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SAND CASTING
Prepared By-
23 feet, 6 tonnes , 99.72% iron, No rust since 5th century AD Big Complex
Iron pillar
Casting
Casting = Pattern making + Mold making + Pouring Molten Metal + Cooling + Removal + Inspection Types of Casting : Expendable Mold, Multiple Use Mold Sand Casting : Expendable Mold casting process uses sand as molding material
Casting Terminology
Parting line
Courtesy: efunda
Pattern Making
What is pattern? Approximate duplicate of product Pattern material: Wood, Metals, Urethanes etc. Types of Patterns: One Piece or solid pattern, Split Pattern, Match-plate pattern, Drag & Cope Pattern Allowances: Shrinkage, Machining, Draft, Distortion
Pattern Making
Split Pattern
Mold Making
Consists : Sand Preparation and Mold Making Sand Properties : Refractoriness, Cohesiveness, Permeability, Collapsibility How to get these properties? Mold Making Methods: Hand Ramming, Sand Slinger, Jolting, Squeezing, Combination
Pouring
Pouring System:
Pouring cup/Basin: Rectangular Shape-No vortex-No suction of Gases
Pouring
Riser Need : Directional Solidification Feeding molten metal to compensate for solidification shrinkage
Cooling/Solidification
Cooling Curve for a Pure Metal:
Pouring Temp.: Temp of first liquid entering Mold cavity Alloy-Distinct M.P.-freezing range High Cooling Rate-fine structures-good mechanical properties Chvorinos rule : ts=B(V/A)n
Start of Solidification
End of Solidification
Effect of Cooling rate: Process Sand Casting Permanent Mold Die Cast Cast Structure:
Solidification
Yield Strength(MPa) 55 62 110 Tensile strength(MPa) 131 158 227 Elongation(%) 8 10 9
Removal of Casting: Shake out-vibrating machine Shot blasting-Removal of internal surface sand
Casting Defects:
Shell Molding: Silica Sand + Thermo setting phenolic resin+ heat sensitive liquid catalystshot on preheated metal pattern-shell formation
Summary:
Includes :Casting=PMPCRI Sand Casting -versatile process -produce almost all size & shape of components -poor surface finish and dimensional accuracy. Sand Casting Methods : Green Sand, CO2 sand , Shell
Acknowledgements:
1. Materials and Processes in Manufacturing, J T Black and Ronald A Cohser, 10 th edition. 2. Assistant Professor M P Gururajan http://mogadalai.wordpress.com/2006/01/14/somethoughts-on-making-presentations/
Thank you