UNIT-I

CASTING
How to prepare mould for sand casting
What is Casting Process
 * Mould Materials
1. Metals :-
- Gray cast iron, Steel, Brass, Alluminium, etc.
2. Non Metals :
- Moulding sands, Graphites, Plaster , Silicon
carbide, ceramic, and wax, etc
 * Factor Influencing for selection
of mould :-

1. Cost
2. Quality of casting required
3. Material to be cast
4. No. of casting required
5. Dimensional Accuracy
* Procedure for making sand mould:-
1. Pattern making
2. Preparing the sand
3. Making mould (by using pattern)
4. Melting of metal
5. Pouring the molten metal into the mould
6. Cleaning of casting
7. Testing and inspection of the casting
* Advantages of casting process :-
1. Cheap
2. Ability to form any shape
3. Identical casting can be produced in large number.
4. Under-cuts and recesses can be produced in cast part.
5. Good machinability
6. Vibration damping capacity
7. Casting simplifies construction in many cases, eg. m/c
bed
8. In many cases the casting reduces machining time.
* Limitation of casting :-
1. When few casting are required, the casting
process is uneconomical.
2. Sand casting process can not produce
dimensionally accurate components.
3. casting are easily affected from shrinkage.
4. Shell moulding and investment casting required
high skill of operation and fine control .
* Moulding sand:-

 Advantages of moulding sand :-

1) With stand high temp.
2) Easily Packed to any shape
3) Permits the gases, air and steam formed in the mould
to escape.
4) Does not chemically react with molten metal
* Principle constituents of moulding sand:-
1. Silica sand (SiO2): - 86 to 90 %, grain size and shape.
2. Water: - 1.5 to 1.8 %, active clay in sand.
3. Clay (Alumina)
4. Impurities
5. Special additives: - Bentonite- by weathering volcanic ash
6. Cereal binder
7. Pitch – Improve hot strength.
8. sea coal- use to improve surface finishing
9.Wood floor :- minimize sand expansion defects, improve flowability,
collapsibility.
10. Perlite:- Better thermal stability
11. Oils
* Properties of moulding sand:-
1. Refractoriness:-
2. Flowability
3. Collapsibility
4. Adhesiveness
5. Cohesiveness or strength
6. Permeability
7. Should not react chemically with molten metal
8. It should be cheap and easily available
* Types of moulding sand:-
A) According to the nature of origin :-
1) Natural sand
2) Synthetic sand
B) According to use
1) Greensand
2) Dry sand
3) Loam Sand
4) facing sand
5) Backing sand
6) System sand
7) Parting sand
8) Core sand
Pattern
 Pattern Materials
1) Wood
2) Metals
a) Cast Iron
b) Brass
c) Aluminum
d) White metal
3) Plaster
4) Plastics
5)Wax
 Factor affecting the selection of
pattern material
1) Design of casting
2) No. of casting to be made
3) Quality of casting
4) Size, Shape and complexity of casting
5) Type of casting method to be used
6) Moulding material to be used
7) Cost of pattern and chances of repeat orders of
the pattern
 Pattern Allowances
1) Shrinkage ( Contraction ) Allowance :-
2) Machining Allowance:-
-Allowance required to remove the rough cast surface. 2 to 25 mm.

3) Draft or Taper Allowance:-

-To facilitate ease of removal, usually ½ to 2 deg.
 Pattern Allowances
4) Distortion Allowance:-

5) Rapping Allowance:-
 Types of Pattern
1) Single piece pattern(solid pattern)

2) Two piece or split pattern

3) Match plate pattern

4) Gated pattern
3) Cope and Drag

4) Loose piece pattern

5) Sweep pattern
6) Skeleton pattern

7) Segmental pattern

8) Lagged up pattern
Core

Core print
Core Boxes
1. Half core box

2. Dump core box

3. Split core box

4. Booked type core box

5. Strickle core box
6. Loose piece core box
7. Right and left hand core box
8. Gang core box
Types of Core
1. Horizontal core

2. Vertical core
3. Balanced core

4. Hanging core
Chaplets
SPECIAL CASTING METHODS
1. PERMANENT MOLD OR GRAVITY DIE CASTING
2. SLUSH CASTING
3. DIE CASTING (PRESSURE DIE CASTING)
a) Hot chamber die-casting
b) Cold chamber die-casting
4. Plaster Mould Casting
5. SHELL MOLD CASTING (Croning process)
6. Investment Casting (Lost Wax Process)
7. CENTRIFUGAL CASTING
8. CONTINNOUS CASTING
Defects in CASTING