Metal Casting

12/05/10 NSY 1
 Casting process

12/05/10 NSY 2
 Casting Definition

Casting is the process of

pouring molten metal into a
mould containing a cavity,
which represents the
required product shape.
12/05/10 NSY 3
 :Words for casting process
Cast: to make a part by pouring liquid metal.1
into a specially shaped mould
Casting-both a part cast and the.2
manufacturing process itself
Foundry-a factory to make a casting. 3
Mould-a cavity which is used to. 4
accommodate melted metal

12/05/10 NSY 4
 Casting steps
Steps in casting are three:
 Melt the metal

 Pour it into a mold

 Let it freeze
 Take the solidified casting out of the mould
 Clean the Casting

12/05/10 NSY 5
12/05/10 NSY 6
 Casting Advantages
 Can create complex part geometries
 Can create both external and internal shapes
 Some casting processes are net shape; others
are near net shape
 Can produce very large parts
 Some casting methods are suited to mass
production.
 It is economical to use.
12/05/10 NSY 7
 Disadvantages of casting
 Limitations on mechanical properties
 Poor dimensional accuracy and surface finish for
some processes; e.g., sand casting
 Safety hazards to workers due to hot molten metals
 Environmental problems

12/05/10 NSY 8
 :Application
Transportation Vehicle
Turbine Blades
Machine Tool Structure
Few Agricultural parts
Aircraft jet engine blades, Mill housing

12/05/10 NSY 9
 Section of casting/Foundry

12/05/10 NSY 10
12/05/10 NSY 11
 Sand Casting

12/05/10 NSY 12
 Casting mold
Open and closed

12/05/10 NSY 13
 Types of molds
 Expandable molds
 After the casting has solidifies, the molds in
these molds are broken up to remove the
casting.
 Permanent molds
 The casting can be easily removed and the
mold used for the next casting.
12/05/10 NSY 14
 Solidification of Metals

12/05/10 NSY 15
 Solidification shrinkage

12/05/10 NSY 16
 Sand Casting
 Properties required in sand
 Permeability
 Strength
 Refractoriness
 Grain size and shape

12/05/10 NSY 17
 Elements of Sand mould

12/05/10 NSY 18
 Pattern

Pattern allowances
 Shrinkage
 Draft

 Machining (Finish)

12/05/10 NSY 19
12/05/10 NSY 20
 Machining Allowances

12/05/10 NSY 21
 Core

12/05/10 NSY 22
 Sand Mold Preparation Steps

12/05/10 NSY 23
 Step 1

12/05/10 NSY 24
 Step 2

12/05/10 NSY 25
 Step 3

12/05/10 NSY 26
 Step 4

12/05/10 NSY 27
 Step 5

12/05/10 NSY 28
 Die Casting

12/05/10 NSY 29
12/05/10 NSY 30
 Die Casting Steps

12/05/10 NSY 31