UNIT -I

METAL CASTING PROCESSES

Sand Casting
Casting is one of the processes used for making components
of complicated shapes in larger quantity.

It is the process of producing metal parts by pouring molten
metal in to the mould cavity of the required shape and
allowing the metal to solidify. The solidified metal piece is
called as Casting .

A plant where the castings are made is called a Foundry

Sand Mould

Mould is the cavity of the required shape
made in moulding sand or in other metal.

Pattern is the model of the required casting
made in wood ,metal or plastics. It is
primarily used to produce the mould cavity in
sand.
Important Processes Involved in
Foundry
Pattern making
Mould making
Casting

Type of patterns
Solid or single piece pattern
Split or two piece pattern
Loose piece pattern
Match plate pattern
Sweep pattern
Skeleton pattern
Segmental pattern
Shell pattern



Solid or single piece pattern


Split or two piece pattern

Loose piece pattern


Match plate pattern


Sweep pattern


Skeleton pattern


Segmental pattern

Pattern Materials
Wood - teak wood ,Mahogany, white pine .
Metal cast iron ,Brass, Aluminium,White metal
Plaster
Plastics
Wax

Pattern Allowances

Moulding sand Properties and testing

Cores

Types and applications

Mould ing machines

Types and applications;

Melting furnaces

Blast and Cupola Furnaces

Principle of special casting processes

Shell - investmen

Ceramic mould

Pressure die casting

Centrifugal Casting

CO2 process

Stir casting

Defects in Sand casting