Unit - 3

Metal Casting

Prepared by
G.VITAL
Asst.prof.
Introduction
• Casting is manufacturing process by which liquid material is usually poured into a
mold, which contains a hollow cavity of the desired shape, and then allowed to
solidify.
• The solidified part is known as casting, which is ejected or broken out of the mold
to complete the process.
• Casting materials are usually metals. All most all metals can be cast.
• Casting is most often used for making complex shapes that
would be otherwise difficult to make by other methods.
Advantages of casting process
• Pats of intricate shapes can be produced.
• Almost all the metals and alloys and some plastics can be cast.
• A part can be made almost to the finished shape before any machining is
done.
• Good mechanical and service properties.
• Mechanical and automated casting processes help decrease the cost of
casting.
• The number of casting can vary from very few to several thousand.
• Applications:
• Automobile engine blocks, cylinder blocks of automobile and air plane
engine, pistons and piston rings, machine tools beds and frames, wheels
and housing of steam and hydraulic turbines, Turbine vanes and aircraft jet
engine blades, water supply pipes, agricultural parts etc.
 Basic Moulding parts used in casing
1. Moulding box or Flask:
2. Shovel:

3. Riddle:

4. Rammer:
5. Trowels

6. Slick
7. Sprue pin
8. Moulding board

9. Sprue pin

10.Vent wire (or) rod

11. Mallet

12. Lifter

13. Strike - off bar

Steps involved in making casting
PATTERNS:
• A pattern is a model or the replica of the object (to be casted).
• It is embedded in molding sand and suitable ramming of molding sand
around the pattern is made.
• The pattern is then withdrawn for generating cavity (known as mold) in
molding sand.
• Thus it is a mould forming tool.
• Pattern can be said as a model or the replica of the object to be cast except
for the various al1owances a pattern exactly resembles the casting to be
made.
• It may be defined as a model or form around which sand is packed to give
rise to a cavity known as mold cavity in which when molten metal is poured,
the result is the cast object.
• When this mould/cavity is filled with molten metal, molten metal solidifies
and produces a casting (product).
• So the pattern is the replica of the casting.
• A pattern prepares a mold cavity for the purpose of making a casting.
Pattern making: