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Metal Casting Processes

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Metal Casting Processes METAL CASTING PROCESSES • Sand Casting • Other Expendable Mold Casting Processes CASTING PROCESS - 3 Assoc Prof Zainal Abidin Ahmad Department of Manufacturing & Ind. Eng. Universiti Teknologi Malaysia 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 2 Basic Steps in making sand Overview of Sand Casting casting • Most widely used casting process, accounting for a • There are seven basic steps in making significant majority of total tonnage cast sand castings: • Nearly all alloys can be sand casted, including metals with high melting temperatures, such as steel, nickel, – Obtaining the casting geometry and titanium – Patternmaking • Parts ranging in size from small to very large – Coremaking • Production quantities from one to millions – Molding – Melting and pouring – Cleaning & inspection – Heat treatment & post processing 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 3 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 4 1 Basic Steps in making sand Sand Casting Process casting 1. Obtaining the casting geometry – The traditional method of obtaining the casting geometry is by sending blueprint drawings to the foundry. This is usually done during the request for quotation process. However, more and more customers and foundries are exchanging part geometry via the exchange of computer aided design files. 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 5 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 6 Basic Steps in making sand Basic Steps in making sand casting casting 2. Patternmaking 3. Coremaking – The pattern is a physical model of the casting used to – Cores are forms, usually made of sand, which make the mold. are placed into a mold cavity to form the – The mold is made by packing some readily formed interior surfaces of castings. Thus the void aggregate material, such as molding sand, around the pattern. When the pattern is withdrawn, its imprint space between the core and mold-cavity provides the mold cavity, which is ultimately filled surface is what eventually becomes the with metal to become the casting. casting. – If the casting is to be hollow, as in the case of pipe fittings, additional patterns, referred to as cores, are used to form these cavities. 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 7 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 8 2 Basic Steps in making sand Sand Casting Process casting 4. Molding – Molding consists of all operations necessary to prepare a mold for receiving molten metal. Molding usually involves placing a molding aggregate around a pattern held with a supporting frame, withdrawing the pattern to leave the mold cavity, setting the cores in the mold cavity and finishing and closing the chaplet casting mold. 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 9 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 10 Basic Steps in making sand casting 5. Melting and Pouring – The preparation of molten metal for casting is referred to simply as melting. Melting is usually done in a specifically designated area of the foundry, and the molten metal is transferred to the pouring area where the molds are filled. 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 11 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 12 3 Basic Steps in making sand Basic Steps in making sand casting casting 6. Cleaning & inspection 7. Heat treatment and post processing • Cleaning refers to all operations necessary to the removal of sand, scale, and excess metal • Before shipment, further processing such from the casting. The casting is separated from as heat-treatment, surface treatment, the mold and transported to the cleaning department. Burned-on sand and scale are additional inspection, or machining may removed to improved the surface appearance of be performed as required by the the casting. Excess metal, in the form of fins, wires, parting line fins, and gates, is removed. customer's specifications. Castings may be upgraded by welding or other procedures. • Inspection of the casting for defects and general quality is performed. 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 13 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 14 1. Obtaining the casting geometry 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 16 4 3rd angle projection 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 17 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 18 2. Pattern making 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 19 5 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 21 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 22 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 23 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 24 6 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 25 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 26 Pattern Material Characteristics • Demonstration of draft allowance TABLE 11.3 Ratinga Characteristic Wood Aluminum Steel Plastic Cast iron Machinability E G F G G Wear resistance P G E F E Strength F G E G G Weightb E G P G P Repairability E P G F G Resistance to: CorrosioncEEPEP SwellingcPEEEE aE, Excellent; G, good; F, fair; P, poor. bAs a factor in operator fatigue. cBy water. Source : D.C. Ekey and W.R. Winter, Introduction to Foundry Technology. New York. McGraw-Hill, 1958. 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 27 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 28 7 3. Core making 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 30 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 31 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 32 8 Multiple cores 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 33 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 34 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 35 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 36 9 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 37 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 38 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 39 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 40 10 4. Molding 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 42 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 43 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 44 11 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 45 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 46 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 47 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 48 12 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 49 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 50 Sequence of Operations for Sand Sequence of Operations for Sand Casting Casting (cont.) Figure 11.11 Schematic illustration of the sequence of operations for sand casting. Source: Steel Founders' Society of America. (a) A mechanical drawing of the part is used to generate a design for the pattern. Considerations such as part shrinkage and draft must be built into the drawing. (b-c) Figure 11.11 (g) The flask is rammed with sand and the plate and inserts are removed. (g) The drag half is Patterns have been mounted on plates equipped with pins for alignment. Note the presence of core produced in a similar manner, with the pattern inserted. A bottom board is placed below the drag and aligned prints designed to hold the core in place. (d-e) Core boxes produce core halves, which are pasted with pins. (i) The pattern, flask, and bottom board are inverted, and the pattern is withdrawn, leaving the together. The cores will be used to produce the hollow area of the part shown in (a). (f) The cope half appropriate imprint. (j) The core is set in place within the drag cavity. (k) The mold is closed by placing the cope on top of the drag and buoyant forces in the liquid, which might lift the cope. (l) After the metal of the mold is assembled by securing the cope pattern plate to the flask with aligning pins, and solidifies, the casting is removed from the mold. (m) The sprue and risers are cut off and recycled and the attaching inserts to form the sprue and risers. (continued) casting is cleaned, inspected, and heat treated (when necessary). 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 51 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 52 13 Squeeze Heads Figure 11.9 Various designs of squeeze heads for mold making: (a) conventional flat head; (b) profile head; (c) equalizing squeeze pistons; and (d) flexible diaphragm. Source: © Institute of British Foundrymen. Used with permission. 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 53 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 54 Desirable Mold Properties and Making the Sand Mold Characteristics • The cavity in the sand mold is formed by packing sand • Strength - to maintain shape and resist erosion around a pattern, then separating the mold into two • Permeability - to allow hot air and gases to pass through halves and removing the pattern voids in sand • The mold must also contain gating and riser system • Thermal stability - to resist cracking on contact with • If casting is to have internal surfaces, a core must be molten metal included in mold • Collapsibility - ability to give way and allow casting to • A new sand mold must be made for each part produced shrink without cracking the casting • Reusability - can sand from broken mold be reused to make other molds? 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 55 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 56 14 5. Melting & pouring 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 58 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 59 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 60 15 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 61 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 62 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 63 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 64 16 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 65 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 66 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 67 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 68 17 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 69 1-Feb-08 Assoc Prof Zainal Abidin Ahmad 70 6.
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