ME 206 Manufacturing Processes

ME206ManufacturingProcesses
AsimTewari
asim.tewari@iitb.ac.in
Room ME Bld 321
RoomMEBld
Ph:7521

Manufacturing

ME206ManufacturingProcessesIbyAsimTewari

Product realization process

Productrealizationprocess

ME206ManufacturingProcessesIbyAsimTewari

Casting Process
CastingProcess
Pouringaliquidmaterialintoamoldandletting
Pouring
a liquid material into a mold and letting
itcoolandsolidifyintothedesiredshape.
FourMajorareas
Patternmaking
MoldingandCoremaking
Melting
Coolingandsolidification
ME206ManufacturingProcessesIbyAsimTewari

Classification based on mold type

Classificationbasedonmoldtype
ExpendableMoldProcesses
Permanent patterns
Permanentpatterns
Clay/waterbonds(greensandmolding)

Shellprocess(Croning process)
Furanhotbox
Phenolic hotbox
Warmbox(furfuryl/catalyst)
Ovenbake(coreoil)

Phenolic urethane
Furan/SO2
/
Freeradicalcure(acrylic/epoxy)
Phenolic ester

Gypsumbond

Nobond

ME206ManufacturingProcessesIbyAsimTewari

Sodiumsilicate/CO2
Sodium
silicate/CO2
Shawprocess(ceramicmolding)
Unicast process(ceramicmolding)
Aluminaphosphate

Pl
Plasterbonds
b d

Furan(acidcatalyzed)
Phenolic (acidcatalyzed)
Oilurethane
Phenolic urethane
Polyol urethane

Silicateandphosphatebonds

Coldboxresinbinderprocesses

Nobakeresinbinderprocesses

Silicasand
Olivinesand
Chromite sand
Zi
Zirconsand
d

Heatcuredresinbinderprocesses

Magneticmolding
Vacuummolding

Classification based on mold type

Classificationbasedonmoldtype
Expendablepatterns

Foamedpatterns
Lostfoamcasting
Replicast process
Wax patterns (investment casting)
Waxpatterns(investmentcasting)
Ethylsilicatebondedblockmolds
Ethylsilicatebondedceramicshellmolds
Colloidalsilicabond
Plasterbond
Countergravitylowpressurecasting

ME206ManufacturingProcessesIbyAsimTewari

Classification based on mold type

Classificationbasedonmoldtype
PermanentMoldProcesses
Diecasting
Highpressurediecasting
Lowpressurediecasting
Gravitydiecasting(permanentmold)(a)

Centrifugalcasting
Verticalcentrifugalcasting
i l
if l
i
Horizontalcentrifugalcasting

Hybridprocesses
Squeezecasting
S
ti
Semisolidmetalcasting(rheocasting)
Ospreyprocess(b)

ME206ManufacturingProcessesIbyAsimTewari

Schematic of a sand mold

Schematicofasandmold

Core

ME206ManufacturingProcessesIbyAsimTewari

Basic operations a sand casting

Basicoperationsasandcasting

ME206ManufacturingProcessesIbyAsimTewari

Typical twopart
Typicaltwo
partsandmold
sand mold