Casting Practices

Introduction

The casting process is a manufacturing method where a liquid material (usually metal) is poured into a
mold with a hollow cavity of the desired shape, and then allowed to solidify. Once solidified, the work
piece is removed from the mold to undergo various finishing processes (if needed), resulting in a final
product.
Key Steps in the Casting Process:
Pattern Creation:
A replica of the object to be cast, called a pattern, is made. The pattern is used to create the mold cavity.
Mold Preparation:
The mold is prepared by placing the pattern in a material (such as sand) to create the mold cavity. Molds can
be made from sand, metal, or ceramic, depending on the casting process.
Melting:
The material (usually metal) is heated in a furnace until it reaches a liquid state.
Pouring:
The molten material is carefully poured into the mold cavity. The mold is filled completely, and the material
is left to cool and solidify.
Solidification:
As the material cools, it solidifies into the shape of the mold. The cooling rate can affect the properties of
the final cast product.
Mold Removal:
After solidification, the mold is removed to reveal the cast object. This step may involve breaking the mold
(for single-use molds) or opening it (for reusable molds).
Finishing:
The cast part may undergo various finishing processes, such as trimming, machining, or surface treatment,
to achieve the desired dimensions and surface quality.
Types of Casting Processes:

Sand Casting: Uses sand as the mold material. It's versatile and commonly used for making large parts like engine
blocks.
Die Casting: Involves forcing molten metal into a mold cavity under high pressure, producing precise and smooth
parts,
often in high volume.
Investment Casting: Involves creating a wax pattern coated with a ceramic shell, which is then melted out and
replaced by molten metal. This process is ideal for complex shapes and fine details.
Permanent Mold Casting: Uses reusable metal molds. It provides better dimensional accuracy and surface finish than
sand casting. It uses gravity to distribute molten metal equally all over the cavity.
Centrifugal Casting: Involves pouring molten metal into a rotating mold. The centrifugal force helps distribute the
metal evenly, commonly used for making cylindrical parts like pipes.
Centrifugal Casting
Sand Casting Process
1. Pattern Making
Pattern Creation: A pattern, usually made of wood, metal, or plastic, is created to match the shape and dimensions of the final part.
Allowance: The pattern is slightly larger than the final part to account for metal shrinkage as it cools.

2. Mold Making
Sand Preparation: The sand is mixed with a binder (like clay) to help it retain the shape of the pattern.
Molding: The pattern is placed in a mold box, and sand is packed around it to create the mold. There are typically two parts to the mold,
the cope (top) and the drag (bottom).
Core Making (if needed): For parts with internal cavities, cores (usually made of sand) are placed inside the mold to create these spaces.

3. Mold Assembly
The mold is assembled, with the pattern removed, leaving a cavity in the shape of the part.
Gating System: Channels (runners and gates) are created in the mold to direct the flow of molten metal into the cavity.

4. Pouring
Melting: The metal is heated in a furnace until it reaches a molten state.
Pouring: The molten metal is carefully poured into the mold through the gating system, filling the cavity.

5. Cooling
The metal solidifies as it cools. The cooling time depends on the size and material of the part.

6. Breaking the Mold

Once the metal has cooled and solidified, the mold is broken open, and the casting is removed.
Shakeout: The sand is separated from the casting.
7. Cleaning
The casting is cleaned to remove any remaining sand, and excess material from the gating system is cut off.
Finishing: The part may be further processed by grinding, machining, or other finishing techniques to achieve the final
dimensions and surface finish.

8. Inspection
The final part is inspected for defects or dimensional accuracy. Any issues may require the part to be reworked or
scrapped.

9. Heat Treatment (Optional)

The casting may undergo heat treatment to alter its mechanical properties, such as hardness or strength.
Advantages of Sand Casting:

• Cost-Effective: Particularly for low to medium production volumes.

• Versatile: Can cast large and complex shapes.

• Material Flexibility: Suitable for casting a wide range of metals, including ferrous and non-ferrous alloys.

Disadvantages of Sand Casting:

• Surface Finish: The surface finish is generally rougher compared to other casting methods.

• Dimensional Accuracy: Not as precise as other casting methods like die casting or investment casting.

• Production Speed: The process can be slower due to the need for mold preparation and cooling time.
Forging Process
 Introduction

Forging is a manufacturing process in which metal is shaped by applying compressive forces, typically through
hammering, pressing, or rolling. During forging, the metal is often heated to make it more malleable, though it
can also be performed at room temperature (cold forging). This process alters the metal’s grain structure,
improving its strength and toughness, and is used to create a wide range of high-strength components, such as
bolts, gears, and shafts, commonly used in industries like automotive, aerospace, and construction.
 Forging Tools
1. Anvil
A large, heavy block of metal with a flat top surface and a horn on one end. The flat surface is used as a base for
hammering, and the horn is used for bending and shaping the metal.

2. Hammer
Various types of hammers are used in forging, including ball-peen hammers, sledgehammers, and cross-peen
hammers. These are used to strike and shape the metal.
3. Tongs
Long-handled tools used to grip and hold hot metal during the forging process. They come in
various shapes and sizes depending on the specific use.

4. Forge
A furnace or hearth used to heat the metal before it is shaped. The forge can be fueled by coal, propane, or natural
gas.
5. Press
A hydraulic or mechanical press used to apply force to shape metal, especially in more intricate or large-scale
operations.

6. Swage Block
A large, heavy block of metal with various shapes and grooves used to form and shape metal, especially for tasks like
bending or creating decorative elements.
7. Chisels
Tools used for cutting or carving the metal during forging. They are struck with a hammer to make
precise cuts or engravings.

8. Hardy Tool
A cutting tool that fits into a square hole in the anvil. It is used for cutting and shaping metal by placing the
metal over the hardy and striking it with a hammer.
 Forging Operations

1. Upset Forging
Upset forging is a specific type of forging process that focuses on increasing the diameter of a portion of a workpiece by
compressing its length. This operation is commonly used to create parts with larger cross-sections in localized areas, such
as bolt heads, fasteners, or other components that require a significant change in diameter.
2. Drawing
Drawing forging is a forging operation where the length of the metal workpiece is increased while its cross-sectional area is
reduced. This process is the opposite of upset forging, where the diameter is increased while the length is reduced.
3. Bending
Bending forging is a forging process where a metal workpiece is deformed to create a specific angle or curve. This
process is commonly used to form components that require a specific bend or curvature while maintaining the material's
strength and structural integrity.
4. Cutting
Cutting is the process of cutting or shearing a metal workpiece during or after the forging process. This step is often necessary
to trim excess material, create specific shapes, or separate forged parts from a larger workpiece.

5. Punching
It is a process used to create holes, depressions, or indentations in a metal workpiece by applying force with a punch tool.
This operation is typically performed while the metal is still hot and malleable, making it easier to shape without cracking or
breaking. Punching is a common step in forging, particularly for components that require openings or features like bolt holes,
slots, or recesses.
Forging Presses and Hammers

• Mechanical Presses
Powered by a motor that drives a flywheel, which stores energy and then releases it to drive a ram downward.

• Hydraulic Presses
Uses hydraulic cylinders to generate force, with the pressurized fluid providing the power to move the ram.

• Screw Presses
A vertical screw mechanism converts rotational motion into linear motion, driving the ram downwards.

• Pneumatic Presses
Uses compressed air to move the ram and apply force to the workpiece.
Advantages of Forging
• Improved Mechanical Properties
• Enhanced Strength
• Superior Durability
• Material Efficiency
• Consistency and Reliability
• Customization and Flexibility
• Cost-Effective for High Volumes
• Improved Surface Finish
• Versatility
• Reduced Production Time
• Resistance to Fatigue and Creep
• Reduced Risk of Failure
Disadvantages of Forging
• High Initial Cost:
Forging requires expensive dies, molds, and specialized equipment, leading to high initial setup costs,
especially for small production runs.
• Limited Complexity:
Forging is less suitable for producing highly complex or intricate shapes, as the process primarily involves
compressing and deforming metal.
• Material Limitations:
Not all materials are suitable for forging; some metals may crack or become brittle when subjected to the
high pressures involved.
• Limited Size Range:
The size of parts that can be forged is often limited by the capacity of the forging press or hammer, making
it challenging to produce very large components.
• Energy-Intensive Process:
Forging requires significant amounts of energy, particularly when working with large parts or high-strength
materials, leading to higher operational costs.