Quest

ion:
Asmal
lbr
onz
egearmustbemadeatahi
ghpr
oduct
ionr
ate.Machi
ningi
srul
ed
outasbeingt ooslow, andal t
houghex trusi
on( forcingmet althroughadi e)oft hesegear scoul
d
beacompet i
tiv
eopt ion,itisalsoruledoutbecausenoext rusionmachi nei sav ail
abletothe
manufacturer.Theor derr equir
es10, 000gear stobedel i
veredwi thi
n30day s.Itwillt
akeabout
18to20day stomakeei thersandcast i
ngpat terns,permanentmol ds,ordiecast ingdies.Thi
s
l
eaves10t o12day sf orpr oducti
on.Thismeanst hatabout1000par tsperdaymustbe
manufactured,all
owi ngt woday sforpackagi ngandshi pping.Themanuf acturerwi l
lrecei
vea
paymentofPKR20mi ll
ionf orthecompl eteorder .Whichcast ingmet hodshoul dbeusedand
gi
veapr operjusti
ficationoft hechoice?
Sol
uti
on:
Requi
rements:
• •Small
sizedbr
onzegear
s
• •10,
000gears(
highpr
oduct
ion)

Cast
ingMet
hods:
Thebestmet hodsf orcast
ingofgear
sar
efol
l
owi
ng:
• •Sandcast ing
• •Investmentcast i
ng
• •Diecast i
ng

Expl
anati
onofcast
ingmet
hods:
Sandcasti
ng:
I
tistypeofcast i
ngi nwhi chmol dismadeofsand.Themol t
enmet
ali
spour
edi
ntomol
dwher
e
i
tsolidif
iesandaf tersolidif
icationpar tisrecover
ed:
Characteri
stics:
Thechar acteri
sticsofsandcastgear sar e,
•Cheaperl ow-qual i
tygearinsmal lnumber s
•Thet ooli
ngcost sar ereasonabl e
•PoorSur facef i
ni shanddi mensi onalaccuracy
•Duet olowpr eci sionandhi ghbackl ash,theyarenoi
sy.
•Theyar esui t
edf ornon-cr i
ticalapplicati
ons

Suit
abili
ty:
Thepr ocessisconf
inedtol
argegear
sthataremachi
nedlat
ertor
equir
edaccur
acy
.Theabov
e
characteri
sti
csshowsthati
tcannotbesuit
ablef
orourr
equir
ements.
I
nvest
mentcast
ing:
Stepsininvestmentcast i
ng:
1.Waxpat ternsar eproduced;
2.Severalpatternsar eattachedtoaspr uetof or
m apatterntree;
3.Thepat t
ernt reeiscoat edwithat hi
nlayerofrefr
actorymat eri
al;
4.Thefullmol di sformedbycov er
ingthecoat edtr
eewithenoughr ef
ract
orymateri
alt
omake
i
trigi
d;
5.Themol dishel dinaninv er
tedpositi
onandheat edtomel tthewaxandper mititt
odripout
ofthecav i
ty;
6.Themol dispr eheatedtoahi ghtemperature,whichensuresthatallcont
aminantsar
e
el
iminatedfrom t hemol d; i
tal
soper mit
st heli
quidmetal t
oflowmor eeasi
lyi
ntothedet
ail
ed
cavit
y;t
hemol tenmet al
ispour ed;
itsoli
difi
es;and
7.Themol
disbr
okenawayf
rom t
hef
ini
shedcast
ing.Par
tsar
esepar
atedf
rom t
hespr
ue.

Charact eri
stics:
Thechar acteri
sti
csofgear sthataremanufactur
edbyi
nvest
mentcast
ingar
e,
•Reasonabl yaccurategears
•Applicabl eforav ari
etyofmat er
ial
s
•Refract orymol dmat er
ial
•All
owshi ghmel t
-temperat
uremat eri
als
•Accur acydependsont heori
ginalmasterpat
ter
nusedfort
hemold.

Suit
abil
i
ty:
Theprocessisusedonl
yifnootherpr
ocessi
ssuit
ablesi
nceproduct
ioncosti
shi
gh.I
tisused
forcomplexpar
t.Thus,
iti
snotsuit
abl
eforourr
equir
ements.
Di
ecast
ing:
Diecastingi sapermanent -moldcastingprocessi nwhi
cht hemol tenmet al
isi nject
edintot
he
moldcav ityunderhighpr essure.
Cycleinhotchambercast i
ng:
1.Withdi eclosedandpl ungerwithdrawn, mol
tenmet alfl
owsi ntothechamber .(incaseofcol
d
chambermol t
enmet ali
spour edintochamberf rom separatecontainercontainingmol t
en
metal)
2.Plungerf orcesmet al
inchambert of lowint
odi e,mai
ntainingpressureduringcool i
ngand
soli
dif
ication;and
3.Plungeri swithdr
awn, dieisopened, andsoli
difi
edparti
sej ect
ed.

Characteri
stics:
Thechar acteri
sti
csofdiecastgearsar
e,
•Bettersurfacefi
nishandaccuracy(t
oothspacingandconcent
ri
cit
y)
•Hight ool
ingcosts
•Suit
edf orlargescalepr
oducti
onApplicat
ions:

Sui
tabi
li
ty:
Theabovecharact
eri
sti
csshownt
hatthebestcast
ingmet
hodf
orsmal
lsi
zedbr
onzegear
s
andforhi
ghproducti
onisdi
ecast
ing.