Casting : A liquid material is usually poured into a mold, which

contains a hollow cavity of the desired shape, and then allowed

to solidify.
OR
Metal or plastic is heated till is molten and sufficient hot so that
it will remain in liquid state till mould is filled up.
Casting process steps:
• Prepare a mould cavity of the shape you want to cast.
• Get the material into molten state.
• Pour it into the mould.
• Allow it to cool so that it becomes solid and cools to handleable
temperature.
• Take the casting out of the mould.
• Remove the runners and riser and clean the casting.
• Pattern: Replica of object/component to be made. Mold
cavity is made with the help of pattern.
• Physical model of the casting used to make the mold.
• Molding usually involves placing a molding aggregate around
a pattern held with a supporting frame, withdrawing the
pattern to leave the mold cavity, setting the cores in the mold
cavity and finishing and closing the mold
• The preparation of molten metal for casting is referred to simply
as melting. Molten material like Al, Fe3C, Brass, Cu, Silver,
Gold, plastic, metal, ceramics.
• Melting is usually done in a specifically designated area of the
foundry, and the molten metal is transferred to the pouring area
where the molds are filled.
• Cleaning: Excess metal, in the form of fins, wires, parting line
fins, and gates, is removed. Inspection of the casting for defects
and general quality is performed.
The generally used methods of casting processes are listed as
follows.
• Sand mould casting
• Die casting
• Centrifugal casting
• Investment casting
• Shell mould casting
• Forge casting
• The sand casting is a way of foundry in sand mold casting
method. Steel, iron and most of the nonferrous metals, about
90% of the casting products are made by sand casting.
https://youtu.be/pwaXCko_Tkw
 MACHINE TOOL STRUCTURES
During 3200 BC

SIDE FRAMES OF RAILWAY

ENGINE BLOCK MOTOR CASING

CASTED SIDE FRAME

SIDE FRAME ABOVE 2 AXLES
 DUMBELLS Pump Housing
CASTED IMPELLERS

CONNECTING ROD C-clamps formed Intricate shapes can be made

Advantages
• Molten metal flows into any small section in mold cavity prepared.

• Intricate shapes can be made.

• Flexibility of size & shape.

• Any material can be casted.

• Tools used are very simple & inexpensive.

• Wastage of raw materials is less.

• Certain metals and alloys can only be processed by castings.

Disadvantages
• Labor intensive process.

• Dimensional accuracy is poor.

• Surface finish is not high.

• Sand moulds can be used only once.
• Mould is destroyed.
• Sand moulds though cheap, cannot maintain the tolerance and smooth
surface finish.
• When ever conventional sand casting can’t produce good results there
special casting techniques (permanent/ metal molds) are used.
• Advantages of Die, Centrifugal, Investment, Shell mould , Forge
• Greater dimensional accuracy.
• Higher metallurgical quality.
• Good surface finish
• High production rates.
• Lower production cost.
• Low labor and finishing costs.
• Stronger & more ductile.
• Die casting: A sand mould is usable for production of only one casting.
It cannot be used twice. Die is essentially a metal mould and can be
used again and again.

• Die is usually made in two portions. One portion is fixed ,other is

movable. Together, they contain the mould cavity in all its details. After
clamping or locking the two halves of the dies together molten metal is
introduced into the dies.

• Die casting is used for mass production of lead, tin, magnesium, zinc
alloys where accurately dimensioned parts are required.

• Dies used are made of hot work die steels, chrome tungsten steel.

• Motors, machine components, hand tools, toys .

• Weight of components are 90 gms to 25 kg.

Centrifugal casting
• A permanent mold is rotated about its axis at high speeds (300 to 3000
rpm) as the molten metal is poured.Uses forces generated by centripetal
acceleration to distribute molten metal into mold.

• fine grain casting with a very fine-grained outer diameter, which is

resistant to atmospheric corrosion.

• Grey cast iron, cast steel, stainless steels, and alloys of aluminum,
copper and nickel.

• cylindrical bodies such as C.I water supply lines, gas pipes, steel gun
barrels, liner for engine cylinders, pressure vessels, other objects such
as gears, disc wheels, pulley.

• Very large castings (length 10 m, dia. 1.8 m, wt. 3.5 tones) are casted.
Centrifugal casting components
Investment casting
• Ferrous & non ferrous metals with close dimensional
tolerances.
• High precision intricate shapes, light parts (1 gm to 35 kg).
• jewellery, surgical instruments.
• vanes, blades for gas turbines, bolts & triggers for fire arms, steel
valve bodies, sewing machine parts, typewriters.
• It uses a wax pattern which is coated with refractory materials to
form a mold.
• Wax is then melted out and mold cavity is filled with molten
metal.
• Cast metal is cooled and then slurry is broken to get the castings.
Investment casting components
Shell casting
• The silica sand is mixed with thermosetting resin is allowed to come
in contact with heated metal plate.
• As a result thin & strong shell of mold is formed around pattern.
• Shell is removed from pattern and cope & drag are removed together
and kept in flask.
• Molten metal in then poured in to mold.
Forge casting: The metal or alloy at a temperature near the
solidus temperature is poured into die cavity and is pressed
between two dies. At that temperature the yield strength is
extremely low and metal easily flow and deformation into fine
cavities of dies.
FORMING:
Large group of manufacturing processes in
which plastic deformation is used to change
the shape of metal workpieces.
• The tool, usually called a die, applies stresses
that exceed the yield strength of the metal.
• The metal takes a shape determined by the
geometry of the die.
• Metal is heated, slightly below the solidus
temperature.
• Large force is applied.
• Desired shape is roll
A d

A o
controlled by tools.
roll
• Large scale
Solid State Manufacturing Process:
Material Properties in Metal Forming:

• Desirable material properties:

– Low yield strength
– High ductility
• These properties are affected by temperature:
– Ductility increases and yield strength decreases when work
temperature is raised
• Other factors:
– Strain rate and friction
Basic Types of Deformation Processes:

1. Bulk deformation
– Rolling
– Forging
– Extrusion
– Wire and bar drawing
2. Sheet metalworking
– Bending
– Deep drawing
– Cutting
Rolling :

Basic bulk deformation processes: rolling

Forging :
 27

Extrusion :

Basic bulk deformation processes: (c) extrusion

 28

Wire and Bar Drawing :

Basic bulk deformation processes: (d) drawing

 29

Sheet Metal Working :

• Forming and related operations performed on
metal sheets, strips, and coils
• High surface area-to-volume ratio of starting
metal, which distinguishes these from bulk
deformation
• Often called pressworking because presses
perform these operations
– Parts are called stampings
– Usual tooling: punch and die
 30

Sheet Metal Bending :

Basic sheet metalworking operations: bending

 31

Deep Drawing :

Basic sheet metalworking operations: drawing

 32

Shearing of Sheet Metal :

Basic sheet metalworking operations: shearing

JOINING PROCESS