Casting

2/27/2017
PE 4652 Teknologi Manufaktur

(Manufacturing Technology)
Pengecoran Logam
TEKNIK DAN SISTEM PRODUKSI

PE4652 – Teknologi Manufaktur
Structure of the lecture

1 Overview of Casting Technology
2 Heating and Pouring
3 Solidification and Cooling

PE5662
1
2/27/2017
Casting overview
Casting adalah
Proses penuangan material
cair (umumnya logam cair)
…ke dalam suatu cetakan
(mold) dengan bentuk
tertentu dan …….
mendinginkannya sampai
mengeras lalu … menjadi
bentuk sesuai dengan
cetakan.

Advantages and Disadvantages

Casting
“Net Shape” or “Near-Net Shape” Process Advantages:
• Product is ~ finished right out of mold.
• High complexity with few steps (usually)
• No machining waste
General Casting Disadvantages:

• Expensive and time-consuming patterns/molds/dies
• Solidification issues: shrinkage, porosity, ~low strength,
brittleness
• Some methods require many steps (e.g., Investment
casting)

PE5662
2
2/27/2017
Work flow in typical sand-casting foundries

Classification

PE5662
3
2/27/2017

Sand-Mold Casting

4
2/27/2017
Steps in the production sequence in sand casting

PE5662

5
2/27/2017


PE5662
To perform a casting operation, the metal must be

heated to a temperature somewhat above its
melting point and then poured into the mold cavity
to solidify.

PE5662
6
2/27/2017
Fluidity
Fluidity is a measure of the capability of a metal to flow

into and to fill the mold before freezing.
Factors affecting fluidity:

Pouring temperature
Metal composition
Heat transfer to the surroundings
Viscosity of the liquid metal

PE5662
Heating the Metal

• The total heat required for pouring is the sum of:
1. Heat to raise temperature to melting point
2. Heat of fusion to convert from solid to liquid
3. Heat to raise molten metal to desired temperature for pouring
H = ρV{Cs∙(Tm-To) + Hf + Cl ∙(Tp- Tm)}

Where, H = total heat for pouring (J)
ρ = density (g/cm3)
V = volume of metal being heated (cm3)
Cs = weight specific heat of solid metal (J/g-C)
Tm = melting temperature
T0 = starting temperature
Hf = Heat of fusion
Cl = weight specific heat of liquid metal (J/g-C)
Tp = pouring temperature

PE5662
7
2/27/2017
One cubicmeter of a certain eutectic alloy is heated in a crucible

from room temperature to 100o C above its melting point for
casting. The alloy’s density = 7.5 g/cm3, melting point = 800o C ,
specific heat = 0.33 J/go C in the solid state and 0.29 J/go C in the
liquid state; and heat of fusion = 160 J/g. How much heat energy
must be added to accomplish the heating, assuming no losses?
Solution:
Assume ambient temperature in the foundry = 25o C and that
the density of the liquid and solid states of the metal are the
same. Noting that one m3 = 106 cm3,
H = (7,5) (106) { 0,33 (800-25) + 160 + 0,29 (100)} = 3335 (106 ) J

PE5662
Molten Metal Flow

• Bernoulli’s Theorem – the sum of energies (head, pressure, kinetic,
and friction) at any two points in a flowing liquid are equal
p1 v12 p v2
h1    F1  h2  2  2  F2
 2g  2g
where, h = head (cm); p = pressure (N/cm2);
ρ = density(g/cm3); v = velocity (cm/s);
g = gravity (981 cm/s2); F = head loss due to friction (cm)
• Ignoring friction and assuming no applied pressure.
v12 v2
h1   h2  2
2g 2g
PE5662
8
2/27/2017
Molten Metal Flow (cont’)

• Solving for velocity at base of sprue assuming the velocity is
negligible: in the pouring cup
v  2 gh
where, h = height of the sprue
• Continuity of Flow Law – volume rate of flow is constant:

Q  v1A1  v 2 A 2
where Q = volumetric flow rate (cm3/s)
• Time to fill a mold cavity:

V Mold cavity volume
TMF 
Q
PE5662
Design of Sprue Taper

• To prevent air bubbles from becoming entrapped
(aspirated) into the molten metal stream, the sprue
diameter is tapered such that the volumetric flow
rate remains constant throughout the length of the
sprue
Q pour  vtop Atop  vbottom Abottom
where, vbottom > vtop thus, Atop > Abottom

9
2/27/2017
A mold sprue is 20 cm long, and the cross-sectional area at its

base is 2.5 cm2. The sprue feeds a horizontal runner leading into
a mold cavity whose volume is 1560 cm3.
Determine: (a) velocity of the molten metal at the base of the
sprue, (b) volume rate of flow, and (c) time to fill the mold.
(a) The velocity of the flowing metal at the base of the sprue
(b) The volumetric flow rate is
(c) Time required to fill a mold cavity of 1560 cm3 at this flow rate is

Flow Characteristics
An important consideration of the fluid flow in gating systems is the
presence of turbulence, as opposed to the laminar flow of fluids
Reynolds number, Re, is used to quantify this aspect of fluid flow.
v is the velocity of the liquid

D is the diameter of the channel
 is the density of the liquid
 is viscosity of the liquid
Re typically ranges from 2000 to 20,000

 up to 2000 represents laminar flow
 Between 2000 and 20,000, it represents a mixture of laminar and
turbulent flow
 Re values in excess of 20,000 represent severe turbulence

10
2/27/2017


PE5662
Cooling Curve for a Pure Metal

PE5662
11
2/27/2017
Solidification of Alloys
• Sebagian besar paduan membeku selama rentang temperatur
daripada temperatur tunggal
Phase diagram and cooling curve for 50%Ni-50%Cu

PE5662
Solidification Patterns
(a) Pola pembekuan besi tuang kelabu ukuran 180 mm2. Catatan: setelah 11 min
pendinginan, pembentukan dendrit, tetapi masih lunak. Perlu 2 dua jam hingga beku.
(b) Solidifikasi dari baja karbon pada cetakan pasir dan logam. Perhatikan perbedaan pola
pemadatan dengan meningkatnya kadar karbon.

PE5662
12
2/27/2017
Solidification Time
• TTS depends on size and shape of casting by relationship
known as Chvorinov's Rule
n
V 
TTS  C m  
 A
where TTS = total solidification time;

V = volume of the casting;
A = surface area of casting;
n = exponent with typical value = 2;
Cm = mold constant (determined experimentally)

PE5662
In-class exercise: solidification time
• Given: Disk diameter D = 500 mm thickness t = 20 mm.

• Material: Al, Cm = 2.0 sec/mm2
in Chvorinov's Rule,
• Find: solidification time
n
V
TTS  C m  
A

PE5662
13
2/27/2017
Riser-Gated Casting
Riser berfungsi sebagai penampung, memasok logam cair

untuk pengecoran yang akan menyusut selama solidifikasi

PE5662
Mold Constant in Chvorinov's Rule
• Mold constant Cm depends on:

– Mold material (sand permeability, etc.)
– Thermal properties of casting metal
– Pouring temperature relative to melting point
• Value of Cm for a given casting operation can be based on

experimental data from previous operations carried out
using same mold material, metal, and pouring temperature,
even though the shape of the part may be quite different

PE5662
14
2/27/2017
What Chvorinov's Rule Tells Us
• A casting with a higher volume-to-surface area ratio

cools and solidifies: more slowly
– To feed molten metal to the main cavity, TTS for the riser
must be greater than TTS for the main casting
• Since mold constants of the riser and casting will be
equal, design the riser to solidify last by having its
volume-to-area ratio as compared to the main casting:
larger
– This minimizes the effects of: shrinkage
PE5662
SHRINKAGE
Shrinkage occurs in three steps:
o Liquid contraction during cooling prior to solidification
o Contraction during the phase change from liquid to solid, called solidification
shrinkage
o Thermal contraction of the solidified casting during cooling to room temperature

PE5662
15
2/27/2017
Solidification Contraction for Various Cast Metals

Volumetric solidification
Metal or alloy
contraction (%)
Aluminum 6,6
Al–4.5%Cu 6,3
Al–12%Si 3,8
Carbon steel 2,5 - 3
1% carbon steel 4
Copper 4,9
70%Cu–30%Zn 4,5
90%Cu–10%Al 4
Gray iron Expansion to 2,5
Magnesium 4,2
White iron 4 – 5,5
Zinc 6,5

PE5662

16
2/27/2017
RISER DESIGN
The riser must remain molten until after the casting solidifies
The Chvorinov’s Rule is used to calculate the riser’s dimensions

PE5662
RISER DESIGN Example
A cylindrical riser must be designed for a sand-casting mold. The

casting itself is a steel rectangular plate with dimensions 7,5 cmx
12,5 cmx 2,0 cm. Previous observations have indicated that the
total solidification time (TTS) for this casting = 1.6 min. The
cylinder for the riser will have a diameter-to-height ratio = 1.
Determine the dimensions of the riser so that its TTS = 2.0 min.

PE5662
17
2/27/2017
First determine the V/A ratio for the plate.

Volume V = 7.5 x 12.5 x 2.0 = 187.5 cm3
surface area A = 2 (7.5 x 12.5 + 7.5 x 2.0 + 12.5 x 2.0 )= 267.5 cm2
Given that TTS = 1.6 min , value of n = 2
Next, design the riser so that its total solidification time is

2.0 min, using the same value of mold constant.

volume of the riser
surface area
Since D/H ratio = 1.0, then D = H
and

18
2/27/2017
V/A ratio = D/6
D = 4.7 cm
Since H = D; then H = 4,7 cm

The riser represents waste metal that will be separated from

the cast part and remelted to make subsequent castings
to be a minimum
volume of the riser in our example problem
V = π (4,7)3 / 4 = 81.5 cm3
44% of the volume of the plate (casting)

total solidification time is ?
19

Casting

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Casting

Uploaded by

Copyright:

Available Formats

2/27/2017

PE 4652 Teknologi Manufaktur

TEKNIK DAN SISTEM PRODUKSI

Structure of the lecture

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

Advantages and Disadvantages

General Casting Disadvantages:

TEKNIK DAN SISTEM PRODUKSI

Work flow in typical sand-casting foundries

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

Steps in the production sequence in sand casting

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

Structure of the lecture

TEKNIK DAN SISTEM PRODUKSI

To perform a casting operation, the metal must be

TEKNIK DAN SISTEM PRODUKSI

Fluidity is a measure of the capability of a metal to flow

Factors affecting fluidity:

TEKNIK DAN SISTEM PRODUKSI

Heating the Metal

H = ρV{Cs∙(Tm-To) + Hf + Cl ∙(Tp- Tm)}

TEKNIK DAN SISTEM PRODUKSI

One cubicmeter of a certain eutectic alloy is heated in a crucible

H = (7,5) (106) { 0,33 (800-25) + 160 + 0,29 (100)} = 3335 (106 ) J

TEKNIK DAN SISTEM PRODUKSI

Molten Metal Flow

• Ignoring friction and assuming no applied pressure.

Molten Metal Flow (cont’)

• Continuity of Flow Law – volume rate of flow is constant:

• Time to fill a mold cavity:

Design of Sprue Taper

Q pour  vtop Atop  vbottom Abottom

where, vbottom > vtop thus, Atop > Abottom

TEKNIK DAN SISTEM PRODUKSI

A mold sprue is 20 cm long, and the cross-sectional area at its

(b) The volumetric flow rate is

TEKNIK DAN SISTEM PRODUKSI

Reynolds number, Re, is used to quantify this aspect of fluid flow.

v is the velocity of the liquid

Re typically ranges from 2000 to 20,000

TEKNIK DAN SISTEM PRODUKSI

Structure of the lecture

TEKNIK DAN SISTEM PRODUKSI

Cooling Curve for a Pure Metal

TEKNIK DAN SISTEM PRODUKSI

Phase diagram and cooling curve for 50%Ni-50%Cu

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

where TTS = total solidification time;

TEKNIK DAN SISTEM PRODUKSI

In-class exercise: solidification time

• Given: Disk diameter D = 500 mm thickness t = 20 mm.

TEKNIK DAN SISTEM PRODUKSI

Riser berfungsi sebagai penampung, memasok logam cair

TEKNIK DAN SISTEM PRODUKSI

Mold Constant in Chvorinov's Rule

• Mold constant Cm depends on:

• Value of Cm for a given casting operation can be based on

TEKNIK DAN SISTEM PRODUKSI