IE 464 Manufacturing Processes Lab

Jordan University of Science and Technology

Faculty of Engineering

Department of Industrial Engineering

IE 464
Production Processes Lab

Lab No. 2

Casting

Fall 2003

Prepared by:
Dr. Mohammed Hayajneh Dr. Bashar El-Khasawneh

Eng. Mohammed Al-Omari

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Irbid-JORDAN

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Lab No. 2
Casting

Lab Objective:
The objectives of this lab are to familiarize the students with a number of casting
processes. Additionally, the students will be able to inspect different casting defects
and identify the reasons behind these defects. Through small groups in the lab,
students should be able to have a hands-on experience with these processes and to
observe things differently and be able to ask more questions.

The learning milestones:

The student is expected to learn the following:
 Get acquainted with different casting processes
 Identify the advantages and disadvantages of the sand casting process
 Learn the signature and reasons for the different defect types

Basic Overview of the Sand Casting

Metal casting is the process in which molten metal is poured into a mold and allowed
to solidify into an object. The object that results from this process is also called a
casting. In sand casting, sand is used to define the cavity inside a mold. In addition,
sand is used to make any cores that are contained in the mold. The molten metal
solidifies in the cavity between the interior of the mold and the exterior of the core.
There are the five basic steps to create a sand casting.

The five basic steps in Sand Casting:

1. Pattern making
2. Core making
3. Molding
4. Melting and pouring the cast metal
5. Cleaning the product

Pattern making
The first step in sand casting is pattern making. The pattern is a replica of the exterior
of the casting with dimensional allocation for shrinkage and finishing. If the casting is
to be hollow, additional patterns called cores are used to create these cavities in the
finished product. Patterns are usually made of wood, plastic, metal, or plaster;
however, other materials or combinations of materials are used if there are additional
specific properties required of the pattern. The number of castings to be made from
the mold and the specifications required of the finished casting are two of the criteria
that determine which material is selected for the creation of the pattern.

Core making
The next step in the sand casting process is core making. Cores are forms that are
placed into the mold to create the interior contours of the casting. They are typically
made of sand (sand mixture combined with water and organic adhesives called

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binders) which is baked to form the core. This allows the cores to be strong yet
collapsible, so they can be easily removed from the finished casting. Since cores are
made in molds, they require a pattern and mold, called a core box. The core pattern is
made in the same fashion as the casting pattern, but the core box is created from a
durable material like metal or wood. Since the cores are made of sand, the mold
cannot also be made of sand.

Molding
Molding is the multi-step process in which molds are created. In horizontal casting,
the mold is contained in a two piece frame, called a flask. The upper portion of the
flask is called a cope and the lower portion is a drag. First, molding sand is packed
into a flask around the pattern. After the pattern is removed, gating and runner
arrangements are positioned in the drag half of the mold cavity and the sprue is placed
the cope portion. Gating systems are necessary for the molten metal to flow into the
mold cavity. Cores are also placed in the drag portion of the mold if they are needed.
To finish the mold, the cope (top) section is placed on the drag (bottom) section, and
the mold is closed and clamped together.

Melting & Pouring

Melting is the preparation of the metal for casting, and its conversion from a solid to a
liquid state in a furnace. It is then transferred in a ladle to the molding area of the
foundry where it is poured into the molds. After the metal has solidified, the molds are
vibrated to remove the sand from the casting, a process called shakeout.

Cleaning
Cleaning generally refers to the removal of all materials that are not part of the
finished casting. Rough cleaning is the removal of the gating systems from the
casting. Initial finishing removes any residual mold or core sand that remains on the
piece after it is free of the mold. Triming removes any superfluous metal. In the last
stages of finishing, the surface of the casting is cleaned for improved appearance. In
addition, at this point, the casting is inspected for defects and adherence to quality
standards. This inspection may include nondestructive testing to determine whether
the part will adequately perform for its intended use.

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Basic Overview of the Centrifugal Casting

Centrifugal Casting is also known as spin casting. A basic spin casting machine
works like this: A two-part of high-temperature silicone rubber mold is clamped
between pressure plates on the spin casting machine. The spin casting machine rotates
the mold at high speed, While the mold rotates, molten metal is poured into a central
funnel that feeds into the mold. Centrifugal force carries the metal into the far reaches
of the mold. Because the centrifugal force acts to increase the pressure on the casting
material, castings with relatively thin parts can be made. A mold for a spin casting
machine is often designed to make an identical parts at one time, with the mold cavity
for each part equally spaced around the disk of the rubber mold. The typical metal
used in this type of spin casting machine like Zinc-Aluminum (ZA) alloys, LEAD-
and-TIN-based alloy are low melting temperature (because we use a silicon rubber as
a mold) .

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Steps to make product using centrifugal casting

Basic Overview of the Shell Casting:
Shell mold casting is a process in which molten metal is poured into a heat-cured, non
reusable shell mold made from silica sand and a resin binder and is held until
solidification of the molten metal occurs.

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Design considerations in Castings

 Shrinkage
Allowance for shrinkage during solidification should be provided for, so as to avoid
cracking of the casting.

Poor Design Hot Tear Better Design

 Corners, angles and section thickness

o Sharp corners and angles and fillets should be avoided, since they cause
cracking and tearing during solidification.
o Fillet radii affects stress concentration and proper liquid-metal flow

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Section changes in casting should smoothly blend into each other. Hot spots can
develop shrinkage cavities and porosity (happens at the largest inscribed circle within
certain area). This can be eliminated by small cores.

Poor Design Better Design

Shrinkage cavity

Core

Better Design
Poor Design Good Design

 Flat areas

o Large flat areas should be avoided since they may warp because of
temperature gradients during cooling, or may develop poor surface finish
because of uneven flow of metal during pouring. Flat surfaces can be
broken up with ribs and serration.

 Parting line
In general, it is desirable for the parting line to be along a flat plane, rather than
contoured.
 Machining allowance

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 Residual stress: stress relieve may be necessary

 Draft
 Tolerance

Electrically heated press & Melting furnace

Spin- Caster machine

Shell casting machine