Casting, one of the oldest manufacturing processes, dates
back to 4000 B.C. when copper arrowheads were made. Casting processes basically involve the introduction of a molten metal into a mold cavity, where upon solidification, the metal takes on the shape of the mold cavity. Simple and complicated shapes can be made from any metal that can be melted. Example of cast parts: frames, structural parts, machine components, engine blocks, valves, pipes, statues, ornamental artifacts.. Casting sizes range form few mm (teeth of a zipper) to 10 m (propellers of ocean liners).
Ken Youssefi Mechanical Engineering Dept., SJSU 1
Casting Processes Preparing a mold cavity of the desired shape with proper allowance for shrinkage. Melting the metal with acceptable quality and temp. Pouring the metal into the cavity and providing means for the escape of air or gases. Solidification process, must be properly designed and controlled to avoid defects. Mold removal. Finishing, cleaning and inspection operations.
Ken Youssefi Mechanical Engineering Dept., SJSU 2
Sand Casting Terminology
Ken Youssefi Mechanical Engineering Dept., SJSU 3
Sand Casting Process
Ken Youssefi Mechanical Engineering Dept., SJSU 4
Solidification Time
Solidification time = C(volume/surface area)2
Where C is a constant that depends on mold
material and thickness, metal characteristics and temperature.
Ken Youssefi Mechanical Engineering Dept., SJSU 5
Solidification Time Sphere, cube and a cylinder with the same volume
Ken Youssefi Mechanical Engineering Dept., SJSU 6
Casting Defects Hot tearing hot tearing, cracking, occurs if casting is restrained from shrinking, during solidification.
Ken Youssefi Mechanical Engineering Dept., SJSU 7
Casting Defects
These defects can be
eliminated by proper mold preparation, casting design and pouring process.
Ken Youssefi Mechanical Engineering Dept., SJSU 8
Casting Defects Hot spots thick sections cool slower than other sections causing abnormal shrinkage. Defects such as voids, cracks and porosity are created.
Ken Youssefi Mechanical Engineering Dept., SJSU 9
Casting Defects and Design Consideration
Ken Youssefi Mechanical Engineering Dept., SJSU 10
Design Consideration
Ken Youssefi Mechanical Engineering Dept., SJSU 11
Die Casting Hot chamber, low-melting Cold chamber, high-melting alloys; tin, zinc, lead. alloys; aluminum, copper. Higher pressure needed
High production rates, good strength, good dimensional
accuracy and surface finish, and good quality parts.
Ken Youssefi Mechanical Engineering Dept., SJSU 12
Centrifugal Casting True centrifugal casting
Centrifuging
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Squeeze Casting
Cast parts have good mechanical properties, good dimensional
accuracy, fine microstructure, good surface finish.
Ken Youssefi Mechanical Engineering Dept., SJSU 14
Precision Casting Plaster Molding Plaster of Paris (gypsum) is used as the mold material, other components are added to improve the strength and reduce the setting time. The pattern is dried at 400 oF and the two halves are assembled and molten metal is poured into the cavity. The process produces fine detail with good dimensional accuracy and surface finish. Used to cast aluminum, zinc and copper-based alloys (low-melting temp.) Ceramic Molding Similar to plaster molding, except it uses ceramic as a mold which is suitable for high temp. applications. Mixture of zircon (ZrSiO4), aluminum oxide (Al2O3), silica (SiO2) and other bounding agents.
Ken Youssefi Mechanical Engineering Dept., SJSU 15
Fabrication of Plastics Injection Molding
Ken Youssefi Mechanical Engineering Dept., SJSU 16
Fabrication of Plastics Hot-Compression Molding
Vacuum Forming
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Design Considerations Wall thickness should be kept uniform if possible. Non uniform wall thickness could lead to warpage and dimensional variations. Minimum recommended; .025 in or .65 mm, up to .125 for large parts. Round interior and exterior corners to .01-.015 in radius (min.), prevents an edge from chipping.
Ken Youssefi Mechanical Engineering Dept., SJSU 18