Lesson Objectives:

Todays lesson objectives: Fundamentals of casting process Applications, advantages and limitations of casting Patterns in casting Cores and core prints in casting

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1. SOLIDIFICATION

P a g e 3

Schematic illustration of various casting processes

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Sand Mould Features

Schematic illustration of a sand mould, showing various features.

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Sand Mould

Schematic illustration of a sand mold, showing various features.

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Sand Casting

Cope & drag (top and bottom halves of a sand mold), with cores in place on the drag
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Sand Casting

Two sets of castings (bronze and aluminium) from the above sand mold
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Casting (also called Foundry)

A process means pouring molten

metal into refractory mould with a cavity of the shape to be made, and allowing it to solidify. The mould cavity is often created via a pattern around which the mould is formed. The pattern is removed before the molten metal is introduced to the mould.
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FOUNDRY (CONT.)
Once poured, the mould material extracts

heat from the liquid and the metal solidifies in the shape of the mould cavity. The solidified metal shape is then removed from the mold and the now superfluous metal (gates, runners, risers, etc.) are removed. The resultant solidified metal discrete component is also called the Casting.
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ADVANTAGES AND DISADVANTAGES

ADVANTAGES

Intricate shapes internal or external can be made Any material can be cast Inexpensive and simple tools used Ideal method for trial production or production of a small lot Weight reduction in design can be achieved
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ADVANTAGES AND DISADVANTAGES

ADVANTAGES

Casting are generally cooled uniformly from all sides and therefore they are expected to have no directional properties Any sizes of product can be cast

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ADVANTAGES AND DISADVANTAGES (CONT.)

LIMITATIONS

Dimensional accuracy and surface finished would not be adequate for final application in many cases Labour intensive Difficult to remove defects arising out of the moisture present in sand castings.
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FOUNDRY PROCESES
PATTERN MAKING MOULDING CORE MAKING GATING SYSTEM

SAND

MOULD

MELTING OF METAL

POURING INTO MOULD

CASTING

HEAT TREATMENT

CLEANING AND FINISHING

Solidification

Shakeout Removal of risers and gates

Additional INSPECTION heat treatment

Defects Pressure tightness Page 13 Dimensions

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Basic Requirements of Foundry Processes

1. 2. 3. 4. 5. 6. A mould cavity A melting process A pouring technique The solidification process Mould removal Finishing (cleaning, inspection etc.)

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PATTERNS
WHAT ARE PATTERNS? - Pattern is the exact replica of the part you want to make. - It is the tool to make the cavity having same size and dimensions.

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PATTERN ALLOWANCES
The modifications that are incorporated into a

pattern are called allowances. The allowances are made mainly due to: 1) Shrinkage allowance (most

important)

2) Machining Allowance

Patterns are made larger than the casting to compensate contraction of the liquid while freezing. Allowance required to remove the rough cast surface. 2 to 25 mm (0.1 to 1)
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Solidification Contraction for Various Cast Metals

TABLE 10.1 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 Magnesium White iron Zinc

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PATTERN ALLOWANCES (cont.)

3) Draft Allowance (slight taper)
To facilitate ease of removal, usually to 2

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Patterns for Sand Casting

Taper on patterns for ease of removal from the sand mold.

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PATTERN MATERIALS
Wood Pine, Teak, Mahagony Metal- Cast iron, Brass, Broze, Al alloys Plastic and Rubber Quick setting

compound, polystyrene, silicone rubber Plaster Gypsum plaster, plaster of Paris Other wax and Mercury

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CHARACTERISTICS OF PATTERNS
Lightweight for handling and working

Strong hard and durable

Easy to work, shape and join Resistance to wear, abrasion, corrosion

and chemical attack Easily available at low cost Easy to repair Ability to give good surface finish
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Pattern Material Characteristics

TABLE 11.3 Characteristic Wood Aluminum Rating Steel
a

Plastic

Cast iron

Machinability E G F G G Wear resistance P G E F E Strength F G E G G Weightb E G P G P Repairability E P G F G Resistance to: Corrosionc E E P E P Swellingc P E E E E aE, Excellent; G, good; F, fair; P, poor. bAs a factor in operator fatigue. cBy water. Source : D.C. Ekey and W.R. Winter, Introduction to Foundry Technology. New York. McGraw-Hill, 1958.
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TYPES OF PATTERN
1. Single piece or solid pattern

2. Two piece or split pattern

3. Multiple piece or loose pattern 4. Match plate pattern 5. Gated pattern 6. Skeleton pattern

7. Cope and drag pattern

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CORES
WHAT ARE CORES? Cores are materials used for making the cavities and hollow projections which cannot normally be produced by pattern alone Any complicated contour or cavity can be made by means of cores so that really intricate shapes can be easily obtained Generally made of sand Subjected to much more severe thermal and mechanical condition and should be of higher strength than moulding sand
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Cores and Core Prints

Cores are made separately by pressing

sand in boxes (core boxes) To support core in the mould an impression is made in the mould with the help of a projection suitably placed on the pattern. The projection is known as core prints.
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Examples of Sand Cores and Chaplets

Examples of sand cores showing core prints and chaplets to support cores.

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CHARACTERISTIC OF A CORE
Green strength
Dry strength Refractoriness

Permeability
Collapsibility Friability

Smoothness
Low gas emission
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TYPE OF CORES
CORE
GREEN SAND CORES Obtained by pattern itself during moulding DRY SAND CORES Made by means by special core sands in a separate core box, baked and placed in the mould before pouring

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Thats all for now.. Any questions??

IQ + EQ + SQ = TQ
Thank You for coming and see you again..