Metal casting- Introduction

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THIS PPT IS STILL UNDER CONSTRUCTION. BUT
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MEANWHILE, READ THIS.

Subject:Manufacturing
technology-II
Class: 4th Sem B.Tech, Mech-B.

Outline of the presentation

Concept
Steps involved in metal casting
Characteristics (+ve and ve)
Classification of the process
Metals processed-break up
World trend and Indias position
Parameters that govern the process

Casting-Concept

A metal-forming process whereby

Raw materials are melted
Moltenmetal is poured into a
cavity in themold
When it solidifies, takes on the
characteristic shape of the cavity.

Generalized steps for any casting

process

Steps in sand casting process

Steps in sand casting process

Outline of the presentation

Concept
Steps involved in metal casting

Characteristics (+ve and ve)

Classification of the process

Metals processed-break up
World trend and Indias position
Parameters that govern the process

Characteristics (+ve and ve)

+ves:
6000 year old process.The oldest surviving
casting is a copper frog from 3200 BC
It is adaptable to
intricateshapes,
to extremely large pieces,
to mass production.
It can provide parts with uniform physical
and mechanical properties throughout
Economical (depends on shape...etc)

Characteristics (+ve and ve)

+ves:
6000 year old process.The oldest surviving
casting is a copper frog from 3200 BC
It is adaptable to
intricateshapes
extremely large pieces
mass production (in some cases).
It can provide parts with uniform physical
and mechanical properties throughout
Economical (depends on shape...etc)

Characteristics (+ve and ve)

+ves:
6000 year old process.The oldest surviving
casting is a copper frog from 3200 BC
It is adaptable to
intricateshapes,
to extremely large pieces,
to mass production.
It can provide parts with uniform physical
and mechanical properties throughout
Economical (depends on shape...etc)

Characteristics (+ve and ve)

+ves:
6000 year old process.The oldest surviving
casting is a copper frog from 3200 BC
It is adaptable to
intricateshapes,
to extremely large pieces,
to mass production.
It can provide parts with uniform physical
and mechanical properties throughout
Economical (depends on shape...etc)

Characteristics (+ve and ve)

+ves:
The necessary tools required for
casting molds are very simple and
inexpensive. As a result, for
production of a small lot , it is the
ideal process.
Grain size of cast component can be
easily controlled by controlling
cooling rate which in turn can be used
to modify the properties.

Characteristics (+ve and ve)

+ves:
Near net shape
Low scrap
Relatively quick process
Easy to make hollow shapes
No limit to size
Supports recycling of metals

Characteristics (+ve and ve)

Negatives:
Poor surface finish and accuracy
compared to other processes
Very high energy consumption
Pollution
Labor intensive process

Outline of the presentation

Concept
Steps involved in metal casting
Characteristics (+ve and ve)
World trend and Indias position
Green sand mold casting:
Steps
Features
Applications
Parameters

Outline of the presentation

Concept
Steps involved in metal casting
Characteristics (+ve and ve)
Classification of the process
Metals processed-break up
World trend and Indias position
Parameters that govern the process

World trend and India's position > 2010 statistics

2011 Statistics

2012 Statistics

Outline of the presentation

Concept
Steps involved in metal casting
Characteristics (+ve and ve)
Classification of the process
Metals processed-break up
World trend and Indias position
Parameters that govern the process

Process parameters

For each casting method, there will be a

particular set of parameters that govern
that process. The following are general
parameters applicable to all processes
Temperatures (Melting and pouring)
Metal composition control
Design parameters of Gating system
and riser
Mould parameters
Cooling rate (knock out time)