08Lecture-p2-ch10 - Manufacturing and Production Processes...

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Manufacturing and Production Processes ENGR 3190U – Lecture 08 – Part 2 Chapter 10 - Fundamentals of Metal Casting We will covers all sections 1. Overview of Casting Technology 2. Heating and Pouring 3. Solidification and Cooling 4. Sand Casting Video Clip 5. Riser Design: 09Lecture-Calc.doc
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Figure 10.1 Classification of solidification processes Starting work material is either a liquid or is in a highly plastic condition, and a part is created through solidification of the material
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Casting Process in which molten metal flows by gravity or other force into a mold where it solidifies in the shape of the mold cavity The term casting also applies to the part made in the process Steps in casting seem simple: 1. Melt the metal 2. Pour it into a mold 3. Let it freeze
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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 very large parts Some casting methods are suited to mass production
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Disadvantages of Casting Different disadvantages for different casting processes: Limitations on mechanical properties Poor dimensional accuracy and surface finish for some processes; e.g., sand casting Safety hazards to workers due to hot molten metals Environmental problems
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Overview of Casting Technology Casting is usually performed in a foundry Foundry = factory equipped for making molds, melting and handling molten metal, performing the casting process, and cleaning the finished casting Big parts Engine blocks and heads for automotive vehicles, wood burning stoves, machine frames, railway wheels, pipes, church bells, big statues, pump housings Small parts Dental crowns, jewelry, small statues, frying pans All varieties of metals can be cast, ferrous and nonferrous
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The Mold in Casting Contains cavity whose geometry determines part shape Actual size and shape of cavity must be slightly oversized to allow for shrinkage of metal during solidification and cooling Molds are made of a variety of materials, including sand, plaster, ceramic, and metal
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Open Molds and Closed Molds Figure 10.2 Two forms of mold: (a) open mold, simply a container in the shape of the desired part; and (b) closed mold, in which the mold geometry is more complex and requires a gating system (passageway) leading into the cavity.
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