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    Workshop Practice: Course Code: Btmp101-18

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    Dhiraj Dhiman
    This document discusses the metal casting process. It begins with an overview of casting and the basic steps: making a mold cavity, melting material, pouring the liquid into the mold, solidification, and removing the product. Key aspects of mold preparation, melting, pouring and solidification are covered. Advantages include the ability to make intricate shapes and cast many materials. Limitations include dimensional accuracy and surface finish without advanced processes. Important terms related to molds, cores, pouring and gates are defined. The six basic steps of sand casting - pattern making, core making, molding, melting and pouring, and cleaning - are outlined.

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    Download as PPTX, PDF, TXT or read online from Scribd

    Workshop Practice: Course Code: Btmp101-18

    Uploaded by

    Dhiraj Dhiman
    269 views12 pages
    This document discusses the metal casting process. It begins with an overview of casting and the basic steps: making a mold cavity, melting material, pouring the liquid into the mold, solidification, and removing the product. Key aspects of mold preparation, melting, pouring and solidification are covered. Advantages include the ability to make intricate shapes and cast many materials. Limitations include dimensional accuracy and surface finish without advanced processes. Important terms related to molds, cores, pouring and gates are defined. The six basic steps of sand casting - pattern making, core making, molding, melting and pouring, and cleaning - are outlined.

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    Workshop Practice

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    This document discusses the metal casting process. It begins with an overview of casting and the basic steps: making a mold cavity, melting material, pouring the liquid into the mold, solidification, and removing the product. Key aspects of mold preparation, melting, pouring and solidification are covered. Advantages include the ability to make intricate shapes and cast many materials. Limitations include dimensional accuracy and surface finish without advanced processes. Important terms related to molds, cores, pouring and gates are defined. The six basic steps of sand casting - pattern making, core making, molding, melting and pouring, and cleaning - are outlined.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    269 views12 pages

    Workshop Practice: Course Code: Btmp101-18

    Uploaded by

    Dhiraj Dhiman
    This document discusses the metal casting process. It begins with an overview of casting and the basic steps: making a mold cavity, melting material, pouring the liquid into the mold, solidification, and removing the product. Key aspects of mold preparation, melting, pouring and solidification are covered. Advantages include the ability to make intricate shapes and cast many materials. Limitations include dimensional accuracy and surface finish without advanced processes. Important terms related to molds, cores, pouring and gates are defined. The six basic steps of sand casting - pattern making, core making, molding, melting and pouring, and cleaning - are outlined.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 12

    DEPARTMENT OF APPLIED SCIENCE

    WORKSHOP PRACTICE

    COURSE CODE: BTMP101-18

    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN


    DEPARTMENT OF APPLIED SCIENCE

    Metal casting processes


    •Casting is one of the oldest manufacturing process. It is the first step in making
    most of the products.

    • Steps:
    - Making mould cavity
    - Material is first liquefied by properly heating it in a suitable furnace.
    - Liquid is poured into a prepared mould cavity
    - allowed to solidify
    - product is taken out of the mould cavity, trimmed and made to shape

    We should concentrate on the following for successful casting operation:


    (i)Preparation of moulds of patterns
    (ii)Melting and pouring of the liquefied metal
    (iii)Solidification and further cooling to room temperature
    (iv)Defects and inspection
    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN
    DEPARTMENT OF APPLIED SCIENCE

    Advantages
    •Molten material 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.
    • Possible to cast practically any material: ferrous or non-ferrous.
    • The necessary tools required for casting moulds are very simple and
    inexpensive. As a result, for production of a small lot, it is the ideal process.
    •There are certain parts (like turbine blades) made from metals and alloys that
    can only be processed this way. Turbine blades: Fully casting + last machining.
    • Size and weight of the product is not a limitation for the casting process.

    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN


    DEPARTMENT OF APPLIED SCIENCE

    LIMITATIONS
    •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.

    • Metal casting is a labour intensive process

    • Automation: a question

    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN


    DEPARTMENT OF APPLIED SCIENCE

    Typical sand mould

    Mould Section and casting nomenclature

    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN


    DEPARTMENT OF APPLIED SCIENCE
    Flask: A metal or wood frame, without fixed top or
    bottom, in which the mould is formed. Depending upon
    Important casting the position of the flask in the moulding structure, it is
    referred to by various names such as drag – lower
    terms moulding flask, cope – upper moulding flask, cheek –
    intermediate moulding flask used in three piece
    moulding.

    Pattern: It is the replica of the final object to be made.


    The mould cavity is made with the help of pattern.

    Parting line: This is the dividing line between the two


    moulding flasks that makes up the mould.

    Moulding sand: Sand, which binds strongly without losing


    its permeability to air or gases. It is a mixture of silica
    sand, clay, and moisture in appropriate proportions.

    Facing sand: The small amount of carbonaceous


    material sprinkled on the inner surface of the mould
    cavity to give a better surface finish to the castings.
    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN
    DEPARTMENT OF APPLIED SCIENCE

    Core: A separate part of the mould, made of sand and generally baked,
    which is used to create openings and various shaped cavities in the
    castings.
    Pouring basin: A small funnel shaped cavity at the top of the mould into
    which the molten metal is poured.
    Sprue: The passage through which the molten metal, from the pouring
    basin, reaches the mould cavity. In many cases it controls the flow of metal
    into the mould.
    Runner: The channel through which the molten metal is carried from the
    sprue to the gate.
    Gate: A channel through which the molten metal enters the mould cavity.
    Chaplets: Chaplets are used to support the cores inside the mould cavity to
    take care of its own weight and overcome the metallostatic force.
    Riser: A column of molten metal placed in the mould to feed the castings as
    it shrinks and solidifies. Also known as “feed head”.
    Vent: Small opening in the mould to facilitate escape of air and Gases

    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN


    DEPARTMENT OF APPLIED SCIENCE

    Steps in making sand castings


    The six basic steps in making sand castings are,
    (i) Pattern making, (ii) Core making, (iii) Moulding, (iv) Melting and pouring, (v)
    Cleaning

    Pattern making
    -Pattern: Replica of the part to be cast and is used to prepare the mould cavity. It
    is the physical model of the casting used to make the mould. Made of either wood
    or metal.

    -The mould is made by packing some readily formed aggregate material, such as
    moulding sand, surrounding the pattern. When the pattern is withdrawn, its imprint
    provides the mould cavity. This cavity is filled with metal to become the casting.

    -If the casting is to be hollow, additional patterns called ‘cores’, are used to form
    these cavities.

    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN


    DEPARTMENT OF APPLIED SCIENCE

    Core making
    Cores are placed into a mould cavity to form the interior surfaces of
    castings. Thus the void space is filled with molten metal and eventually
    becomes the casting.

    Moulding
    Moulding is nothing but the mould preparation activities for receiving molten
    metal.
    Moulding usually involves: (i) preparing the consolidated sand mould around a
    pattern held within a supporting metal frame, (ii) removing the pattern to leave
    the mould cavity with cores.
    Mould cavity is the primary cavity.

    The mould cavity contains the liquid metal and it acts as a negative of the
    desired product.

    The mould also contains secondary cavities for pouring and channeling the
    liquid material in to the primary cavity and will act a reservoir, if required.

    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN


    DEPARTMENT OF APPLIED SCIENCE

    Melting and Pouring


    The preparation of molten metal for casting is referred to simply as melting. The
    molten metal is transferred to the pouring area where the moulds are filled.

    Cleaning
    Cleaning involves removal of sand, scale, and excess metal from the casting. Burned-on
    sand and scale are removed to improved the surface appearance of the casting. Excess
    metal, in the form of fins, wires, parting line fins, and gates, is removed. Inspection of the
    casting for defects and general quality is performed.

    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN


    DEPARTMENT OF APPLIED SCIENCE

    https://www.youtube.com/watch?v=
    LmjAQGvSrF0

    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN


    DEPARTMENT OF APPLIED SCIENCE

    Thanks and Queries

    WORKSHOP PRACTICE Er. DHIRAJ PARKASH DHIMAN

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