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Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-1
Introduction
Casting
Penuangan logam cair ke cetakan sesuai dengan
bentuk yang diinginkan. Setelah penuangan,
dilanjutkan dengan proses pembekuan pada
cetakan dan benda dikeluarkan dari cetakan
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-2
Introduction
- Dapat digunakan untuk menghasilkan geometri yang
kompleks baik internal maupun eksternal
- Beberapa proses pengecoran dapat mengasilkan
komponen net shape (tidak memerlukan proses
pengerjaan manufaktur lanjutan)
- Dapat menghasilkan komponen yang sangat besar (berat
lebih dari 100 ton)
- Dapat digunakan untuk berbagai jenis logam yang dapat
dipanaskan sampai fasa cair
- Beberapa tipe proses casting cocok untuk mass
production
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-3
TABLE 11.1
Process
Ringkasan
Proses proses
Pengecoran
Advantages
Limitations
Sand
Shell mold
Expendable pattern
Plaster mold
Ceramic mold
Limited size.
Investment
Permanent mold
Die
Centrifugal
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-4
2001 Prentice-Hall
Page 11-5
2001 Prentice-Hall
Page 11-6
Contoh : Die-Casting
(a)
(b)
Figure 11.1 (a) The Polaroid PDC-2000 digital camera with a AZ91D die-cast, high purity
magnesium case. (b) Two-piece Polaroid camera case made by the hot-chamber die casting
process. Source: Courtesy of Polaroid Corporation and Chicago White Metal Casting, Inc.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-7
Process
Sand
Shell
Expendable
mold
pattern
Typical
materials
cast
Minimum
Maximum
All
All
0.05
0.05
No limit
100+
5-25
1-3
4
4
1-2
2-3
0.05
No limit
5-20
0.05
50+
1-2
0.005
100+
0.5
<0.05
--
All
Nonferrous
Plaster
(Al, Mg, Zn,
mold
Cu)
All
(High melting
Investment
pt.)
Permanent
mold
All
Nonferrous
(Al, Mg, Zn,
Die
Cu)
Centrifugal
All
Weig ht (kg)
Typical
surface
finish
(mm, Ra)
Minimum
Maximum
3
2
3
2
No limit
--
No limit
1-2
--
1-3
75
300
2-3
2-3
3-4
50
50
5000+
1-2
2-10
1-2
1-2
3-4
3-4
1
3
0.5
2
12
100
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-8
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-9
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-10
Proses pembekuan
2001 Prentice-Hall
Page 11-11
Laju pendinginan
Rapid cooling cenderung menghasilkan butir
equiaxed (bulat)
Slow cooling cenderung menghasilkan butir
kolumnar (memanjang) yang tumbuh dengan
arah ke bagian tengah
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-12
Pembekuan logam
Dendrites
Tree-like structures that form during the solidification of alloys
2001 Prentice-Hall
Page 11-13
2001 Prentice-Hall
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2001 Prentice-Hall
Page 11-16
Cetakan Pasir
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-17
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-18
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-19
Characteristic
Wood
Aluminum
Rating
Steel
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.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-20
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-21
Figure 11.8 Examples of sand cores showing core prints and chaplets to support cores.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-22
Squeeze Heads
Figure 11.9 Various designs
of squeeze heads for mold
making: (a) conventional
flat head; (b) profile head;
(c) equalizing squeeze
pistons; and (d) flexible
diaphragm. Source:
Institute of British
Foundrymen. Used with
permission.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-23
Figure 11.11 Schematic illustration of the sequence of operations for sand casting. Source: Steel
Founders' Society of America. (a) A mechanical drawing of the part is used to generate a design for the
pattern. Considerations such as part shrinkage and draft must be built into the drawing. (b-c) Patterns
have been mounted on plates equipped with pins for alignment. Note the presence of core prints designed
to hold the core in place. (d-e) Core boxes produce core halves, which are pasted together. The cores will
be used to produce the hollow area of the part shown in (a). (f) The cope half of the mold is assembled by
securing the cope pattern plate to the flask with aligning pins, and attaching inserts to form the sprue and
risers. (continued)
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-24
Figure 11.11 (g) The flask is rammed with sand and the plate and inserts are removed. (g) The drag half is
produced in a similar manner, with the pattern inserted. A bottom board is placed below the drag and aligned
with pins. (i) The pattern, flask, and bottom board are inverted, and the pattern is withdrawn, leaving the
appropriate imprint. (j) The core is set in place within the drag cavity. (k) The mold is closed by placing the
cope on top of the drag and buoyant forces in the liquid, which might lift the cope. (l) After the metal solidifies,
the casting is removed from the mold. (m) The sprue and risers are cut off and recycled and the casting is
cleaned, inspected, and heat treated (when necessary).
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-25
Figure 11.12 Surface roughness in casting and other metalworking processes. See also Figs. 22.14 and
26.4 for comparison with other manufacturing processes.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-26
Ceramic Molds
Figure 11.16 Sequence of operations in
making a ceramic mold. Source: Metals
Handbook, vol. 5, 8th ed.
2001 Prentice-Hall
Page 11-27
Figure 11.18
Schematic
illustration of
investment
casting, (lostwax process).
Castings by this
method can be
made with very
fine detail and
from a variety of
metals. Source:
Steel Founders'
Society of
America.
Investment
Casting
Proses
investment
casting disebut
juga dengan lostwax process
pattern dibuat
dari wax atau
plastic seperti
polystyrene
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-28
Figure 11.19 Investment casting of an integrally cast rotor for a gas turbine. (a) Wax pattern assembly.
(b) Ceramic shell around wax pattern. (c) Wax is melted out and the mold is filled, under a vacuum,
with molten superalloy. (d) The cast rotor, produced to net or near-net shape. Source: Howmet
Corporation.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-29
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-30
Vacuum-Casting Process
Figure 11.21 Schematic illustration of the vacuum-casting process. Note that the mold has a
bottom gate. (a) Before and (b) after immersion of the mold into the molten metal. Source:
From R. Blackburn, "Vacuum Casting Goes Commercial," Advanced Materials and Processes,
February 1990, p. 18. ASM International.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-31
Pressure Casting
Figure 11.22 (a) The bottom-pressure casting process utilizes graphite molds for the production of steel
railroad wheels. Source: The Griffin Wheel Division of Amsted Industries Incorporated. (b) Gravitypouring method of casting a railroad wheel. Note that the pouring basin also serves as a riser. Railroad
wheels can also be manufactured by forging.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-32
(b)
Figure 11.23 (a) Schematic illustration of the hot-chamber die-casting process. (b) Schematic
illustration of the cold-chamber die-casting process. Source: Courtesy of Foundry Management and
Technology.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-33
(a)
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-34
Figure 11.24 (b) 800-ton hot-chamber die-casting machine, DAM 8005 (made
in Germany in 1998). This is the largest hot-chamber machine in the world
and costs about $1.25 million.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-35
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-36
Yield
strength
(MPa)
Elongation
in 50 mm
(%)
320
160
2.5
300
150
2.5
380
200
15
230
160
280
--
10
320
--
Alloy
Aluminum 380 (3.5 Cu-8.5 Si)
13 (12 Si)
5 (4 Al-1 Cu)
Applications
Appliances, automotive components,
electrical motor frames and housings
Complex shapes with thin walls, parts
requiring strength at elevated
temperatures
Plumbing fiztures, lock hardware,
bushings, ornamental castings
Power tools, automotive parts, sporting
goods
Automotive parts, office equipment,
household utensils, building hardware,
toys
Appliances, automotive parts, building
hardware, business equipment
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-37
2001 Prentice-Hall
Page 11-38
Semicentrifugal Casting
Figure 11.28 (a) Schematic illustration of the semicentrifugal casting process. Wheels with spokes can
be cast by this process. (b) Schematic illustration of casting by centrifuging. The molds are placed at
the periphery of the machine, and the molten metal is forced into the molds by centrifugal force.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-39
Squeeze-Casting
Figure 11.29 Sequence of operations in the squeeze-casting process. This process combines the
advantages of casting and forging.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-40
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-41
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-42
Melt Spinning
Figure 11.32 Schematic
illustration of melt-spinning to
produce thin strips of
amorphous metal.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-43
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-44
Casting Defects
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-45
Casting Defects
Porosity may be caused by shrinkage and/or gases
Thin sections solidify faster than thick sections; therefore
the molten metal cannot be supplied to thick regions that
are solidifying
Gases become less soluble in a metal as it cools and
solidifies, causing it to be expelled and sometimes form
or expand porosity
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-46
Casting Defects
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-47
Casting Defects
Chills
Pieces of material placed in the mold to speed up
heat transfer in thicker areas of the part to
prevent shrinkage porosity
Internal chills are left within the cast part; external
chills are removed
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-48
Chills
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall
Page 11-49