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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
Processes
Sand Shell Plaster Ceramic Investment Lost foam Pressure Vacuum Die Centrifugal Squeeze Semi-solid Single crystal Directional solidification Slush Continuous
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
Breakdown of Castings
Ingots for bulk deformation processing 85% Cast to near net shape - 15%
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
Ingots
Iron or steel molds Water-cooled molds Water cooled Continuous casting
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
Shapes
Permanent mold (cavity)
die casting hot chamber cold chamber ld h b
Expendable Molds
sand shell slurry investment
lost wax lost foam
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
Shapes
Centrifugal
pipes spinning
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
Capabilities
Dimensions
sand casting - as large as you like small - 1 mm or so
Tolerances
0 005 in to 0 1 in 0.005 0.1
Surface finish
di casting 8 16 micro-inches (1 3 m) die ti 8-16 i i h (1-3 ) sand casting - 500 micro-inches (10-25 m)
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009 10
Casting Steps
quick route from raw material to finished product
Melt metals Pour / force liquid into hollow cavity (mold) Cool / Solidify Remove Finish
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009 11
Melting
Raw material (charge)
scrap alloying materials scrap,
Heat
Furnace Atmosphere
Atmosphere Heating
Raw materials
Air (oxygen), vacuum inert gas (argon) (oxygen) vacuum, External - electric gas oil electric, gas, Internal - induction, mix fuel with charge
steel making in blast furnace -mix coke with iron mix
Furnace material
refractory ceramics
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009 12
Furnaces
Blast furnace
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
Furnaces
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
Furnaces
Induction Furnace
Electric Furnace
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Sand Casting g
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Sand Casting
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Sand Casting
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Die Casting
Cold chamber
Hot chamber
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Continuous Casting
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Investment Casting C ti
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Vacuum Casting
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Centrifugal Casting
horizontal
vertical
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Centrifugal Casting
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Directional Solidification
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Casting Characteristics
Table 5.6 Typical materials cast
All All
Weig ht (kg)
Process
Sand Shell Expendable E pendable mold pattern
Minimum
0.05 0.05
Maximum
No limit 100+
Porosity*
4 4
Minimum
3 2
Maximum
No limit --
All Nonferrou Plaster s (Al, Mg, mold Zn, Cu) All (High melting Investment pt.) Permanent mold All Nonferrou s (Al Mg (Al, Mg, Die Zn, Cu) Centrifugal All
0.05
No limit
5-20
No limit
0.05
50+
1-2
1-2
--
0.005 0.5
100+ 300
1-3 2-3
3 2-3
1 3-4
1 1
1 2
75 50
<0.05 50 1-2 1-2 3-4 1 -5000+ 2-10 1-2 3-4 3 *Relative rating: 1 best, 5 worst. Note : These ratings are only general; significant variations can occur, depending on the methods used.
0.5 2
12 100
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Microstructure
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Microstructure - Dendrites
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Microstructure - Dendrites
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Fluidity
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Casting Defects
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Shrinkage
TABLE 5.1 Volumetric solidification contraction (%) 6.6 6.3 3.8 2.53 4 4.9 Volumetric solidification contraction (%) 4.5 4 Expansion to 2.5 4.2 45.5 6.5
Metal or alloy Aluminum Al4.5%Cu Al12%Si Carbon steel 1% carbon steel Copper Source: After R. A. Flinn.
Metal or alloy 70%Cu30%Zn 90%Cu10%Al Gray iron g Magnesium White iron Zinc
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Differential Cooling
Transition between thicker and thinner sections can lead to porosity p y
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Pipe Defect
D t shrinkage giving rise t Due to h i k i i i to a funnel-like cavity Solutions
insulate top (glass wool) heat top (exothermic mixture thermit)
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Chills
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Casting costs
TABLE 5.10 Cost Cost* Process Die Sand L Shell-mold LM Plaster LM Investment MH Permanent mold M Die H Centrifugal M *L l L, low; M medium; H hi h M, di H, high. Equipment L M-H M L-M M H H Labor L M LM LM MH H LM LM LM Production rate (Pc/hr) <20 20 <50 <10 <1000 <60 <200 <50
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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Process economics
ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton GIT 2009
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