Scribd
Upload
94 views

Training Material For Casting & Forgings

There are several common casting processes that are categorized based on the material used to make the molds. The basic steps in any casting process are patternmaking to design the mold, coremaking to create interior surfaces, molding to form the mold cavity, melting and pouring the metal into the mold, and finishing the casting. Forging also applies force to shape a workpiece without removing material, and common forging types include open-die, closed-die, and roll forging. The key difference between casting and forging is that casting involves pouring molten material into a mold cavity, while forging uses compressive forces on solid material.

Uploaded by

Nilesh Ghodekar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
94 views

Training Material For Casting & Forgings

There are several common casting processes that are categorized based on the material used to make the molds. The basic steps in any casting process are patternmaking to design the mold, coremaking to create interior surfaces, molding to form the mold cavity, melting and pouring the metal into the mold, and finishing the casting. Forging also applies force to shape a workpiece without removing material, and common forging types include open-die, closed-die, and roll forging. The key difference between casting and forging is that casting involves pouring molten material into a mold cavity, while forging uses compressive forces on solid material.

Uploaded by

Nilesh Ghodekar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 8

Types of Casting Processes

There are several different casting methods, each of which requires slight variations in the process.
The categorization of the different types of processes are based on the material used to make the
molds. Casting options include:

 Sand casting
 Plaster casting
 Shell molding
 Wax casting
 Die casting
 Centrifugal casting

Basic Steps in Casting Process


While each casting method creates unique challenges and process enhancements, all techniques
retain the same basic steps. These steps are:

 Patternmaking
 Coremaking
 Molding
 Melting and pouring
 Finishing
 Patternmaking

To create a casting mold, a manufacturer must first design a physical model. The process of
fabricating this model is called patternmaking. Using computer-assisted design (CAD) systems, the
manufacturer designs dimensions and geometry of a mold, and then packs an aggregate material,
such as sand, concrete or plastic, around the pattern. Once the pattern is removed, the mold cavity in
the sand can be filled.

Coremaking
Many part designs require the inclusion of cores in the casting mold. Cores are solid materials placed
inside the mold cavity to create interior surfaces of a casting. For example, a metal pipefitting will
require a cylindrical core inside the mold cavity to create the hollow construction of the component's
interior.

Molding
At this point, the manufacturer can create the casting mold. A material such as sand, plaster or wax is
used in expendable mold casting, whereas metal and other durable materials are used in non-
expendable mold casting techniques. The material fills the casting mold model and is allowed to
harden, at which point the manufacturer removes it from the cavity and the casting of the component
can now begin.

Melting and Pouring


Metal must be properly melted prior to being placed in the mold. Typically, this is done by using what
is known as a crucible. Crucibles are containers made of porcelain or another melt-resistance
substance in which a manufacturer can heat a metal beyond its melting point. Once properly melted,
the molten metal is poured into the casting mold to cool and harden.

Finishing
Because metal can sometimes fill in cracks in a casting mold or sprues, the pouring channel for the
mold, manufacturers must often finish the metal following casting. This can be accomplished through
a variety of finishing techniques, including sanding, grinding and buffing. Once proper appearance
and surface texture has been achieved, further post-treatment processes such as blasting.
Forging Process
Types of forging
Forging is the process of applying force to shape the workpiece without removing any material or
changing the state of the matter.

Unlike die punches, forging applies force to shape the workpiece, instead of shearing and removing
the material.

Open-die Forging

Closed-die Forging
Roll Forging

Differences between casting & Forgings


Simple Visual Difference between Casting & Forgings

SAND CASTING

INVESTMENT CASTING

You might also like