FETTLING

Removal of gates and risers. Gates and risers can be removed from casting by
several methods depending upon size and metal used. With chipping hammer. It is
particularly suited in case of grey iron castings and brittle materials. The gates
and risers can easily be broken by hitting the hammer. With cutting saw. These
saws may be hand saw and power saw are used for cutting the ferrous like steel,
malleable iron and for non ferrous materials except aluminum. Mostly the hand
saws are used for small and medium but when power and used for large work.
With flame cutting. This type of method is specially used for ferrous materials of
large sized castings where the risers and gates are very heavy. In this the gas
cutting flames and arc cutting methods may be employed. (It is not applicable for
small castings.)
For sprue cutting. The shear is specially made tool on punch press base. In this
there are heavy matching steel jaws are fitted. It is mostly used for melable iron
soft and medium, hard steel brass bronze Al, Mg. Shears are limited to small work,
but are very fast and economical. With abrasive cut of machine. These machines
can work with all metals but are specially designed for hard metals which cannot
saw or sheared also where flame cutting and chipping is not feasible. It is more
expensive than other methods. Removal of fins, rough spots and un wanted
projections. The casting surface after removal of the gates may still contain some
rough surfaces left at the time of removal of gates. Sand that is fused with
surface. Some fins and other projections on the surface near the parting line.
The need to be cleaned thoroughly before the casting is put to use.
Casting defects are usually not an accident but they occur because steps in the
preparation of molds are not properly controlled. Actually several types of defects
may occur during casting considerably reducing the total output of casting besides
increasing the cost of their production. It is therefore essential to understand the
causes behind these defects so that they may be suitably eliminated. Casting
defects may be defined as those characteristics that create a deficiency or
imperfection contrary to the quality specification imposed by the design and service
requirements. Defects in casting may be of two basic types. Major defects which
cannot be rectified, resulting in rejections, total loss. Minor defects which can be
remedied and thereby leave a reason able margin for profit. Broadly the defects
may be attributed to. Unsatisfactory material used in molding, core, mold making.
Incorrect advice by supervisor.
Advantages and limitations
Investment casting is particularly advantageous for small precision parts of
intricate design that can be made in multiple moulds. Thin walls down to 0.030
in. (0.76 mm), can be cast readily. Surfaces have a smooth matte appearance with
a roughness in the range of 60 to 90 Ilin. The machining allowance is about 0.010

to 0.015 in. (0.25 to 0.38 mm). Tolerances of:!: 0.005 in.lin. (0.005 mm / mm) are
normal; closer tolerances can be obtained without an excessive amount of
secondary operations. Investment moulds usually do not exceed 24 in. (60.96 cm)
maximum dimension. Preferably, the casting should weigh 10 Ib (4.53 kg) or less
and be under 12 in. (30.48 cm) in maximum dimension.