Casting

CASTING
It is the process of producing metallic parts by pouring molten metal in to the mould and allowing the metal to solidify. Eg:Automobile engines, Pistons, machine tool

components, wheels & housings of steam turbines, sanitary fittings etc., Mould is a void/cavity created in the compact sand mass which, when filled with molten metal produce a casting.
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Steps in a Casting process

Pattern making Sand preparation and testing Core making Moulding Metal melting Metal pouring Solidification & Cooling to room temperature Finishing operations
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Dept. of Mech & Mfg. Engg.

Dept. of Mech & Mfg. Engg.

Green sand mold

Pattern

Drag

Molding board

FIRST OP
Vents Weight Cope Riser Lifter Pouring basin

Riser pin

Sprue pin

Parting line

Parting line

Runner Gate

Core 6 SECOND OPERATION COMPLETE MOLD

Drag

Sand Casting
Here a suitable foundry sand is rammed around a wooden pattern The two halves of the moulding box being capable of separation The pattern can be withdrawn leaving a mould cavity into which the molten metal can be poured MOULDING SAND- SAND CASTING METAL MOULD- DIE CASTING
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Casting process
Metal is heated above melting Liquid metal poured into mold Metal solidifies into shape of mold Part removed from mold Post Casting Operations
Clean Up Machining
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Properties/ Requirements of a molding sand

Porosity (permeability)
Sand must be porous to allow the gases/ moisture present within the molds to be removed freely/escape when molten metal is poured

Adhesiveness
sand particles must be capable of adhering to sides of molding boxes

Cohesiveness / Strength
Ability of sand particles to stick/bind together firmly Should be sufficient to permit the mold to be formed to the desired shape even after the hot metal is poured in the mold

Refractoriness -enables to withstand high temperature of the molten metal without fusing thus facilitating a clean casting.
Molding sands with a poor refractoriness may burn on to the casting.
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Properties of a molding sand

Collapsibility Mold made out of sand has to automatically collapse as the molten metal gets solidified in it Flowability/plasticity Ability of the sand to behave like a fluid so that, when rammed sand will flow to all portions of a mold and around the pattern and take up the required shape/packs properly around the pattern It increases as clay & water content increase High flowability is required of a molding sand of uniform density To obtain good impression of the pattern in the mold.

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Molding sand classification

They can be classified as: 1. Natural molding sand (Green sand) - Taken from river beds & contain major amount of clay - easily available at low cost 2. Synthetic sand - contain little or no binder (clay) - strength & bonding property can be easily controlled - more expensive than natural sand

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Sand preparation
Very few natural sands have all the qualities required by a molding sand It is mixed with other sands which possess the required characteristics Sufficient moisture must be added to the sand Sand must be properly conditioned before use

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PATTERN
A pattern is a replica of a casting to be made. Using pattern, impressions (mould cavity) can be formed in the damp sand to make a mould. Difference b/n pattern & casting. Pattern size is slightly larger than the casting size to compensate for the shrinkages and allowances. Pattern may not have all holes and slots like casting. Pattern may be single /two piece.
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Pattern materials
-Any material which will retain exact outline of the design for required number of molds

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Pattern materials Wood Most commonly used, easy to work, readily

available, light in weight, cheap & abundantly available. Can be cut in to required shapes. Used when small number of castings is required. Disadvantages- Wears out quickly, absorb moisture content and hence changes dimension in long run/life is less with good dimensional accuracy. Metal - do not change their shape when subjected to moist condition, surface finish, dimensional accuracy is good compared with wood - used when large number of castings is required with close dimensional accuracy.

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 Plastics do not absorb moisture,

smooth , can be withdrawn from the mold easily,without damaging the mold Plaster WAX

Dept. of Mech & Mfg. Engg.

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Types of patterns
-Single piece pattern

-Split pattern
-Cope & Drag pattern - Match plate pattern -Loose-piece pattern -Gated pattern
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Types of patterns

Dowel pins

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Single piece pattern

Made from one piece & does not contain loose pieces Inexpensive & are of simplest type

Split pattern
Most widely used pattern for intricate castings Here the pattern is split in to 2 parts so that one part is in the cope & other is in the drag Two halves of the pattern is aligned properly by using dowel pins
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Match Plate pattern Gated pattern Cope plate

Sand

Drag plate Cope & Drag pattern Gated pattern

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Cope and Drag pattern

Similar to split patterns The cope & drag halves of the pattern along with the gating and risering systems But they are attached separately to the metal or wooden plate along with alignment pins

Match plate pattern

An extension of cope and drag pattern Here the cope & drag patterns along with the gating & risering are mounted on a single matching or metal plate on either side
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Loose piece pattern

Used when contour of the part is such that withdrawing the pattern from the mold is not possible Obstructing part is held as a loose piece

SEGMENTAL PATTERN:FOLLOW BOARD PATTERN:SKELETON PATTERN:-

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Gated pattern
Usually made of metal which increases their strength and reduces tendency to warp Section connecting different patterns serve as runner and gates A gated pattern can manufacture many castings at one time Used in systems mass production
Sand

Gated pattern

Gated pattern
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Sweeps are used for preparing the mouldsOf large symmetrical castings. The sweep is rotated about the spindle to form the cavity. Once the cavity is formed, the hole made by the removal of the spindle is patched-up by filling the foundry sand. Eg: Bells,cast iron kettles are prepared by this method.

Sweep pattern
WOODEN BOARD/ SWEEP

Dept. of Mech & Mfg. Engg.

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Components of a gating system

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Runner:- serves as a passage through which the molten metal is poured. Riser (sprue, Pin) :- indicates that mould is filled up or not. Both runner and riser Supplies the metal to the casting to compensate the shrinkage In the first stages of cooling. Vents :- Holes are provided to escape gases and vapours from the mould Gate :- one of the channel which leads molten metal into mould cavity

Dept. of Mech & Mfg. Engg.

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Pattern Allowances
1. Shrinkage allowance 2. Machining or Finishing allowance 3. Draft or Taper allowance 4. Shake or Rapping allowance 5. Camber or distortion allowance 6. Mould wall movement allowance
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Pattern Allowances
1. Shrinkage allowance
Most of the metals used in casting contract during cooling from pouring temperature to room temperature Provided to compensate for solid contraction by providing adequate allowances in the pattern Amount of contraction varies with different metals

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Pattern Allowances
2. Machining allowance
Given on the surface of the pattern by increasing the metal thickness there to compensate for loss of metal due to machining on these surfaces Depends mainly upon method of machining to be employed Given in addition to the shrinkage allowance

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Pattern Allowances
3. Draft or Taper allowance
Given slight taper on the vertical surfaces of the pattern parallel to the direction of withdrawal from the mould Provided on both internal & external surfaces For easy withdrawal of pattern from the mould

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Pattern Allowances
4. Rapping / Shake allowance
Negative allowance to be provided in the pattern When pattern is withdrawn from the mould by striking over it from side to side, size of the cavity increases To compensate this rapping allowance is provided

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Pattern Allowances
5. Distortion allowance
Castings having irregular shape, will not have uniform contraction during their cooling Results in distortion of the castings Remedy: An opposite distortion is provided in the pattern

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Pattern Allowances
6. Mould wall movement allowance
Mould wall movement takes place because of excessive heat and pressure applied by the molten metal on the surface layer of the sand Affects the size of the casting

Remedy: Provide proper allowance in the pattern Controlling the density & temperature of molten metal Controlling the composition of the molding sand
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Scooping
It is the process of making a cavity in the sand mould without using a pattern. Instead it makes use of casting hand tools like shovel, rammer etc.

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Defects in casting Sand castings are subjected to defects which in a well designed are controllable by proper technique, but are not preventable.

certain casting foundry wholly

Dept. of Mech & Mfg. Engg.

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Defects in casting
Blowholes
Smooth round holes appearing in the form group of small holes below the surface of casting Due to entrapped bubble of gases
Pinholes:These are nothing but tiny blow holes found in large numbers occur either at or just below the casting surface.

Scabs
Projection on the casting that occur when a portion of the mould lifts and metal flows

Drop
Occurs when upper surface of the mold cracks and pieces of sand falls in to the molten metal

Shrinkage cavity- Insufficient molten metal

Void created in the casting mainly due to uncontrolled solidification of the metal
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 Internal air pocket

It appears as small holes inside the casting, due to rapid pouring of molten metal in to the mold

Shifts
An external defect caused due to core misplacement or mismatching of top and bottom parts of the casting

Fin
A thin projection of the metal Caused due to incorrect assembling of molds or cores

Swell
Enlargement of metal cavity by metal pressure This is caused by improper ramming

Warpage
Undesirable deformation in a casting that occurs during solidification
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Shrinkage cavity-Insufficient molten metal

Warpage

Scabs

General Casting Defects

Back
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Blowholes Shifts

Drop

Swell

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Casting Advantages Complex Part Geometries Net Shape Processes Available Suitable for Very Large Parts Suitable for Any Metal
Depends on the Specific Process

Some Methods Suited to Mass Production.

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Casting Disadvantages Vary By Method Limitation on Metal Properties Porosity Poor Dimensional Accuracy Surface Finishes Safety and Environmental Concerns High Initial Cost (Patterns)

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***Explain with sketches, the method of preparing a green sand mould.

The drag box is first placed inverted over the moulding platform as shown in Fig A. The bottom half of the pattern is kept inverted in the centre of the box such that its parting surface lies on the top face of the platform. Now the drag box is filled with the moulding sand and is rammed firmly round the pattern. The drag is then inverted along with the pattern and placed upright as shown in Fig. B. The other half of the pattern is then placed over the bottom half of the pattern in the drag. Fine dry sand, known as the parting sand is sprinkled over the exposed mould surface of the drag. After the runner or sprue pin and the riser pin are placed in the appropriate places, the cope box is filled with the moulding sand and suitably rammed. The pouring basin is cut by hand around the runner or sprue pin. Suitable number of vent holes are made by piercing the vent rod: The riser and sprue pins are withdrawn. The cope is lifted off carefully and placed upside down on a prepared sand platform. The patterns are lifted out from the cope and drag by gently rapping. Now the core is placed in its position. The cope is lifted and placed over the drag. [Sketch = 2 marks Expln = 2 marks]

Dept. of Mech & Mfg. Engg.

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