me_350_-_lect_8_-_ch_10.20090916.4ab198ea2d4e52.62660486

me_350_-_lect_8_-_ch_10.20090916.4ab198ea2d4e52.62660486 -...

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ME 350 – Lecture 8 – Chapter 10 FUNDAMENTALS OF METAL CASTING: Overview of Casting Technology Heating and Pouring Solidification and Cooling
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Capabilities and Advantages of Casting Can create complex part geometries Can create both external and internal shapes Some casting processes are net shape; others are near net shape Can produce a wide variety of sized parts: Large parts: e ngine blocks, wood burning stoves, railway wheels, pipes, church bells, statues, etc. Small parts: d ental crowns, jewelry, small statues, frying pans
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Limitations of Casting 1. Limitations on mechanical properties (cold working, heat treating, alloy segregation, etc.) 2. Poor dimensional accuracy and surface finish for some processes; e.g., sand casting 3. Safety hazards to workers due to hot molten metals
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Two Categories of Casting Processes 1. Uses a mold which is destroyed to remove casting: Mold materials: sand, plaster, and similar materials, plus binders 2. Uses a mold which can be used over and over: Made of metal (or, less commonly, a ceramic refractory material
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Sand Casting Mold
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Sand Casting Mold Terms Mold consists of two halves: Upper half of mold: Bottom half of mold: Mold halves are contained in a box, called: The two halves separate at the: Gating system consists of: Horizontal tube openings through which metal travels to the main cavity: Vertical tube opening of varying diameter designed to control metal flow velocity: Topmost opening designed to minimize splash and turbulence:
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Riser Reservoir in the mold which acts as a source of liquid metal during solidification to: In order to satisfy its function, the riser must be designed to freeze (before or after) the main casting
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Use of a Core in the Mold Cavity The mold cavity provides the external surfaces of the cast part In addition, a casting may have internal surfaces, determined by a core , placed inside the mold cavity to define the interior geometry of part In sand casting, cores are generally made of sand
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Heating the Metal The heat required is the sum of: 1. Heat to raise temperature to melting point 2. Heat of fusion to convert from solid to liquid
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This note was uploaded on 01/15/2010 for the course ME 350 taught by Professor Staff during the Spring '08 term at University of Illinois, Urbana Champaign.

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me_350_-_lect_8_-_ch_10.20090916.4ab198ea2d4e52.62660486 -...

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