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    Metal Casting

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    Sujay Das Sonu
    Casting is a manufacturing process where molten material is poured into a mold and solidifies to form a desired shape. It allows for complex shapes that would be difficult or uneconomical to produce through other methods. The key advantages of metal casting are that intricate shapes can be formed, only simple and inexpensive tools are required, certain alloys can only be processed this way, and there are no limitations to size or weight. However, limitations include potential issues with dimensional accuracy, surface finish, and it being a labor intensive process. Common casting methods include sand casting, die casting, investment casting, and permanent mold casting.

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    Metal Casting

    Uploaded by

    Sujay Das Sonu
    34 views2 pages
    Casting is a manufacturing process where molten material is poured into a mold and solidifies to form a desired shape. It allows for complex shapes that would be difficult or uneconomical to produce through other methods. The key advantages of metal casting are that intricate shapes can be formed, only simple and inexpensive tools are required, certain alloys can only be processed this way, and there are no limitations to size or weight. However, limitations include potential issues with dimensional accuracy, surface finish, and it being a labor intensive process. Common casting methods include sand casting, die casting, investment casting, and permanent mold casting.

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    Casting is a manufacturing process where molten material is poured into a mold and solidifies to form a desired shape. It allows for complex shapes that would be difficult or uneconomical to produce through other methods. The key advantages of metal casting are that intricate shapes can be formed, only simple and inexpensive tools are required, certain alloys can only be processed this way, and there are no limitations to size or weight. However, limitations include potential issues with dimensional accuracy, surface finish, and it being a labor intensive process. Common casting methods include sand casting, die casting, investment casting, and permanent mold casting.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    34 views2 pages

    Metal Casting

    Uploaded by

    Sujay Das Sonu
    Casting is a manufacturing process where molten material is poured into a mold and solidifies to form a desired shape. It allows for complex shapes that would be difficult or uneconomical to produce through other methods. The key advantages of metal casting are that intricate shapes can be formed, only simple and inexpensive tools are required, certain alloys can only be processed this way, and there are no limitations to size or weight. However, limitations include potential issues with dimensional accuracy, surface finish, and it being a labor intensive process. Common casting methods include sand casting, die casting, investment casting, and permanent mold casting.

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    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 2

    Introduction

    There are four basic production processes for producing desired shape of a product.
    These are casting, machining, joining (welding, mechanical fasteners, epoxy, etc.),
    and deformation processes. Casting process exploit the fluidity of a metal in liquid
    state as it takes shape and solidifies in a mould. Machining processes provide
    desired shape with good accuracy and precision but tend to waste material in the
    generation of removed portions. Joining processes permit complex shapes to be
    constructed from simpler components and have a wide domain of applications.

    Metal Casting
    Introduction
    Virtually nothing moves, turns, rolls, or flies without the benefit of cast metal
    products. The metal casting industry plays a key role in all the major sectors of our
    economy. There are castings in locomotives, cars, trucks, aircraft, office buildings,
    factories, schools, and homes. Casting is a 6000-year-old process. The oldest
    surviving casting is a copper frog from 3200 BC.
    Casting is a manufacturing process in which a liquid material is usually poured into
    a mould, which contains a hollow cavity of the desired shape, and then allowed to
    solidify. The solidified part is also known as a casting, which is ejected or broken
    out of the mould to complete the process. Casting materials are usually metals or
    various cold setting materials that cure after mixing two or more components
    together; examples are epoxy, concrete, plaster and clay. Casting is most often
    used for making complex shapes that would be otherwise difficult or uneconomical
    to make by other methods.
    By this process, intricate parts can be given strength and rigidity frequently not
    obtainable by any other manufacturing process.  The mould, into which the metal is
    poured, is made of some heat resisting material. Sand is most often used as it
    resists the high temperature of the molten metal. Permanent moulds of metal can
    also be used to cast products. Some metal cast parts are shown in figure below.

    Figure 1: Metal Cast parts


    Advantages
    The metal casting process is extensively used in manufacturing because of its many
    advantages.
    1. Molten material, ferrous or non-ferrous can flow into very small sections so
    that intricate shapes can be made by this process. As a result, many other
    operations, such as machining, forging, and welding, can be minimized or
    eliminated and also large saving in weight can be achieved as the metal can
    be placed exactly where it is required.
    2. The necessary tools required for making moulds are very simple and
    inexpensive. As a result, for production of a small lot, it is the ideal process.
    3. There are certain parts made from metals and alloys that can only be
    processed this way.
    4. Size and weight of the product is not a limitation for the casting process.
    Limitations
    1. Dimensional accuracy and surface finish of the castings made by sand casting
    processes are a limitation to this technique. Many new casting processes
    have been developed which can take into consideration the aspects of
    dimensional accuracy and surface finish. Some of these processes are Die
    Casting process, Investment Casting process, Vacuum-sealed Moulding
    process, and Shell Moulding process.
    2. The metal casting process is a labour intensive process.
    Examples of metal castings are
    Centrifugal casting, Full mould casting, Investment casting, Permanent or Gravity
    Die Casting, Plaster Mould Casting, Sand Casting, Shell Mold casting, Squeeze
    Casting, Pressure die casting, Gravity Die Casting etc.
    The method to be used depends upon the nature of the products to be cast.

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