CASTING

BY:RISHABH GOYAL PANKAJ KATARIYA

 Casting is a manufacturing process by which a

liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. The plant where castings are made is called Foundary .

Advantages of casting
Any small or large shape can be produced.

Almost all metals and alloys and some plastic can be

cast. Mechanical and automated casting process decrease the cost. It is used as a prototype means few products can be produced at any time.

Application of Casting process

Automobile engine blocks , airplane engines , pistons

and piston rings. Machine tool bed and frames , wheels and housing of steam and hydraulic turbines. Sanitary fittings and agriculture parts. In machine tools internal combustion engines , compressors etc.

Classification of Casting Process

We classify the casting process on the basis that

whether moulds , patterns and cores are permanent or expandable(disposable). Various types are 1. Expendable Mould Casting 2. Permanent mould casting 3. Semi-permanent mould casting

Expandable mould casting

Mould pattern is obtained by consolidate a refractory

material around pattern. Moulds are to be broke to take out casting from mould cavity. Molding material can be sand or some other refractory material. Its limitations are that surface finish and dimensional accuracy are not good.

Permanent mould casting

Mould is use repeatedly and not destroyed after

soldification of casting. It is used to produced bulk of casting materials. The casting produced by this method have smooth surface and increased accuracy of dimensions. Due to high cost it is less in use and cant use to generate few material.

Semi-permanent mould casting

These moulds are prepared from high refractory

materials. These moulds are not durable as permanent moulds. So it can not used for mass or quantity production, but only for tens of casting.

SAND-MOULD CASTING
It is single casting moulds and completely destroyed

after casting is done. Molding material is sand mixed with binders and additive and water to improve cohesive strength and moudability of sand. Depending on type of process its types are:1. Permanent or removable pattern process 2. Expandable or disposable pattern process

 On basis of hand or on moulding machines it is of

various types : Bench moulding Floor moulding Pit moulding

Types of sand moulds

Green sand mould Dry sand mould Skin-dry sand mould Loam sand mould Cemented-bonded moulds CO2 moulds Resin-bonded sand moulds

Dry sand core mould

Cold box mould process Composite moulds