Maharashtra State Board of Technical

Education
Government Polytechnic College, Murtizapur
Mechanical Engineering Department
2023-2024

Topic Name:-

Prepare a cast product of piston and connecting rod with wax

material

Subject :-

Manufacturing Processes

Subject Code :- 22446

Sub. Teacher :- M.M.Ghulaxe

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 MAHARASHTRA STATE
BOARD OF TECHNICAL EDUCATION

Certificate
This is to Verify That
Mr./Miss………………………………………………...

Roll No… of Forth Semester of Diploma in Mechanical

ENGINEERING of Institute of GOVERNMERNT POLYTRCHNIC
MURTIZAPUR (code:.1241) has completed the Micro-Project
Satisfactory in course Manufacturing Processes (MPR)for the academic
year 2024-2025 as prescribed in the curriculum.

Place…………………. Enrollment no…………………...

Date…………………. Exam Seat No.………………….

Course Teacher Head of the Department Principal

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 Submitted by
Sr.No. Roll Enrollment No. Name
No.

1) 61 23410260528 Tanushri Sunil Shinde

2) 62 23410260529 Purvesh Gopalrao Mugal

3) 63 2212410295 Kartik Ramesh Ghayawat

4) 64 2212410310 Mansi Rajesh Khanzode

5) 50 23410260517 Dhammshil Gajanan Khirade

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 Index

Sr. No. Topic Page No.

1. Aim of the Micro-Project 5

2. Resources Required 5

3. Brief Introduction 6

4. 7
TYPES OF WELDING JOINTS.

5. 11
Advantages and Disadvantages.

6. 13
USE OF WELDING JOINT IN INDUSTRIES.

7. Conclusion 15

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 8. References 16

 Aim of the Micro-Project

The aim of this microproject is to create a small-scale cast product of a
piston and connecting rod using wax material and the investment casting
process. This project serves as an educational exercise to understand the
basics of investment casting and to produce a tangible example of a
complex mechanical component.

Resources Required

S.No Name of Resource/material Specifications Qty Remarks

1. Wax - 1 Ok

2. Modeling Material - 4 Ok

3. Metal Alloy 25mm 10 Ok

Sprue Material - 6 Ok

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 Brief Introduction

The production of mechanical components through casting processes has

been a cornerstone of manufacturing for centuries. Among these methods,
investment casting stands out for its ability to create intricate and detailed
parts with excellent dimensional accuracy. In this microproject, we embark
on the journey of creating a cast product of a piston and connecting rod
using wax material and the investment casting technique.

Investment casting, also known as lost-wax casting, involves the creation

of a wax pattern, which is then surrounded by a ceramic mold. Once the
mold is formed, the wax is melted out, leaving behind a cavity into which
molten metal is poured. After solidification, the ceramic mold is broken
away, revealing the cast metal component.

The piston and connecting rod are vital components in internal combustion
engines, converting linear motion into rotational motion. By undertaking
this microproject, we aim to not only explore the intricacies of investment
casting but also to produce tangible examples of these essential mechanical
parts. Through hands-on experience, we will delve into the intricacies of
wax injection, mold preparation, metal casting, and finishing techniques.

This microproject serves as an educational endeavor, providing participants

with practical insights into the manufacturing process while fostering
teamwork, problem-solving skills, and an appreciation for the artistry and
precision involved in producing complex mechanical components.
Through collaboration and dedication, we aim to achieve a successful

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 outcome, culminating in the creation of high-quality cast pistons and
connecting rods.

TYPES OF WELDING JOINTS.

Certainly! There are two main types of investment casting methods

commonly used in industry: traditional investment casting and lost foam
casting. Here's a brief overview of each:

1. Traditional Investment Casting:

**Process:**

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 1. **Pattern Creation**: A wax pattern of the desired part (in this case, the
piston and connecting rod) is created using an injection molding process.
2. **Assembly**: The wax patterns are attached to a central wax sprue to
form a tree-like structure.
3. **Investment**: The wax assembly is coated with a ceramic slurry and
then covered with a fine ceramic material called stucco. This process is
repeated several times to build up a thick ceramic shell around the wax
pattern.
4. **De-Waxing**: The ceramic shell is heated to melt out or "burn out" the
wax, leaving behind a cavity in the shape of the original wax pattern.
5. **Casting**: Molten metal is poured into the cavity created by the
removed wax.
6. **Cooling and Solidification**: The metal solidifies within the ceramic
mold.
7. **Shell Removal and Finishing**: After cooling, the ceramic shell is
broken away, revealing the cast metal part. The part is then cleaned and
finished as necessary.

**Advantages:**
- Suitable for complex shapes and intricate details.
- High dimensional accuracy and surface finish.
- Can accommodate a wide range of metals and alloys.

**Disadvantages:**
- Time-consuming process.
- Expensive setup and tooling costs.

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 - Limited to smaller production runs.

2. Lost Foam Casting:

**Process:**
1. **Pattern Creation**: A foam pattern of the part is produced by molding
or carving.
2. **Foam Assembly**: The foam patterns are attached to a sprue to form a
cluster.
3. **Coating**: The foam cluster is coated with a refractory coating to create
a shell.
4. **Mold Assembly**: The coated foam cluster is placed in a flask, and
loose sand is packed around it.

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 5. **Pouring**: Molten metal is poured directly into the mold, vaporizing
the foam pattern and filling the cavity left behind.
6. **Cooling and Solidification**: The metal solidifies within the sand
mold.
7. **Mold Breakout and Finishing**: After cooling, the sand mold is broken
away, revealing the cast metal part. The part is then cleaned and finished as
necessary.

**Advantages:**
- Lower tooling costs compared to traditional investment casting.
- Can produce larger parts and larger production runs.
- Minimal machining required due to close tolerances achieved.

**Disadvantages:**
- Limited to simpler part geometries.
- May have lower surface finish compared to traditional investment
casting.
- Requires precise control of foam pattern production and handling
to avoid defects.

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 Both traditional investment casting and lost foam casting offer
unique advantages and are suitable for different applications
depending on the complexity of the part, production volume, and
specific requirements of the project
Advantages and Disadvantages.

1.Advantages.

1. Complex Geometry: Investment casting allows for the creation of

intricate and complex shapes, making it suitable for producing detailed
components like pistons and connecting rods with precision.

2. Dimensional Accuracy: The investment casting process yields parts

with excellent dimensional accuracy and surface finish, reducing the need
for extensive machining and finishing operations.

3. Material Versatility: Wax material can be easily molded to create

patterns of various sizes and shapes, offering versatility in design and
production.

4. Cost-Effective for Small Batches: Investment casting is cost-effective

for producing small to medium-sized batches of components, making it
suitable for prototype development and low-volume manufacturing.

5. Reduced Material Waste: Investment casting minimizes material

waste compared to traditional machining methods since it utilizes only the
amount of metal needed to fill the mold cavity.

6. Enhanced Design Freedom: Wax patterns can be modified or

replicated quickly and easily, allowing for design iterations and
customization without significant tooling costs.

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2.Disadvantages.

1. Time-Consuming Process: Investment casting involves multiple steps,

including pattern creation, mold preparation, casting, and finishing,
which can be time-consuming compared to other manufacturing
methods.

2. High Initial Investment: Setting up an investment casting facility

requires significant initial investment in equipment, molds, and
infrastructure, which may not be feasible for small-scale operations.

3. Limited Material Choices: While investment casting supports a wide

range of metal alloys, certain materials may not be suitable for this
process due to their melting and casting characteristics.

4. Surface Defects: Surface defects such as porosity, shrinkage, and

surface irregularities may occur during the casting process, requiring
additional inspection and corrective measures.

5. Mold Complexity: Creating intricate ceramic molds for investment

casting can be challenging and requires skilled craftsmanship and
attention to detail.

6. Environmental Considerations: Investment casting involves the use

of materials and processes that may have environmental impacts, such
as the generation of waste materials and energy consumption during
melting and casting.

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USE OF a cast product of piston and connecting rod with
wax material IN INDUSTRIES.

The production of cast pistons and connecting rods using wax material and the
investment casting process finds widespread application across various
industries, particularly in automotive, aerospace, and industrial machinery.
Here's how these cast components are utilized:

1. **Automotive Industry**:
- **Engine Manufacturing**: Cast pistons and connecting rods are integral
components of internal combustion engines. They play a crucial role in
converting fuel energy into mechanical motion.
- **Performance Enhancement**: Investment casting allows for the creation
of complex geometries and lightweight designs, leading to improved engine
performance, fuel efficiency, and reduced emissions.
- **Customization**: Investment casting enables the production of custom-
designed pistons and connecting rods tailored to specific engine
configurations and performance requirements.

2. **Aerospace Industry**:
- **Gas Turbines and Jet Engines**: Cast pistons and connecting rods are
utilized in gas turbines and jet engines, where they endure extreme
temperatures, pressures, and dynamic loads.

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 - **Weight Reduction**: Investment casting facilitates the production of
lightweight components with intricate cooling passages and aerodynamic
profiles, contributing to enhanced aircraft performance and fuel efficiency.
- **High Precision**: Investment casting allows for the creation of parts
with tight tolerances and complex internal features, meeting the stringent
requirements of aerospace applications.

3. **Industrial Machinery**:
- **Power Generation**: Cast pistons and connecting rods are utilized in
various industrial machinery, including compressors, pumps, and generators,
where they withstand high temperatures and pressures.
- **Durability and Reliability**: Investment casting produces parts with
excellent metallurgical properties, such as high strength, corrosion resistance,
and fatigue resistance, ensuring long-term durability and reliability in
demanding industrial environments.
- **Cost Efficiency**: Investment casting offers cost-effective solutions for
producing small to medium-sized batches of complex components, allowing
manufacturers to achieve economies of scale and competitive pricing.

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 CONCLUSION.

In conclusion, the journey of creating a cast product of a piston and connecting

rod using wax material and the investment casting process has been both
enlightening and rewarding. Through meticulous planning, precise execution,
and collaborative effort, we have successfully navigated the intricate steps of
this manufacturing technique..

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 REFERENCES.

1.www. Wikipedia.com
2. www.Educationmaster.com
3. www.Sciencedrict.Com
4. .https://chat.openai.com/
5.Reference book.

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