Kwame Nkrumah University of

Science & Technology, Kumasi, Ghana

ME 270
CASTING
GROUP 20
 Kwame Nkrumah University of
Science & Technology, Kumasi, Ghana

CONTENTS

• Justification for the suitability of sand casting for the connecting

rod
• Design and making of the pattern
• Preparation of the mould
• Design of the sprue and riser
• Post-processing
Justification for the suitability of
sand casting
The connecting rod is sand cast because;
• Sand casting is suitable for complex parts if the
correct cores/gating system are used.
• The process is highly adaptable and can be
implemented in the mass production of the parts
• Sand casting has a low set-up cost and is cost-
effective to modify

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Design and making of the pattern
PATTERN MAKING PROCESS
Pattern making is one of the first and most
important steps in the casting process. Usually made
out of wood, metal or model board, patterns are
used to create cavities in moulds. Allowances must
be built into the pattern such as:
• Draft
• Shrinkage allowance
• Distortion allowance
• Machining allowance

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Systems will also be needed for connecting rod patterns such as:
1. Pouring cup
2. Sprue and runner
3. Gate(added with separate pattern pieces)
4. Riser

Common tools used by a pattern maker:

• Cutting tools: chisel, hammer, saw, driller
• Measuring tools
• Boring tools
• Holding tools: bench vice
• Miscellaneous tools

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 Preparation of mould
1. Get a 2-piece mold frame.
2. Place the pattern of the connecting rod to be cast in 1 of
the mold frames.
3. Cover the top of the connecting rod with parting dust.
4. Dampen and toss molding sand to create a molding paste.
5. Fill the cast with molding sand.
6. Tamp the sand down and scrape off any excess.
7. Flip your mold over and place the other half frame on top.
8. Repeat the process with the other side of the mold.
9. Create a sprue hole using a dowel rod.
10.Cut a gate between the connecting rod and sprue hole.

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11. Make riser holes to contain excess metal.
12. Remove the connecting rod carefully.
13. Join both frame pieces together after you’ve
removed the connecting rod

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 Design of the sprue and riser
Sprue Design
Assuming the sprue is 10cm long and the cross-sectional area at its base is
1.5cm2
The velocity of the flowing metal at the base of the sprue is given by v =
√(2gh)
v= 2 981 5 = 99.04 cm/s
The volumetric flow rate is Q = A2V2
Q = (1.5)(99.04) = 148.6 cm3/s
Time to fill the mould cavity =
TMF = 52.05/148.6 = 0.35s

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Sprue Design
A cylindrical riser is selected since it would have a longer solidification time.
Considering the solidification time of the mold to be 4 minutes The ideal solidification
time required for the riser should be 25%greater than that of the mold solidification
time which is equal to 5 minutes

Volume of cast is assumed to be the same as the volume of the connecting rod
Given:
Ideal solidification time for riser = 5 minutes
Riser height = 5 cm = 0.05 m
Chvorinov’s constant, = 4.0 min/cm2

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Mold constant, n = 2 since this is an expendable mold
The diameter of the riser is calculated using, Time for solidification =
𝑉
Cm(𝐴)n
( . )
4 52 05
5 = 4( 𝜋𝑑 2 )
( . )
16 52 05
d=√ 25𝜋 = 3.3 cm

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 Post-processing of the cast
TRIMMING
Trimming involves the removal of the riser, gate, sprue, runner and excess
part which do not form part of the final casting. Trimming can be done with
the use of a file, sand machine, grinder or any cutting machine.

CLEANING
Cleaning is performed to remove burned-on, scaling, excess metal particles
and extraneous materials from the casting. Due to sticky sand and
roughness, life of casting decreases, hence it is necessary to clean the
casting. Cleaning methods include either using a shot blast with steel shot,
grit blast with an iron free medium or a mass finishing machine. In the case
of a finishing machine, a tumbling media (plastic tumbling media) is added
which is responsible for cleaning, deburring, degreasing, surface smoothing
and polishing. Air grinders are also used for hand cleaning of casting.

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INSPECTION

Casting inspection methods are used in place to ensure that all

hidden defects are identified during the manufacturing process.
Surface , inclusion , and cooling detects are some common
casting defects. Inspection methods include;
1. Visual inspection .
2. Dimensional inspection ( multi inspection bench can be used
for testing straightness, roundness, positions,as well as taper
and out-of-round in bearing bore).
3. Radiographic inspection.

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MACHINING
Machining is any process in which a cutting tool is used to
remove small chips of material from the component. It brings
out the final detail of the casting. Turning, milling, and drilling
are the three main kinds of machining processes. Connecting
rod machining process include,
• Machining of the screw head location flat with a solid
carbide milling cutter.
• Pre-drilling and chamfering with a solid carbide step drill.
• Drilling of a thread core bore with a solid drill.
• Pre-drilling, chamfering and drilling of the thread core with a
single-shot solid carbide step drill.
• Boring of the small end bore .
• Boring and milling of large end bore.
• Reaming of the small and large end bore hole
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HEAT TREATMENT

Heat treatment is a controlled process used to alter the

microstructure of the casting. Heat treatment process are used
to increase surface hardness, strength, ductility and
temperature resistance. The kind of process to use depends on
the kind of metal used for the casting and the function or
purpose of the casting. Due to the properties of connecting rods
such as high strength, uniformity of mass etc, hardening,
tempering and carburizing heat treatment processes can be
used

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THANK YOU

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