezing of the
casting. After the sequence has been established, the process
can be controlled automatically using temperature and
pressure controllers to oversee the operation of more than one
diecasting machine.
LOW PRESSURE DIE CASTING HIGH PRESSURE DIE CASTING HIGH PRESSURE DIE CASTING
In the high pressure die casting process the metal is forced into a high grade High pressure die casting uses a machine to inject molten
steel tool at high speed and -pressure. The casting temperature is roughly
metal into permanent metal dies under high pressure. It is a
700°C during casting.
This equipment consists of two vertical platens on which bolsters are located
good technique for manufacturing complex parts with a high
which hold the die halves. One platen is fixed and the other can move so that degree of accuracy, particularly lightweight parts with thin
the die can be opened and closed. A measured amount of metal is poured into walls that require consistent dimensions. The high pressure is
the shot sleeve and then introduced into the mould cavity using a needed to fill the mold completely and avoid solidification
hydraulically-driven piston. Once the metal has solidified, the die is opened
and the casting removed.
during the casting process.
In this process, special precautions must be taken to avoid too many gas High pressure die casting utilizes two distinct velocities. The
inclusions which cause blistering during subsequent heat-treatment or molten metal is first pushed at a low velocity (1st velocity) in
welding of the casting product. order to avoid turbulence and the formation of bubbles. Just
Both the machine and its dies are very expensive, and for this reason pressure before the material enters the mold, the velocity increases (2nd
die casting is economical only for high volume production.
velocity) and the molten metal is injected very quickly into the
High pressure die casting is a competitive casting method when components
have requirements which cannot be achieved by other casting processes such die assembly to fill it completely.
as:
high volumes
better tolerances
smooth surface finish
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HIGH PRESSURE DIE CASTING HIGH PRESSURE DIE CASTING VACCUM DIE CASTING
A steel die is enclosed in an airtight bell housing. The housing or
receiver has two openings: the sprue, at the bottom, through which
molten metal enters the die and the vacuum outlet at the top. The
sprue opening is submerged below the surface of the molten metal
and the vacuum is drawn within the receiver, creating a pressure
differential between the die cavity and the molten metal in the
crucible. This pressure differential causes the molten metal to flow up
the sprue and into the die cavity, where it solidifies. The die is
removed from the receiver, opened, and the casting ejected. The cycle
is then repeated with each shot producing from one to several
castings, depending on the number of cavities in the die.
By controlling the vacuum, the pressure differential between the die
cavity and the molten metal can be varied allowing for differential fill
rates necessitated by part design and gating requirements. This
results in tight control of the fill rate which also directly influences
the soundness of the casting. Through proper part design, die design
and the use of the vacuum die process, voids, shrinks, and gas
pockets can be greatly reduced or eliminated in critical areas.
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Molten metal is continuously supplied from the ladle to the intermediate ladle
(tundish) from which it is continuously poured into the mold at a controllable rate
keeping the melt level at a constant position.
The water-cooled copper mold (primary cooling zone) extracts the heat of the metal
causing its solidification. The mold oscillates in order to prevent sticking with the
casting.
When the casting goes out from the mold it is cooled in the secondary cooling zone
by water (or water with air) sprayed on the casting surface.
Most of vertical continuous casting machines are equipped with strand guide units
bending the casting and changing its configuration from vertical to horizontal.
The casting is continuously extracted from the mold by the withdrawal unit
followed by a cut-off unit.
The casting process begins from inserting a dummy (primary) bar into the mold. Horizontal continuous casting machine is generally used for casting non-ferrous alloys.
Then a molten metal is poured into the mold where it solidifies and grips the end Horizontal continuous casting in stationary mold with graphite water-cooled molds, Twin-
of the dummy bar. roll caster and Twin-belt caster are most popular methods of this type.
The dummy bar is disconnected from the casting after passing the withdrawal
unit. Due to the water cooling (primary and secondary) solidification rate provided by
Direct Chill (DC) casting method is used for vertical semi-continuous casting of continuous casting is higher than in other casting methods therefore continuous castings
non-ferrous metals (Aluminum alloys, Copper alloys, Magnesium alloys). have more uniform and finer grain structure and enhanced mechanical properties.
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