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2.casting process basics

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7 views

2.casting process basics

Uploaded by

64 Pushpesh Ranjan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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MANUFACTURING

PROCESSES
Casting Processes
Casting Process
Component of the Desired Size and
Shape is acquired by the
Solidification (with Uniform cooling)
of the Molten metal (Metal in at very
high temperature) poured into a
Cavity of approximately same size
and shape, made in a suitable
medium.
Moulding Process
Casting Process
Key Aspects of Casting Processes
• Material of the Medium of the Mould.
• Mould Cavity and its making.
• Pattern
• Melting and Pouring of the Molten metal.
• Solidification (Cooling)
• Fluid Flow (at very High Temperature)
A Typical Casting Process
Casting Process
Elements of Gating System

• Pouring Basin
• Sprue
• Sprue Base well
• Runner
• Ingate
• Mould cavity
• Riser
Types of Gating systems
Aspiration Effect & Shape of Sprue
Foundry Materials
Moulding Sand

Material of Medium, in Mould


and its Properties
Moulding Sand materials
Typical Moulding Sand, Comprises of:
-Silica sand
-Binder (Clay, Dextrin etc)
-Additives (Courn Flour etc (Sea Coal)
-Moisture.
Sources of Silica Sand
• Damodar & Barkar Areas & Rajmahal Hills in
Bihar.
• Batala in Punjab.
• Bhavnagar and Satara in Maharashtra.
• Sicandarabad in Andhra.
• Avadi and Veeriyambkkam in Madras.
• Kumardhubi and Hoogly in Bengal.
• Haridwar and Allahabad in Uttar Pradesh.
• Rourkela in Orissa.
Types of Sands in Foundry

Natural sand:
(Occurring Naturally, with Clay etc.)
Types of Sands in Foundry

Silica sand/(also called Sharp sand-free of


Bond): Only Silica Sand without any Additive.
Types of Sands in Foundry

Green Sand
(Moulding sand with Moisture).
Types of Sands in Foundry

Dry sand
(Moulding sand without Moisture)
Types of Sands in Foundry
Synthetic sand
(Prepared Sand with Clay Additive etc.)
Types of Sands in Foundry

Moulding Sand:
(Formulated Sand with Clay Additive etc,
as per the Requirement.)
Types of Sands in Foundry

Loam sand:
(Having High % Binding
material).
Types of Sands in Foundry

Oil & Molasses sand:


(Oil/Molasses as Binding agent)
Types of Sands in Foundry

• Core sand: Used for Making Cores


Types of Sands in Foundry
Facing sand:
(Sand Adjacent to Pattern)
Types of Sands in Foundry

Floor Black or Backing sand:


Sand behind the Facing sand.
Types of Sands in Foundry

Parting sand:
(Sand parting Cope and Drag)
Types of Sands in Foundry
Heap sand
(Sand kept in form of Heap.)
Types of Sands in Foundry

System sand
(Mechanical sand preparation &
Handling)
Moulding Sand
Moulding Sand

Material of Medium, in Mould


and its Properties
Properties of
Moulding Sand
Different Shapes of Sand Grains

Rounded Compounded
Sand Grains Sand Grains

Angular
Sand Grains
• Sub angular
• Sand Grains
Properties of Moulding Sand

(For Escaping of Vapour & Gases)


Properties of Moulding Sand

(Sustaining Heat Temperature)


Properties of Moulding Sand

(Ease of Flow of Moulding sand)


Properties of Moulding Sand

(Binding within the Sand mass)


Properties of Moulding Sand

(Binding of Sand mass with Flask


etc)
Properties of Moulding Sand

(Distribution of Sand particles)


Properties of Moulding Sand

(Ease of Collapsing of the Sand


mass after Casting operation)
Properties of Moulding Sand

(Tendency of Expansion on Heating)


Properties of Moulding Sand

(Shelf Life)
• Sand Testing Methods
Sand Testing Methods
Grain Fineness Number
Calculation of AFS No.
Sand Testing Methods
Moisture Content Test set up
Sand Testing Methods
Permeability Test
Sand Testing Methods
Strength Tests of Moulding Sand
Specimen for Strength Testing
Specimen Preparation for
Strength Testing
Moulding Sand materials
Moulding Sand materials
Typical Moulding Sand, Comprises of:
-Silica sand
-Binder (Clay, Dextrin etc)
-Additives (Corn Flour etc (Sea Coal)
-Moisture.
Moulding materials : Binders

Inorganic Binders : Most common are


1-Clay,
2-Sodium Silicate &
3-Portland cement
Moulding materials : Binders

Organic Binders (Specific use in Core making)

• 1-Dextrin
• 2- Molasses
• 3-Linseed oil
• 4-Cereal binders
• 5-Pitch (upto 2% max)
• 6-Resins (Phenol and Urea Formeldehydes)
Moulding materials : Additives
• Coal dust Grey/Malleable cast iron (Avoiding
Oxidation of Metal)
• Sea Coal (2 to 8%) Finely grounded Soft coal
used for Grey/ Malleable cast iron Preventing
mould wall movement & Improves surface
finish)
• Cereal or Corn Flour (0.25 to 2.0%)
Create Voids by Burning, accommodating
Expansion & creating space reducing Expansion
defect
Moulding materials : Additives
• Silica flour: (upto 35%) Increases Hot strength,
decreases Metal penetration & Expansion
defect
• Wood flour (.5 to 2%), Create Voids,
accommodating Expansion
• Pitch : Improves Hot strength and Surface
finish of iron casting. Beyond 2% it may affect
Green strength
Moulding materials : Additives
• Dextrin Mollasses
• (Increasing dry strength of the Sand)
Books for the Subject Content
Books for the Subject Content

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