Casting - FundamentalsofCasting Introduction Products go...

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Fundamentals of Casting
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Introduction Products go through a series of processes before they are produced Design Material selection Process selection Manufacture Inspection and evaluation Feedback Materials processing is the science and technology that converts a material into a product of a desired shape in the desired quantity
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Shape-Producing Processes Figure 11-1 The four materials processing families, with subgroups and typical processes.
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Introduction to Casting Basic Idea Exploit the properties of a liquid as it flows into and assumes the shape of a prepared container, and then solidifies upon cooling Especially suitable when production involves Complex shapes Parts involving hollow sections or internal cavities Parts containing irregular, curved surfaces Very large parts or parts from metals that are hard to machine Casting processes use Different mold materials (sand, metal, various ceramics) Pouring methods (gravity/vacuum/low-pressure or high-pressure)
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Basic Requirements of Casting Processes 1 . Mold cavity Mold must contain features in relief Must withstand the high temperature of molten metal and not contaminate it Single-use (small quantity / high-melting materials) or Multiple-use / permanent mold (large scale production) 2. Melting process Must produce molten metal that is flows and fills the entire mold cavity before solidification of any portion of the casting 3. Pouring technique Design with provision for escape of all gases / air from cavity
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Basic Requirements of Casting Processes 4. Solidification process Design / control such that solidification process & associated shrinkage does not produce internal porosity or voids Mold must not restrain the casting too much, or it may cause the casting to crack 5. Mold removal Single-use molds are broken away from the casting Permanent molds must be designed so that removal does not damage the part 6. Cleaning, finishing, and inspection operations Remove extraneous material usually attached where the metal enters the cavity
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Casting Terminology Pattern- An approximate duplicate of the final casting Molding material- packed around the pattern, and the pattern removed to create all or part of the mold cavity Flask- rigid metal / wood frame that holds the molding aggregate Cope- top half of the pattern/flask/mold/core Drag- bottom half of the pattern/flask/mold/core Core- sand or metal shape that is inserted into the mold to create internal features of a casting, such as holes or passages for water cooling Cores are produced in wood, metal or plastic tooling known as core boxes Core print – feature added to a pattern/core/mold that is used to locate and support a core within the mold
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Casting Terminology Mold cavity- mold material + cores combine to form a completed mold cavity, a shaped hole into which molten
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This note was uploaded on 01/19/2012 for the course IE 230 taught by Professor Xangi during the Spring '08 term at Purdue University-West Lafayette.

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Casting - FundamentalsofCasting Introduction Products go...

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