Casting
When the solidified metal is removed from the mould it acquires the shape of the mould. Thus the solidified object obtained is known as "casting". It consist of Pattern making, making moulds,melting the metal and pouring the molten metal in cavity. It find in modern eqiument such as transportation, construction, industry, Automobile,Communication.
Steps involved in casting
1.Prepare Pattern
2. Moulding
3. The metal should be Melting and pouring
4. Solidification process
5. By remove of casting and felting
6. Machining process
7. Heat treatment process
8. Finishing product to obtain required product from casting.
1.Prepare Pattern
A pattern is the replica of the final product required. It's depends on the size, shape and casting process factors of a pattern is prepared with either wood, metal or wax component. pattern is prepared must include all the allowances. This is process sand casting process.
2. Moulding
It is the main step involves in casting process to make cavity.
The following steps involves in moulding
1. First step is drag is placed in the inverted position on moulding table
2. Second step pattern is placed in suitable position inside the drag
3. Third step Parting sand is now sprinkled in the pattern and over all the drag
4. Fourth step Now pouring the facing sand on pattern and it is thoroughly pressed on the pattern
so that every pattern is obtained
5. Fifth step Now also Poured backing sand all over the drag and then rammed thoroughly. This process repeated.
6. Six step To obtain all over the drag to get better mould cavity in ramming should done
7. Seventh step The excess sand can be removed
8. Eight step by using vent rod vent holes are made which air escapes
9. Ninth step Now drag is again reversed direction placed
10. Tenth step Cope is placed exact position above the drag and parting sand is sprinkled.
11. Eleventh step Now sprue and riser are placed in position in the cope
12. Twelfth step sprue is placed beside the pattern the riser should directly above position of the pattern
13. Thirteenth step Excess sand remove by using strike off bar vent process done
14. Fourteenth step Now sprue and risers removed and pouring basin is cut using a gate cutter near the spue
15. Fifteenth step Cope is now lifted and kept at other side.
16. Sixteenth step The pattern is slowly removed by without cavity disturbed.
17. Seventeenth step cope again placed over the drag moulding is done and cavity obtained.
3. The metal should be Melting and pouring
Required metal melted in oil furnace and using the saddles molten are poured into cavity.
Now molten metal is poured with uniform velocity as to obtaining sand casting.
4. Solidification process
Molten metal poured it is allowed to cool for certain time, so that induced stresses are reduced.
Solidification duration is depends on the volume and surface of the casting.
5. By remove of casting and felting
When the metal gets solidified casting now removed from the mould and felting done in this stage. Felting is cleaning operation of the cast using brush to remove sand particles on metal
6. Machining process
The casting obtained has sprue, risers and ingates,basewell and pouring basin.
7. Heat treatment process
High induced stresses are obtain in casting process so it can be affect the performance of casting product.This can be reduced heat treatment is done.
8. Finishing product to obtain required product from casting
It is last stage to obtain required casting product with good accuracy and surface finish.
Advantages of casting process
1. To produce small, large shape components of metallic
2. Metals,alloys, some plastics are to be cast
3. Large metals can be casting process through made
4. The cost is minimum
5. Surface finish of the product is high
6. Plastic material is easily prepared
7. Complex shapes to be casting
Disadvantages of casting process
1. It is time taking process
2. It needs High energy consuming process
3. The productivity is less than other processes.
Applications of casting
1. Automobile Blocks
2. Cylinder blocks
3. Machine tools frames beds
4. Piston and piston rings
5. wheels
6. Aeroplane engines
7. Jet engine
8. Agricultural parts
9. Hydraulic Turbines
10.Steam turbines
Defects in casting
1. Swell
2. warpage
3. fin
4. shifts
5. blow holes
6. pin holes
7. buckels
8. hot tears
9. shrinkages
10. cold cracks
11.misplaced cores
12 surface roughness
When the solidified metal is removed from the mould it acquires the shape of the mould. Thus the solidified object obtained is known as "casting". It consist of Pattern making, making moulds,melting the metal and pouring the molten metal in cavity. It find in modern eqiument such as transportation, construction, industry, Automobile,Communication.
Steps involved in casting
1.Prepare Pattern
2. Moulding
3. The metal should be Melting and pouring
4. Solidification process
5. By remove of casting and felting
6. Machining process
7. Heat treatment process
8. Finishing product to obtain required product from casting.
1.Prepare Pattern
A pattern is the replica of the final product required. It's depends on the size, shape and casting process factors of a pattern is prepared with either wood, metal or wax component. pattern is prepared must include all the allowances. This is process sand casting process.
2. Moulding
It is the main step involves in casting process to make cavity.
The following steps involves in moulding
1. First step is drag is placed in the inverted position on moulding table
2. Second step pattern is placed in suitable position inside the drag
3. Third step Parting sand is now sprinkled in the pattern and over all the drag
4. Fourth step Now pouring the facing sand on pattern and it is thoroughly pressed on the pattern
so that every pattern is obtained
5. Fifth step Now also Poured backing sand all over the drag and then rammed thoroughly. This process repeated.
6. Six step To obtain all over the drag to get better mould cavity in ramming should done
7. Seventh step The excess sand can be removed
8. Eight step by using vent rod vent holes are made which air escapes
9. Ninth step Now drag is again reversed direction placed
10. Tenth step Cope is placed exact position above the drag and parting sand is sprinkled.
11. Eleventh step Now sprue and riser are placed in position in the cope
12. Twelfth step sprue is placed beside the pattern the riser should directly above position of the pattern
13. Thirteenth step Excess sand remove by using strike off bar vent process done
14. Fourteenth step Now sprue and risers removed and pouring basin is cut using a gate cutter near the spue
15. Fifteenth step Cope is now lifted and kept at other side.
16. Sixteenth step The pattern is slowly removed by without cavity disturbed.
17. Seventeenth step cope again placed over the drag moulding is done and cavity obtained.
3. The metal should be Melting and pouring
Required metal melted in oil furnace and using the saddles molten are poured into cavity.
Now molten metal is poured with uniform velocity as to obtaining sand casting.
4. Solidification process
Molten metal poured it is allowed to cool for certain time, so that induced stresses are reduced.
Solidification duration is depends on the volume and surface of the casting.
5. By remove of casting and felting
When the metal gets solidified casting now removed from the mould and felting done in this stage. Felting is cleaning operation of the cast using brush to remove sand particles on metal
6. Machining process
The casting obtained has sprue, risers and ingates,basewell and pouring basin.
7. Heat treatment process
High induced stresses are obtain in casting process so it can be affect the performance of casting product.This can be reduced heat treatment is done.
8. Finishing product to obtain required product from casting
It is last stage to obtain required casting product with good accuracy and surface finish.
Advantages of casting process
1. To produce small, large shape components of metallic
2. Metals,alloys, some plastics are to be cast
3. Large metals can be casting process through made
4. The cost is minimum
5. Surface finish of the product is high
6. Plastic material is easily prepared
7. Complex shapes to be casting
Disadvantages of casting process
1. It is time taking process
2. It needs High energy consuming process
3. The productivity is less than other processes.
Applications of casting
1. Automobile Blocks
2. Cylinder blocks
3. Machine tools frames beds
4. Piston and piston rings
5. wheels
6. Aeroplane engines
7. Jet engine
8. Agricultural parts
9. Hydraulic Turbines
10.Steam turbines
Defects in casting
1. Swell
2. warpage
3. fin
4. shifts
5. blow holes
6. pin holes
7. buckels
8. hot tears
9. shrinkages
10. cold cracks
11.misplaced cores
12 surface roughness