CASTING PROCESS Introduction to casting processes, Pattems : Pattern materials, types of pattern, allowances patter design, Moulding sand, Properties of moulding sands, Core making, Melting practices and furnaces, Pouring and Gating system design, Numerical estimation to find mold filing time, Riser design and placement, Principles of cooling and solidification of casting, Directional and Progressive soliditication, Estimation of solidification rate, Cleaning anid Finishing of casting, Detects and remedies, Principle and ‘equipments of Permanent (or Pressure Die) mould casting, Investment casting, Centrifugal casting, Continuous casting 1.1 Introduction to Manufacturing Process 143 Risers in Casting 1.2 Types of Manufacturing Process 1.14 Principles of Cooling and Solidification of. Castings 13 Introduction to Casting Process 14 Pattern 145 Solidification Shrinkage 15 Moulding Materials 1.16 Directional and Progressive Solidification 16 Moulding Sand 4.17 Heating of Molten Metal 17 Moulding 1,18 Pouring of Molten Metal 1.19 Cleaning and Finishing, Defects and Remedies, 18 Types of Moulding Methods Inspection Techniques 19 Moulding Equipment’s 1.20 Casting Process 140 Core 1.21 Metals used for Casting 4111 Melting Practices and Furnaces 1.22. 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We ain eed fr fi ~ alam re, ¢ = Thay manne V = Yolen? Seon tethering moles tli ed nae Se Grote araae oxen seen S vectra Sanna set a wn cen acme toe ” ee age ‘eta nr pst atmo LET neanatnment " 7 Cte hae ot ma ay 5 Wve rae rat sen «rh thane arta VishwaBE Manufacturing Processes (SPPU) 1-55 Casting Process soln: Given: case2 Fig. P.2.13.13 caset: Side of Cube = 2 Volume of Cube = V1 Surface Area of Cube = SA: ‘According to Chvorinor’s rule, we Solidification time fora cube, = oH, case2: Now, Side of Cubeisincreased by 30% = 13a New Volume of Cube = Vz=13Vi New Surface Area of Cube = SAz=1.3 SA: New Solidification time fora cube = t,= c@ SA), v But, &), - (3%), Therefore, b cf ec(sa2)f nore 20, sam. 1.14 Principles of Cooling and Solidification of Castings aoe ‘Solidificatic ick Into solid state, Study of Soliaification| Q After pouring the molten metal in mould, the molten metal cools and solidifies. As soon as the molten metal is poured in a sand mold, the process of solidification starts. During solidification, cast | forms develops cohesion and acquires structural characteristics, The mode of solidification affects the properties | of the casting acquires a metallographic structure which Is determined during solidification, The metallographic structure of casting consists of following parameters : 1) Grain size, shape and orientation. 2) Distribution of alloying elements. (Copyright Reg, No. L-98621/2021) weening re 11.6 Directional and Progressive Soldication 2 ree ote nn hho ee ° es one mun decor erase emi reegner pnt a pe rg eon a afore ae Ty wc gunna anne moe Ty nt 2 tea ne EN caret gaa nA wy amo eet : pe sence eussionctene tment tint me mea : cat 1am Sax, a 1 Tedd neta pg tpete M5 Rettemicpe hp atacand Vane 2 tm ean i 3 menage i eas ee 1 Factor Acting Pog ten at Sickest tg near rena ‘sar suhag hemi yee ont ne ‘Satncnongnne = rn rai ee ne et an iy el here, + Pesaran pone fat, Lien, = Sete oatoa arg Re ERT& wongectarng Process SPY a sting Pr Ex. 1.18.1 + A 200 mm long down sprue has an area of cross section 650 mm? where the pouring basin meets the down sprue. A constant head of molten matal is maintained by the pouring basin. The molten head flow rato is 65 x 108 mY. Consdering the ond of tha down sor tobe open to atmosohara and accelaraton dv to gravy as 10 move? at ts ends find he area of he spun atthe end Soin, Given: Areaof sprue, A, = 650mm? Height of sprue, Hl = 200mm Flow rate, Q = 65x 105 mm?/s Acceleration due to gravity,g = 10* mm/s? Area f sprue tend, A, = ? From continuity equation, = AVF ALY, igh =[2x10%200 2x10? mm/sec Also, ie AkV, 65010 = A,x2x10? A, = 325mm* Ans. 1.19 Cleaning and Finishing, Defects and Remedies, Inspection Techniques ‘Once the casting operations is completed and the product is taken out from the mould cavity. It requires to be leaned and machined properly to make it suitable for application. There are impurities such as sand particles, abrasives, resins etc. attached to the parts. These are removed and cleaned by machines or manually 1.19.1 Some Common Method used for Cleaning and Finishing ‘Some common methods used for cleaning and finishing are as follows : 1. Sand or Water Blasting 2. Grinders 3. Sand or Emily paper 4. Cut off Machines 5. Ultrasonic Machines 6. Vibratory Machines 1. Sand or Water Blasting : High pressure water jet or sand mixed with high compressed air is applied on the castings to remove the abrasives and clean the surfaces. 2. Grinders : Grinders can be either machine operated or hand operated. The grinding machines have metal or non- metal grinders depending on requirements. The grinders are used to remove sand, epoxy, resins from the casting, surface and give good surface finish. The operation with grinders are more controlled, it can also be used after Sand or water ballasting for surface finish. (Copyright Reg. No. L-98621/2021) Pree»* ren nt ee _ gy 8 HE 0 a oie soe Sa emag cee ete te en sed annie wae. tn, ce ae ae natn ane ae min et cc eT ct net of ton reac mc etd me TS an dan a oa Lei natemm ed eg sine epee ‘ange ey eae cence oa pet fr ay dee (Magee Pre Tet Th ped ofr bad mas. 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