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Metal Casting Complete PPT With Question Ans

Metal Casting Complete PPT With Question Ans

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Published by: vikaskumarsharma on Mar 27, 2012
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01/04/2013

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8/28/20111
 
e a
 
as ng
By 
 
S
 
K
 
Mondal
Compiled
 
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Easy 
Sand
 
casting
Sand casting uses ordinary sand as the primary mould material.
The sand grains are mixed with small amounts of other materials, such as clay and water, to improve,packed around a pattern that has the shape of thedesiredcasting.
The pattern must be removed before pouring, themold isusually made in twoormorepieces.
An opening called a
sprue hole
is cut from the top of the mold through the sand and connected to asystemof channelscalled
runners.
Contd….
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The molten metal is poured into the sprue hole, flowsthrough the runners, and enters the mold cavitthroughanopeningcalled a
gate.
Gravity flow is the most common means of introducingthe metal intothe mold.
After solidification, the mold is broken and thefinishedcasting isremoved.
The casting is then “fettled” by cutting off the ingateand the feederhead.
Because the mold is destroyed, a new mold must bemadeforeachcasting.
Contd…
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Sequential
 
steps
 
in
 
making
 
a
 
sand
 
casting
 
pattern
 
board
 
is
 
placed
 
between
 
the
 
bottom
 
(drag)
 
and
 
top
 
(cope)
 
halves
 
of 
 
a
 
flask,
 
 with
 
the
 
bottom
 
side
 
up.
Sand
 
is
 
then
 
packed
 
into
 
the
 
drag
 
half 
 
of 
 
the
 
mold.
 
 
bottom
 
board
 
is
 
positioned
 
on
 
top
 
of 
 
the
 
packed
 
sand,
 
and
 
the
 
mold
 
is
 
turned
 
over,
 
showing
 
the
 
top
 
(cope)
 
half 
 
of 
 
pattern
 
 with
 
sprueand
 
riser
 
pins
 
in
 
place.
 
The
 
cope
 
half 
 
of 
 
the
 
mold
 
is
 
then
 
packed
 
 with
 
sand.
 
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The mold is opened, the pattern board is drawn(removed), and the runner and gate are cut into thesurfaceof thesand.
The mold is reassembled with the pattern boardremoved, and molten metal is poured through thesprue.
The contents are shaken from the flask and the metalsegment is separated from the sand, ready for furtherprocessing.
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Compiled
 
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Easy Compiled
 
by:
 
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Casting
 
Terms
Flask:
A moulding flask is one which holds the sandmould intact. It is made up of wood for temporary a licationsor metal forlon
termuse.
Drag:
Lowermoulding flask.
Cope:
Uppermoulding flask.
Cheek:
Intermediate moulding flask used in three
piecemoulding.
Contd…
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Pattern:
Pattern is a replica of the final object to bemadewithsome modifications.
Parting line:
This is the dividing line between the twomoulding las s that ma esup thesand mould.
Bottom board:
This is a board normally madeof wood, which isused at thestartof the mould making.
Contd…
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Moulding sand:
The freshly prepared refractory material used for making the mould cavity. It is amixture of silica, clay and moisture in appropriateproportions.
Backing sand:
This is made up of used and burntsand.
Core:
Used formaking hollowcavities incastings.
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Pouring basin:
A small funnel
shaped cavity at the topof the mould intowhich the molten metal ispoured.
Sprue:
The passage through which the molten metal.
Runner:
Thepassage ways in the parting plane through which molten metal flow is regulated before they reachthemould cavity.
Gate:
The actual entry point through which moltenmetalentersthe mould cavity inacontrolled rate.
Contd…
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Chaplet:
Chaplets are used to support cores inside themould cavity.
Chill:
Chills are metallic objects, which are placed int e mou to ncreaset ecoo ng rateo cast ngs.
Riser:
It is a reservoir of molten metal provided in thecasting so that hot metal can flow back into the mouldcavitywhen there is areduction in volumeof metal duetosolidification
Contd…
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Padding
Tapering of thinner section towards thicker sectionis knownas 'padding'.
Thiswill requireextra material.
If padding is not provided, centre line shrinkage orporositywill result in thethinnersection.
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IES
2001
The mainpurposeof chaplets is(a) Toensuredirectionalsolidification(b) Toprovideefficientventing(c) Foraligning the mold boxes(d) Tosupportthecores
 Ans. (d)
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IES
1996
 Which of the following methods are used forobtainingdirectional solidification forriserdesign1. Suitableplacementof chills2. Suitableplacementof chaplets3. EmployingpaddingSelectthecorrectanswer.(a) 1 and 2 (b) 1 and 3 (c) 2 and 3 (d) 1, 2 and 3
 Ans. (b)
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IES
 
2007
 Which one of the following is the correctstatement?Gateisprovided in mouldsto(a) Feed thecasting ataconstantrate(b) Givepassage togases(c) Compensateforshrinkage(d) Avoidcavities
 Ans. (a)
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GATE
2009
Match
 
the
 
items
 
in
 
Column
 
I
 
and
 
Column
 
II
.Column
 
I
 
Column
 
II
P.
 
Metallic
 
Chills
 
1.
 
Support
 
for
 
the
 
coreQ.
 
Metallic
 
Chaplets
 
2.
 
Reservoir
 
of 
 
the
 
molten
 
metalR.
 
Riser
 
3.
 
Control
 
cooling
 
of 
 
critical
 
sectionsS.
 
Exothermic
 
Padding
 
4.
 
Progressive
 
solidification(a) P
1,Q
3,
 
2,
 
S
4 (b) P
1,Q
4,
 
2,
 
S
3(c) P
3,
 
Q
4,
 
2,
 
S
1 (d) P
4,
 
Q
1,
 
2,
 
S
3
 Ans.
 
(d)
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Easy 

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