Ch. 11

Ch. 11 - Chapter 11 Fundamentals of Casting 11.1...

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1 Chapter 11: Fundamentals of Casting 11.1 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 quantitiy
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2 Shape-Producing Processes Four basic categories Casting processes Material removal processes Deformation processes Consolidation processes Decisions should be made after all alternatives and limitations are investigated Shape-Producing Processes Figure 11-1 The four materials processing families, with subgroups and typical processes.
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3 11.2 Introduction to Casting Casting process Material is melted Heated to proper temperature Treated to modify its chemical makeup Molten material is poured into a mold Solidifies Casting can produce a large variety of parts Basic Requirements of Casting Processes Six basic steps of casting 1. Mold cavity is produced having the desired shape and size of the part Takes shrinkage into account Single-use or permanent mold 2. Melting process Provides molten material at the proper temperature 3. Pouring technique Molten metal is poured into the mold at a proper rate to ensure that erosion and or defects are minimized
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4 Six Basic Steps of Casting 4. Solidification process Controlled solidification allows the product to have desired properties Mold should be designed so that shrinkage is controlled 5. Mold removal The casting is removed from the mold 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 Excess material along parting lines may have to be machined 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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5 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 11.3 Casting Terminology Pattern- approximate duplicate of the part to be cast Molding material- material that is packed around the pattern to provide the mold cavity Flask- rigid frame that holds the molding aggregate Cope- top half of the pattern Drag- bottom half of the pattern Core- sand or metal shape that is inserted into the mold to create internal features
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6 Casting Terminology Mold cavity- combination of the mold material and cores Riser-additional void in the mold that provides
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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.

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Ch. 11 - Chapter 11 Fundamentals of Casting 11.1...

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