Professional Documents
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Machine Tool & Casting
Machine Tool & Casting
Lathe
Lathe
A lathe is a large machine that rotates the work, and
cutting is done with a non-rotating cutting tool. The
shapes cut are generally round, or helical. The tool is
typically moved parallel to the axis of rotation during
cutting.
head stock - this end of the lathe contains the driving
motor and gears. Power to rotate the part is delivered
from here. This typically has levers that let the speeds
and feeds be set. FIGURE The bed is the foundation of the
ways - these are hardened rails that the carriage rides lathe. The ways are precision-ground rails that
are frequently flame hardened for durability.
on. Do not lay tools on the ways to prevent
tail stock - this can be used to hold the other end of the excessive wear and damage.
part.
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Lathe
Bed - this is a bottom pan on the lathe that catches chips,
cutting fluids, etc.
carriage - this part of the lathe carries the cutting tool and
moves based on the rotation of the lead screw or rod.
Lead screw - A large screw with a few threads per inch used
for cutting threads. It has ACME threads with included angle
of 29o for easy engagement and disengagement of half nut.
Lead rod - a rod with a shaft down the side used for driving
FIGURE The carriage supports cutting tools and moves along the
normal cutting feeds.
ways to provide tool movement. The top section The critical parameters on the lathe are speed of rotation
that rests on the ways is the saddle and the apron is suspended from
the saddle and hangs down in front of the bed. (speed in RPM) and how far the tool moves across the work
for each rotation (feed in IPR)
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Threading
Threading - The cutting tool is moved quickly cutting
threads.
Threading Lead lead is the linear distance the nut travels and the
In one revolution of the spindle, carriage must travel lead screw for every one revolution.
the pitch of the screw thread to be cut. Lead=pitch*starts
N s Pz s N L Lz L
P Pitch of the screw thread to be cut
L Pitch of the lead screw
z s Number of start of the screw thread to be cut
z L Number of start of the lead screw
icg gear ratio of spindle N s to carriage N L gear train
Facing Tapering
Facing - The end of the part is turned to be square. Tapering - the tool is moves so as to cut a taper (cone
shape).
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Drilling/Boring Knurling
Drilling/Boring - a cutter or drill bit is pushed into the Knurling is a manufacturing process whereby a
end to create an internal feature. visually-attractive diamond-shaped (criss-cross)
pattern is cut or rolled into metal.
This pattern allows human hands or fingers to get a
better grip on the knurled object than would be
provided by the originally-smooth metal surface.
Spinning
Metal Spinning is a process by which circles of metal are
Reaming
shaped over mandrels (also called forms) while mounted A reamer enters the workpiece axially through the end
on a spinning lathe by the application of levered force and enlarges an existing hole to the diameter of the
with various tools. tool. Reaming removes a minimal amount of material
and is often performed after drilling to obtain both a
more accurate diameter and a smoother internal
finish.
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Lathe chucks
Lathe chucks are used to support a wider variety of
workpiece shapes and to permit more operations to be
performed than can be accomplished when the work is
held between centers.
Three-jaw, self-centering chucks are used for work that
has a round or hexagonal cross section. 3 Jaw Chuck 4 Jaw Chuck
Each jaw in a four-jaw independent chuck can be moved
inward and outward independent of the others by means
of a chuck wrench. Thus they can be used to support a
wide variety of work shapes.
Combination four-jaw chucks are available in which each
jaw can be moved independently or can be moved
simultaneously by means of a spiral cam.
Turning
Face Plate
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Setting the tool below the centre decrease actual rake angle,
while clearance angle increases by the same amount. Thus
cutting force increased.
Setting the tool above the centre causes the rake angle to
increase, while clearance angle reduces. More rubbing with
flank.
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The term automatic is somewhat loosely applied, but is Headstock travels enabling axial feed of the bar stock
normally restricted to those machine tools capable of against the cutting tools.
producing identical pieces without the attention of an There is no tailstock or turret
operator, after each piece is completed. Thus, after High spindle speed (2000 – 10,000 rpm) for small job
setting up and providing an initial supply of material, diameter
further attention beyond replenishing the material The cutting tools (upto five in number including two on
supply is not required until the dimensions of the work the rocker arm) are fed radially
pieces change owing to tool wear.
Used for lot or mass production of thin slender rod or
A number of types of automatic lathes are developed tubular jobs, like components of small clocks and wrist
that can be used for large volume manufacture watches, by precision machining.
application, such as single spindle automatics, Swiss type
automatics, and multi-spindle automatics.
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Norton type Tumbler-gear quick-change Gear box Norton type Tumbler-gear quick-change Gear box
It comprises a cone of gears 1 to 8 mounted on shaft S2.
The tumbler gear can slide on shaft S1. It can mesh with any
gear on shaft S2 through an intermediate gear which is
located on a swinging and sliding lever so that it can engage
gears 1 to 8 of different diameters, on shaft S2.
The lever can be fixed in any desired ratio position with the
help of a stop pin.
The drive is usually from the driving shaft S1 to the driven
shaft S2.
Drilling
INTRODUCTION
In a drilling machine holes may be drilled quickly and
at low cost. The hole is generated by the rotating edge
of a cutting tool known as the drill which exerts large
force on the work clamped on the table. The cutting
motion is provided by rotating the drill and feeding is
done by giving rectilinear motion to the drill in the
axial direction. Here the drill used has two cutting
edges called lips.
Gang drill
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Drilling Operations
Drilling operation
Drilling – Process of making hole
in solid body.
2) Boring – Enlarging a hole
completely with an adjustable tool
with only one cutting edge.
3) Counter boring - Enlarging one
end of the hole to form a square
shoulder with original hole to avoid
projections in assemblies.
4) Counter sinking - Making a cone
shaped enlargement to provide a
recess for a screw head.
Chip formation
Drill
The twist drill does most of the cutting with the tip of
of a drill
the bit.
•There are flutes
to carry the chips
up from the
cutting edges to
the top of the
hole where they
are cast off.
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Drill Drill
Axial rake angle is the angle between the face and the
line parallel to the drill axis. At the periphery of the drill,
it is equivalent to the helix angle/rake angle.
The lip clearance angle is the angle formed by the
portion of the flank adjacent to the land and a plane at
right angles to the drill axis measured at the periphery of
the drill. Large angles (80–120) are used for ductile matls.
to compensate elastic recovery. Small angles (60–80) are
used for brittle matls.
Drill
Drill sizes are typically measured across the drill points with a
micrometer
The drill blanks are made by forging and then are twisted to
provide the torsional rigidity. Then the flutes are machined
and hardened before the final grinding of the geometry.
Lead of the helix is the distance measured parallel to the
drill axis, between corresponding point on the leading edge Deep hole drilling requires special precautions to take care of
of the land in one complete revolution. the removal of large volume of chips.
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GATE- 1997
Helix angle of fast helix drill is normally
The helix results in a positive cutting rake (a) 35o
This angle is equivalent to back rake angle of a single point (b) 60o
cutting tool.
(c) 90o
Usual – 20° to 35° – most common
Large helix : 45° to 60° suitable for deep holes and softer
(d) 5o
work materials
Small helix : for harder / stronger materials
Zero helix : spade drills for high production drilling micro-
drilling and hard work materials
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GATE- 2002
The time taken to drill a hole through a 25 mm thick
plate with the drill rotating at 300 r.p.m. and
moving at a feed rate of 0.25 mm/revolution is
(a) 10 sec (b) 20 sec
(c) 60 sec (d) 100 sec
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Reaming
Reaming removes a small amount of material from the
surface of holes.
It is done for two purposes: to bring holes to a more exact
size and to improve the finish of an existing hole.
Multiage cutting tools that has many flutes, which may be
Reaming straight or in a helix are used.
No special machines are built for reaming. The same
machine that was employed for drilling the hole can be used
for reaming by changing the cutting tool.
Only a minimum amount of materials should be left for
removal by reaming. As little as 0.1 mm is desirable, and in
no case should the amount exceed 0.4 mm.
A properly reamed hole will be within 0.025 mm of the
correct size and have a fine finish.
Reamer
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Trepanning
Trepanning – Operation of producing a hole by
removing metal along the circumference of a hollow
cutting tool. Used for producing large holes in plates.
Trepanning Tool
Boring
Boring
Boring always involves the enlarging of an existing hole,
which may have been made by a drill or may be the result of a
core in a casting.
An equally important and concurrent purpose of boring may
be to make the hole concentric with the axis of rotation of
the workpiece and thus correct any eccentricity that may
have resulted from the drill drifting off the centerline.
Concentricity is an important attribute of bored holes.
When boring is done in a lathe, the work usually is held in a
chuck or on a faceplate. Holes may be bored straight,
tapered, or to irregular contours.
Boring is essentially internal turning while feeding the tool
parallel to the rotation axis of the workpiece.
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Boring Boring
The same principles are used for boring as for turning. Because the tool overhang will be greater, feeds and
The tool should be set exactly at the same height as the depths of cut may be somewhat less than for turning to
axis of rotation. Slightly larger end clearance angles prevent tool vibration and chatter.
sometimes have to be used to prevent the heel of the tool In some cases, the boring bar may be made of tungsten
from rubbing on the inner surface of the hole. carbide because of this material's greater stiffness.
The boring tool is a single-point cutting tool.
Hole quality, finish boring can typically achieve holes
within tolerances of IT9.
Surface finishes better than Ra 1 micron can be achieved.
Cutting Time, CT L A O
fN
M RR
D 2
1 D 22 D a v g d fN
4 / fN
Broaching
Broaching is a multiple-tooth cutting operation with the
tool reciprocating.
Since in broaching the machining operation is
completed in a single-stroke as the teeth on the cutting
tool, called broach, are at gradually increasing height
Broaching corresponding to the feed per tooth of a milling cutter.
The shape of the broach determines the shape of the
machined part.
Broaching was originally developed for machining
internal keyways, but looking at the advantages, it has
been extensively used in the mass production of
automobile component manufacture for various other
surfaces as well.
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ViDEO 11
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A d d D d
1000 2 2
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GATE - 1993
A milling cutter having 8 teeth is rotating at 150
rpm. If the feed per tooth is 0.1 mm, the table speed
in mm per minute is
(a) 120 (b) 187
(c) 125 (d) 70
GATE - 1992
In horizontal milling process…………. (up/down)
milling provides better surface finish and…………..
(up-down) milling provides longer tool life.
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Shaper Shaper
The relative motions between the tool and the workpiece,
shaping and planing use a straight-line cutting motion with a
single-point cutting tool to generate a flat surface.
In shaping, the workpiece is fed at right angles to the cutting
motion between successive strokes of the tool.
For either shaping or planing, the tool is held in a clapper box
which prevents the cutting edge from being damaged on the
return stroke of the tool.
Relatively skilled workers are required to operate shapers and
planers, and most of the shapes that can be produced on
them also can be made by much more productive processes,
such as milling, broaching, or grinding.
Hydraulic Shaper
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Slotter
GATE - 2005
A 600 mm x 30 mm flat surface of a plate is to be
finish machined on a shaper. The plate has been
fixed with the 600 mm side along the tool travel
direction. If the tool over-travel at each end of the
plate is 20 mm, average cutting speed is 8 m/min,
feed rate is 0.3 mm/stroke and the ratio of return
time to cutting time of the tool is 1:2, the time
required for machining will be
(a) 8 minutes (b) 12 minutes
(c) 16 minutes (d) 20 minutes
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Grinding
Grinding is the most common form of abrasive
machining.
It is a material cutting process which engages an abrasive
tool whose cutting elements are grains of abrasive
material known as grit.
These grits are characterized by sharp cutting points,
high hot hardness, and chemical stability and wear
resistance.
The grits are held together by a suitable bonding
material to give shape of an abrasive tool. Fig- cutting action of abrasive grains
Grinding can be compared with milling with an infinite
number of cutting edge.
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Interaction of the grit with the workpiece How is chip accommodation volume is
Grit with favourable geometry can produce chip in shear related to material removal rate?
mode.
However, grits having large negative rake angle or Volume of chip accommodation space ahead of each grit
rounded cutting edge do not form chips but may rub or must be greater than the chip volume produced by each
make a groove by ploughing leading to lateral flow of the grit to facilitate easy evacuation of the chip from the
workpiece material. grinding wheel.
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Bonding Materials for Grinding wheels Bonding Materials for Grinding wheels
Type of Bond Attributes Type of Bond Attributes
Vitrified bonds Composed of clays and other ceramic Rubber bond For use in thin wheels, replaced by resin
substances, porous, strong, rigid, and bond.
unaffected by oils, water, or Oxychloride Limited use.
temperature. Brittle and can not be used bond
for high wheel speed. Metal bond Extensively used with super abrasive
Resinoid, or Plastic bond, replaced shellac and wheels, high toughness, high accuracy,
phenolic rubber wheels, not with alkaline large stock removal.
resins grinding fluid. Electroplated Used for small wheel, form wheel and
Shellac bond For flexible cut off wheels, replaced by bond thin super abrasive wheels, for abrasive
resin bond. milling and ultra high speed grinding.
Replace by electroplated bond
Glazing Loading/Clogging
With continuous use a grinding wheel becomes dull with Some grinding chips get lodged into the spaces between
the sharp abrasive grains becoming rounded. the grits resulting in a condition known as loaded wheel.
This condition of a dull grinding wheel with worn out Loading is generally caused during the grinding of soft
grains is termed as glazing. and ductile materials.
A loaded grinding wheel cannot cut properly and need
dressing.
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Video-5
State the basic advantage of a creep feed Cylindrical Grinding
grinder over a conventional surface Center-type cylindrical grinding is commonly used far
producing external cylindrical surfaces.
Productivity is enhanced and life of the grinding wheel is The grinding wheel revolves at an ordinary cutting
extended. speed, and the workpiece rotates on centers at a much
slower speed.
Grinding machines are available in which the workpiece
is held in a chuck for grinding both external and internal
cylindrical surfaces.
Depth of cut is more BUT Feed is low
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Centerless Grinding
Centerless Grinding
The regulating wheel controls the rotation and
longitudinal motion of the workpiece and usually is a
plastic- or rubber-bonded wheel with a fairly wide face.
The workpiece is held against the work-rest blade by the
cutting forces exerted by the grinding wheel and rotates
at approximately the same surface speed as that of the
regulating wheel.
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Honing Honing
It is desired that
1. Honing stones should not leave the work surface
2. Stroke length must cover the entire work length.
3. In honing rotary and oscillatory motions are
combined to produce a cross hatched lay pattern.
2. oscillation speed
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Super Finishing
Buffing is a finishing operation similar to polishing, in
which abrasive grains are not glued to the wheel but are
contained in a buffing compound that is pressed into the
outside surface of the buffing wheel while it rotates. As
in polishing, the abrasive particles must be periodically
Fig. super finishing of end face
replenished. Buffing is usually done manually.
of a cylindrical work piece in radial mode
Machines are also available to do buffing automatically.
Negligible amount of material is removed in buffing
In this both feeding and oscillation of the super
while a very high luster is generated on the buffed finishing stone is given in the radial direction.
surface.
The dimensional accuracy of the parts is not affected by
the buffing operation.
Super Finishing
State the specific application of a planetary
internal grinder.
Planetary internal grinders find application for grinding
holes in workpieces of irregular shape or large heavy
workpieces.
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Sand casting
Sand casting uses ordinary sand as the primary
mould material.
The sand grains are mixed with small amounts of
other materials, such as clay and water, to improve
Sequential steps in making a sand casting The mold is opened, the pattern board is drawn
A pattern board is placed between the bottom (drag) (removed), and the runner and gate are cut into the
and top (cope) halves of a flask, with the bottom side up. surface of the sand.
Sand is then packed into the drag half of the mold. The mold is reassembled with the pattern board
removed, and molten metal is poured through the
sprue.
A bottom board is positioned on top of the packed sand,
and the mold is turned over, showing the top (cope) half
of pattern with sprue and riser pins in place. The contents are shaken from the flask and the metal
segment is separated from the sand, ready for further
processing.
The cope half of the mold is then packed with sand.
Contd…
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Casting Terms
Flask: A moulding flask is one which holds the sand
mould intact. It is made up of wood for temporary
applications or metal for long-term use.
Contd…
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Pouring basin: A small funnel-shaped cavity at the top Chaplet: Chaplets are used to support cores inside the
of the mould into which the molten metal is poured. mould cavity.
Sprue: The passage through which the molten metal Chill: Chills are metallic objects, which are placed in
from the pouring basin reaches the mould cavity. the mould to increase the cooling rate of castings.
Runner: The passage ways in the parting plane through Riser: It is a reservoir of molten metal provided in the
which molten metal flow is regulated before they reach casting so that hot metal can flow back into the mould
the mould cavity. cavity when there is a reduction in volume of metal due
Gate: The actual entry point through which molten to solidification
metal enters the mould cavity in a controlled rate. Contd… Contd…
Padding Pattern
Tapering of thinner section towards thicker section
A pattern is a replica of the object to be made by the
is known as 'padding'.
casting process, with some modifications.
This will require extra material.
The main modifications are
If padding is not provided, centre line shrinkage or
The addition of pattern allowances,
porosity will result in the thinner section.
The provision of core prints, and
Elimination of fine details, which cannot be obtained
by casting and hence are to be obtained by further
processing
Contd…
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Solid shrinkage is the reduction in volume In grey cast iron and spheroidal graphite iron, the
caused, when a metal loses temperature in the amount of graphitization controls the actual
solid state. The shrinkage allowance is provided to shrinkage. When graphitization is more, the
take care of this reduction. shrinkage would be less and vice versa.
GATE-2004 GATE-2008
Gray cast iron blocks 200 x 100 x 10 mm are to be While cooling, a cubical casting of side 40 mm
cast in sand moulds. Shrinkage allowance for
pattern making is 1%. The ratio of the volume of undergoes 3%, 4% and 5% volume shrinkage
pattern to that of the casting will be during the liquid state, phase transition and solid
state, respectively. The volume of metal
(a) 0.97 (b) 0.99 (c) 1.01 (d) 1.03
compensated from the riser is
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http://nptel.ac.in/courses/112107144/metalcasting/lecture4.htm
Shake Allowance
At the time of pattern removal, the pattern is rapped
all around the vertical faces to enlarge the mould
cavity slightly to facilitates its removal.
DRAFT ALLOWANCE
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Types of Pattern
Match Plate Pattern
The cope and drag patterns along with the gating
and the risering are mounted on a single
matching metal or wooden plate on either side.
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Collapsibility: At the time of cooling, casting shrinks, and important consideration at the time of removal.
unless the core has good collapsibility (ability to decrease
in size) it is likely to provide resistance against shrinkage Smoothness: Surface of the core should be smooth
and thus can cause hot tears.
for good finish to the casting.
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Vc
A t Vt A c Vc At A c
Vt
Contd…
…3
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hc
A t Ac
ht
Where H = actual
sprue height
and ht = h + H
Pouring time
GATE-2001
Time taken to fill the mould with top gate
Where A = Area of mould The height of the down-sprue is 175 mm and its
A.H
tA H = Height of mould cross-sectional area at the base is 200 mm2. The
A g 2gh m
Ag = Area of Gate cross-sectional area of the horizontal runner is
hm = Gate height also 200 mm2. Assuming no losses, indicate the
correct choice for the time (in seconds) required to
fill a mould cavity of volume 106 mm3. (Use g = 10
Time taken to fill the mould with bottom gate
m/s2).
2A (a)2.67 (b)8.45 (c)26.72 (d)84.50
tB
A g 2g
hm hm H
GATE-2007
A 200 mm long down sprue has an area of cross
section of 650 mm2 where the pouring basin meets the
down sprue (i.e. at the beginning of the down sprue).
A constant head of molten metal is maintained by the
pouring basin. The Molten metal flow rate is 6.5 × 105
mm3/s. Considering the end of down sprue to be open
to atmosphere and an acceleration due to gravity of
104mm/s2, the area of the down sprue in mm2 at its end
(avoiding aspiration effect) should be
(a)650.0 (b)350.0 (c)290.7 (d)190.0
Contd…
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GATE-2007
Volume of a cube of side 'l' and volume of a sphere of
radius ‘r’ are equal. Both the cube and the sphere are solid
and of same material. They are being cast. The ratio of the
solidification time of the cube to the same of the sphere is:
3 6 2 2 3 2 4
4 r 4 r 4 r 4 r
b c d
a 6 l
6 l
6 l
6 l Tsp :Tcy : Tcu=1:0.763:0.649
has the same length and cross-sectional area as the risers of the same volume with one has cylindrical shape
round casting. Both pieces are cast under the same and other is parallopiped. [30 Marks]
Modulus Method
It has been empirically established that if the modulus
of the riser exceeds the modulus of the casting by a
factor of 1.2, the feeding during solidification would be D2
D2
satisfactory.
4
MR = 1.2 Mc
Modulus = volume/Surface area
In steel castings, it is generally preferable to choose a
riser with a height-to-diameter ratio of 1.
Contd…
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Caine’s Method
Conventional Question IES-2008 Freezing ratio = ratio of cooling characteristics of casting to
the riser.
Calculate the size of a cylindrical riser (height and diameter A V Casting
X
equal) necessary to feed a steel slab of long bar casting of AV Riser
dimensions 30 x 30 x 6 cm with a side riser, casting poured The riser should solidify last so x > 1
horizontally into the mould.
a
[Use Modulus Method] According to Caine X= c
Yb
[10 - Marks] Vriser
Y= and a, b, c are constant.
Vcasting
Chills
Conventional Question IES-2007 External chills are masses of high-heat-capacity, high-thermal-
Calculate the size of a cylindrical riser (height and conductivity material that are placed in the mould (adjacent to
the casting) to accelerate the cooling of various regions.
diameter equal) necessary to feed a steel slab Chills can effectively promote directional solidification or
increase the effective feeding distance of a riser. They can often
casting of dimensions 25 x 25 x 5 cm with a side be used to reduce the number of risers required for a casting.
riser, casting poured horizontally into the mould. Internal chills are pieces of metal that are placed within the
mould cavity to absorb heat and promote more rapid
[Use Caine’s Method] solidification. Since some of this metal will melt during the
operation, it will absorb not only the heat-capacity energy, but
[ For steel a = 0.10, b = 0.03 and c = 1.00 ] also some heat of fusion. Since they ultimately become part of
the final casting, internal chills must be made from the same
alloy as that being cast.
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2A
tB
A g 2g
hm hm H
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Shrinkage Cavities
These are caused by liquid shrinkage occurring during
the solidification of the casting.
To compensate for this, proper feeding of liquid metal is
required. For this reason risers are placed at the
appropriate places in the mold.
Sprues may be too thin, too long or not attached in
the proper location, causing shrinkage cavities.
It is recommended to use thick sprues to avoid shrinkage
cavities.
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Fusion Swell
This is caused by the fusion of the sand grains with Under the influence of metallostatic forces, the mold
wall may move back causing a swell in the dimension
the molten metal, giving a brittle, glassy appearance of the casting. A proper ramming of the mold will
correct this defect.
on the casting surface.
The main reason for this is that the clay or the sand Inclusions
particles are of lower refractoriness or that the Particles of slag, refractory materials sand or
deoxidation products are trapped in the casting during
pouring temperature is too high. pouring solidification. The provision of choke in the
gating system and the pouring basin at the top of the
mold can prevent this defect
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Pouring Metal Defects The mis-run and cold shut defects are caused either by
The likely defects in this category are a lower fluidity of the mold or when the section
Mis-runs and thickness of the casting is very small. Fluidity can be
Cold shuts improved by changing the composition of the metal
and by increasing the pouring temperature of the
metal.
A mis-run is caused when the metal is unable to fill
the mold cavity completely and thus leaves unfilled
cavities.
A cold shut is caused when two streams while meeting
in the mold cavity, do not fuse together properly thus
forming a discontinuity in the casting.
Contd…
Mold Shift
The mold shift defect occurs when cope and drag
or molding boxes have not been properly aligned.
Special Casting
Shell Moulding
The sand is mixed with a thermosetting resin is
allowed to come in contact with a heated metal pattern
(2000C).
A skin (shell) of about 3.5 mm of sand and plastic
mixture adhere to the pattern.
Then the shell is removed from the pattern.
The cope and drag shells are kept in a flask with
necessary backup material and the molten metal is
poured into the mold.
Shell moulding process
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Molding Sand in Shell Molding Hot coating: the mixture is heated to 150oC– 180oC
The molding sand is a mixture of fine grained quartz prior to loading the sand. In the course of sand mixing,
sand and powdered bakelite. the soluble phenol formaldehyde resin is added. The
mixer is allowed to cool up to 80 – 90o C. Hot coating
Cold coating and Hot coating methods are used for
gives better properties to the mixtures than cold
coating the sand grains with bakelite.
method.
Cold coating: quartz sand is poured into the mixer and
then the solution of powdered bakelite in acetone
and ethyl aldehyde are added. (mixture is 92% quartz
sand, 5% bakelite, 3% ethylaldehyde )
Contd…
Advantages Limitations
Dimensional accuracy. Expensive pattern
Smoother surface finish. (Due to finer size grain used) Small size casting only.
Very thin sections can be cast. Highly complicated shapes cannot be obtained.
Very small amount of sand is needed. More sophisticated equipment is needed for handling
Piston rings
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Investment Casting
Investment casting process or lost wax process
Basic steps:
1. Produce expendable wax, plastic, or polystyrene patterns.
2. Assemble these patterns onto a gating system
3. Investing or covering the pattern assembly with refractory
slurry (extremely fine grained silica, water and binder)
4. Melting the pattern assembly to remove the pattern material
5. Firing the mould to remove the last traces of the pattern
material
6.Pouring molten metal
7. Knockout, cutoff and finishing.
Advantages
Tight dimensional tolerances
Limitations Applications
Costly patterns and moulds Aerospace and rocket components.
Labour costs can be high Vanes and blades for gas turbines.
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Disadvantages Applications
High initial mold cost
Pistons/cylinders/rods
Shape, size, and complexity are limited
Mold life is very limited with high-melting-point Gears
metals such as steel.
Low melting point metals can be cast Kitchenware
- Aluminum
- Zinc
- Magnesium alloys
- Brass
- Cast iron
Die Casting
Molten metal is injected into closed metal dies under
Die casting machines can be
pressures ranging from 100 to 150 MPa.
After which the dies separate and the casting is ejected Cold chamber
along with its attached sprues and runners.
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Hot Chamber
Advantages
Extremely smooth surfaces (1 µm) Limitations
Excellent dimensional accuracy High initial die cost
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Centrifugal Casting
Applications Process: Molten metal is introduced into a rotating sand,
Carburettors metal, or graphite mould, and held against the mould
Automotive parts wall by centrifugal force until it is solidified
Bathroom fixtures
A mold is set up and rotated along a vertical (rpm is
Toys
reasonable), or horizontal (200-1000 rpm is reasonable)
Properties
The mechanical properties of centrifugally cast jobs are
better compared to other processes, because the inclusions
such as slag and oxides get segregated towards the centre
and can be easily removed by machining. Also, the
pressure acting on the metal throughout the solidification
causes the porosity to be eliminated giving rise to dense
metal.
No cores are required for making concentric holes in the
case of true centrifugal casting.
Advantages Limitations
Fine grained structure at the outer surface of the More segregation of alloy component during pouring under
casting free of gas and shrinkage cavities and the forces of rotation
porosity
Contamination of internal surface of castings with non-
Formation of hollow interiors in cylinders without
cores metallic inclusions
Can produce a wide range of cylindrical parts, Inaccurate internal diameter
including ones of large size.
Shape is limited.
Good dimensional accuracy, soundness, and
cleanliness Spinning equipment can be expensive
There is no need for gates and runners, which
Poor machinability
increases the casting yield, reaching almost 100 %.
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Centrifuging
Uses centrifuging action to force the metal from a central
pouring reservoir into separate mold cavities that are
offset from the axis of rotation.
Low speed
Types:
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Plaster Casting
Process: A slurry of plaster, water, and various additives is
Creep and thermal shock resistance properties. additives is pouted over a pattern and allowed to set. The
pattern is removed and the mould is baked to remove
excess water. After pouring and solidification, the mould is
broken and the casting is removed.
Advantage: High dimensional accuracy and smooth
surface finish, thin sections and intricate detail can
produce.
Limitations: Lower-temperature nonferrous metals only:
Common metals: Primarily aluminium and copper
It is costly.
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