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Casting
Process in which molten metal flows by gravity or
other force into a mold where it solidifies in the
shape of the mold cavity
The term casting also applies to the part made
in the process
Steps in casting seem simple:
1. Melt the metal
2. Pour it into a mold
3. Let it freeze
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Disadvantages of Casting
Different disadvantages for different casting
processes:
Limitations on mechanical properties
Poor dimensional accuracy and surface
finish for some processes; e.g., sand
casting
Safety hazards to workers due to hot molten
metals
Environmental problems
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Solidified Cast
Part
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vent
Gate
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Cope Vent
Drag Riser (Reservior)
Pattern Parting Line
Core Flask
Sprue Green Sand
Runner Dry Sand
Gate Cheek
Pouring Basin
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Gating System
Channel through which molten metal flows into cavity from
outside of mold
Consists of a downsprue, through which metal enters a
runner leading to the main cavity
At the top of downsprue, a pouring cup is often used to
minimize splash and turbulence as the metal flows into
downsprue
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Riser
Reservoir in the mold which is a source of liquid metal
to compensate for shrinkage of the part during
solidification
The riser must be designed to freeze after the main
casting in order to satisfy its function
Near Top
Sprue Diameter, d1
Diameter Velocity, V1
Height, h
Bottom
Diameter, d2
Velocity, V2
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Sprue Diameters
A1V1 A2V2
d12 d 22 d12V1 d 22V2
V1 V2
4 4
V1
d2 d1 NOTE: V2 > V1 so d2 < d1
V2
Thus diameter decreases from top to bottom
Sprue Height
At 1, Total Energy, E1
1
E1 PE KE
1 2
E1 mgh mv1
Height
(h)
2
v1 0 (pouring) – In the basin
2
Thu E1 mgh
s
1
At bottom E2 mgh mv22 h0
2
1 2
E 2 mv2
2
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Conservation of Energy
E1 E 2
1 2
mgh mv2
2
v2 2 gh h can be calculated if ν2
is known
Desired Area at Base of Sprue
Q Q
Ab OR Ab
V2 2 gh
2
1 Q
h
2 g Ab
Volume Poured
MFT
Q
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Heat Required
H s mcs T
Temp H s mcs Tm T0
Tp
L
Tm S+L
S
To
Time
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Example 1- Heating
Disc, D = 40 cm Thickness, t = 5 cm
Pure Aluminum; Latent heat, hf = 389.3 J/kg
t Specific Heat, Cs = 0.21 Cal/g-oC
D Cl = 0.21 Cal/g-oC
Density ρ = 2.70 g/cm3
Temperatures: To = 25 C Tm = 660 C Tp = 800 C
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Solidification of Metals
Transformation of molten metal back into solid
state
Solidification differs depending on whether the
metal is
A pure element or
An alloy
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Solidification of Alloys
Most alloys freeze over a temperature range
rather than at a single temperature
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Solidification Time
Solidification takes time
Total solidification time TTS = time required for
casting to solidify after pouring
TTS depends on size and shape of casting by
relationship known as Chvorinov's Rule
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Chvorinov’s Rule n
V
Total Solidification Time, TST, TST Cm
Where V = Volume of Casting
A
A = Surface Area of Casting exposed to Mold and Cores
1. Cube
V a3 A 6a 2
a
V a
Modulus,
a
a
A 6
2. 4
Sphere a
V a 3 A 4a 2
3
V a
Modulus,
A 3
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V r 2 h
A 2rh 2r 2
h
r1 r2
V r22 r12 h
h
A = Exposed Area
A 2r2 h 2r1h 2 r22 r12
(a)
r
r1 r2
h
t h
w (b)
t
b
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Riser Design
V TST 2
Solve
A riser Cm
Cylindrical Riser
Modul
D 2 h
4
TST 2
1
D
D 2 C
us of Dh m
4 riser
Solid h
Cylind
er: Determine D/h ratio.
Put D in terms of h, solve for h
OR
Using D/h ratio and knowing h,
solve for D
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Spherical Riser
1
a TST 2
a
3 C
m
A steel casting has a cylindrical geometry with 4.0 in diameter and weighs 20
lb. This casting takes 6.0 min to completely solidify. Another cylindrical-
shaped casting with the same diameter-to-length ratio weighs 12 lb. This
casting is made of the same steel and the same conditions of mold and
pouring were used. Determine: (a) the mold constant in Chvorinov's Rule; and
(b) the dimensions, and (c) the total solidification time of the lighter casting.
Note: The density of steel = 490 lb/ft3.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
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©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
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Solidification Shrinkage
Occurs in nearly all metals because the solid
phase has a higher density than the liquid
phase
Thus, solidification causes a reduction in
volume per unit weight of metal
Exception: cast iron with high C content
Graphitization during final stages of freezing
causes expansion that counteracts
volumetric decrease associated with phase
change
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Shrinkage Allowance
Patternmakers account for solidification
shrinkage and thermal contraction by making
mold cavity oversized
Amount by which mold is made larger relative
to final casting size is called pattern shrinkage
allowance
Casting dimensions are expressed linearly, so
allowances are applied accordingly
Pattern Allowances
Pattern: A replica of the part to be cast and is used to prepare the mold.
It is made either of wood or metal. Metals: Al, Mg, commonly used.
It is made somewhat larger than the final part for various reasons.
This excess in dimensions is referred to as “pattern allowance”.
Shrink Rule: A special ruler with the expansion added to the dimensions
Regular Rule – 1 ft
Shrink Rule
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1. Shrinkage Allowance:
A linear allowance added to the dimensions to
compensate for contractions of the casting.
Liquid Solid (Room Temp)
Solid (Freezing
Temp)
Desired Part
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Directional Solidification
To minimize damaging effects of shrinkage, it is
desirable for regions of the casting most distant
from the liquid metal supply to freeze first and
for solidification to progress from these remote
regions toward the riser(s)
Thus, molten metal is continually available
from risers to prevent shrinkage voids
The term directional solidification describes
this aspect of freezing and methods by
which it is controlled
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External Chills
Group Project
Identify any machine component that is (or could be)
manufactured using sand casting. Then describe in detail
with the aid of suitable diagrams how the identified
machine component is shaped using sand casting
technique. Your response must include the following:
1. Justification for the suitability of sand casting for the
identified machine component,
2. Design and making of the pattern,
3. Preparation of the mould,
4. Design of the sprue and riser,
5. Trimming, cleaning, inspection, machining, and heat
treatment of the solidified cast machine component.
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