CENTRIFUGAL CASTING PROCESS

INTRODUCTION: In this process, the mould is rotated rapidly about its central axis as the metal is poured into it. Because of the centrifugal force, a continuous pressure will be acting on the metal as it solidifies. Magnitude of centrifugal force produced by rotation is large compared with normal hydrostatic forces and is utilized in two ways. 1) The first of these is seen in pouring, where the force can be used to distribute liquid metal over the outer surfaces of a mould. This provides a means of forming hollow cylinders and other annular shapes. 2) The second is the development of high pressure in the casting during freezing. This, in conjunction with directional solidification, assists feeding and accelerates the separation of non-metallic inclusions and precipitated gases. Since the metal is always pushed outward because of centrifugal force, no core needs to be used for making the concentric hole. The mould can be rotated about a vertical, horizontal or an inclined axis or about its horizontal and vertical axes simultaneously. The length and outside diameter are fixed by the mould cavity dimensions while the inside diameter is determined by the amount of molten metal poured in the mould. This process is normally used for making the hollow pipes, tubes, hollow, bushes etc. Mould material is determined partly by shape and partly by the number of castings required. For simple shapes, metal moulds are usually preferred on economic grounds as well as for their effect in inducing directional freezing. These can either be wholly of steel or of cast iron supported in a steel shell. They are used with various types of coating for protection and ease of stripping: coatings range from refractory slurries to dry powdered dressings containing graphite, ferrosilicon and other substances, which serve both to insulate and inoculate. For more complex shapes or for parts required in small quantities, refractory moulds are normally used: these may be based on high strength conventional moulding mixtures or on investments. Graphite moulds have also been used for special applications.

TYPES OF CENTRIFUGAL CASTING: 1. True Centrifugal Casting 2. Semi Centrifugal Casting 3. Centrifuge Casting

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TRUE CENTRIFUGAL CASTING:

In True centrifugal, Without a central core, the mould assembly is rotated about its central axis, the cooling takes place from periphery toward the central axis. The widest application of centrifugal casting is for the production of components which are essentially cylindrical and therefore suitable for casting by the open bore or true process. True centrifugal casting is also used for the manufacture of plain cylindrical blanks or pots for the production of rings, bushes and other annular components by machining. The casting of a plain pipe or tube is accomplished by rotation of a mould about its own axis, the bore shape being produced by centrifugal force alone and the wall thickness determined by the amount of molten metal poured. The rotational axis may be horizontal, vertical or inclined Horizontal is very common Casting cools and solidifies from outside toward the axis of rotation thereby providing condition which setup directionally solidification to produce casting free from shrinkage. These types of castings may be produce in metal or sand mould coated with refractory material, depending largely upon the quantity desired.

Semi Centrifugal Castings In the case of a component of varying internal diameter or irregular wall thickness such sections are produced by incorporation of a central core may be used to form the internal contours, feeder heads then being introduced to compensate for solidification shrinkage. Semi centrifugal castings are generally made by vertical machine. The mould cavity arranged within the mould so that its centrifugal axis is vertical and concentric with the axis of rotation.

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This method is also employed for making large sized castings which are symmetrical about their own axis. Mould rotates about a vertical axis in a properly balanced state, the metal is poured into a central spur from where it first enters the hub and then is forced outwards to the rim by centrifugal force. Owing to bulk of mould and the tendency of molten metal to spurt out of the mould joint. the spinning speeds used are lower than in the case of centrifugal casting. Since the speed are low high pouring pressure are not developed and the impurities are not effectively separated from metal. The semi centrifugal casting is spun about its own axis, but does not have a centrally located core and solidification Proceeds from the central axis towards periphery as well as from periphery towards the central axis. In order to accomplish directional solidification takes place from maximum outside diameter of the casting toward the centre, it is necessary to resort to the use of pads, auxiliary gates or chills.

Centrifuge Casting Process: Parts not symmetrical about any axis of rotation may be cast in a group of moulds in a circle to balance each other. The axis of mould and that of rotation do not coincide with each other .the setup is revolved around the centre of circle to induce pressure on the metal in the moulds. . Casting shape imposes no special limitations in this process and no of smaller shape can be cast. Mould cavities are fed by a central sprue under the action of centrifugal forces. When castings in multiple layers one above the other are produced in one mould, the moulds is called STACK MOULDING. It is used for producing valve bodies, plugs, yokes, pillow blocks and wide variety of other industrial castings in large quantities.

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FUNDAMENTAL PARAMETER: Centrifugal force: The centrifugal force acting upon a rotating body is proportional to the radius of rotation and to the square of the velocity:

Fc = mr2 =mv2/r
Where Fc = centrifugal force (in N) m = mass (in kg) r = radius (in m) = angular velocity (in rad/s) v = peripheral speed (in m/s) The gravitational force on the same mass would be given by:

Fg = mg
Where g = acceleration due to gravity (in m/s2). Hence the factor by which the normal force of gravity is multiplied during rotation is given by:

G factor = Fc = V2 Fg rg
Expressed in the more convenient speed units of revolutions per minute, N, the expression becomes:

G Factor = 1 (DN)2 = 0.011rN2/g rg (60)2

Therefore;

N = (G factor g)1/2 (0.011r)1/2 N = 42.3(G factor g)1/2 (D)1/2

Where = D rotational diameter (in meter).

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DEFECTS IN CENTRIFUGAL CASTING:

Conventional static casting defects like internal shrinkage, gas porosity and non metallic inclusions are less likely to occur in centrifugal casting Particular hazards in centrifugal casting are laps and tears, Laps arising from imperfect flow. They are most prone to occur in alloys of low fluidity, especially those carrying strong oxide surface films. Apart from cold metal, turbulence and excessively slow or uneven pouring are the principal causes. Circumferential tears in tubular castings and tears in semi centrifugal and pressure castings can result from contraction hindrance by the mould. Hot tears are encountered primarily in true centrifugal castings, for which the highest rotational speeds are employed. Longitudinal tears occur when contraction of the casting, combined with expansion of the mould, generates hoop stresses exceeding the cohesive strength of the metal at temperatures in the solidus region. The stress required to produce tearing is of the order of 0.5 MPa, depending on the alloy: since hoop stress is proportional to the squares of the angular velocity and of the radius of rotation, excessive speed is the factor most directly concerned as a production variable. Pouring temperature, pouring speed and mould temperature are also involved, since they determine the temperature distribution and development of cohesion in the casting. Segregation:- Centrifugal castings are subject to various forms of segregation, especially in heavy sections. Centrifugal separation of suspended crystals or insoluble phases can occur within the liquid in either direction, creating a tendency for the less dense constituents to be transported towards the centre. Banding, a condition encountered in horizontally cast, thick walled cylinders, is a form of structural irregularity in which concentric zones of dissimilar microstructure are associated with segregation of alloy constituents and impurities. Various theories explain this, one states vibration is the main cause of banding.

ADVANTAGES OF CENTRIFUGAL CASTING PROCESS:

Relatively lighter impurities within the liquid metal such as sand, slag, oxides and gas floats more quickly towards the centre of rotation from where they can be easily machined out thereby giving a clean metal casting. Very high standard of soundness in the casting is achieved. Dense and fine grained casting with good physical properties Improve comparable with the forgings. Process is suitable for no. of commercial alloys.

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Achieve high casting yield as centrifugal casting seldom requires feed heads. Except with castings having greater wall thickness, there is proper direction solidification can be achieved. Fettling and cleaning costs are considerably reduced. Production rate is high so it is adopted for mass production.

DISADVANTAGES OF CENTRIFUGAL CASTING PROCESS:

True centrifugal casting is limited to certain shapes. Equipment costs are high. Skilled Workers are required for operation and maintenance.

APPLICATION OF CENTRIFUGAL CASTING PROCESS:

True centrifugal casting method used for the production of cast iron pipes and cylinder liners, the Former typifying the as-cast product and the latter the component machined from a pot. The process also suitable for production of tubes and annular components in most types of commercial casting alloy including carbon, low alloy and high alloy steels, and copper and nickel based alloys. The process is especially valuable for the shaping of alloys unsuitable for forging or for wrought tube manufacture. Centrifugal casting has also been used for the manufacture of blanks for mechanical working. One example is the production of hollow blanks for wrought tube production as an alternative to piercing a solid billet, reducing the total deformation required to reach the finished form. Centrifugal Casting process is used in variety of industries including aerospace, industrial marine, and power transmission. Typical parts including bearings, bushings, coils, pressure vessels, rings, wheels. Bimetal tubes can be produced, alloys of widely different properties can be combined in a single structure by successive pouring of the two alloys under closely controlled conditions.
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REFERNCES:
1. Principles of Metal Casting by Heine and Rosenthal 2. Foundry Technology by Beelay 3. Foundry Technology by O.P.Khanna 4. Foundry Technology by P.L.Jain 5.

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