ch11 - Chapter 11: Fundamentals of Casting 11.1...

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1 Chapter 11: Fundamentals of Casting 11.1 Introduction s Products go through a series of processes before they are produced b Design b Material selection b Process selection b Manufacture b Inspection and evaluation b Feedback s 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 s Four basic categories b Casting processes b Material removal processes b Deformation processes b Consolidation processes s 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 s Casting process b Material is melted b Heated to proper temperature b Treated to modify its chemical makeup b Molten material is poured into a mold b Solidifies s Casting can produce a large variety of parts Basic Requirements of Casting Processes s Six basic steps of casting b 1. Mold cavity is produced having the desired shape and size of the part s Takes shrinkage into account s Single-use or permanent mold b 2. Melting process s Provides molten material at the proper temperature b 3. Pouring technique s 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 s 4. Solidification process b Controlled solidification allows the product to have desired properties b Mold should be designed so that shrinkage is controlled s 5. Mold removal b The casting is removed from the mold s Single-use molds are broken away from the casting s Permanent molds must be designed so that removal does not damage the part s 6. Cleaning, finishing, and inspection operations b Excess material along parting lines may have to be machined Capabilities and Advantages of Casting s Can create complex part geometries s Can create both external and internal shapes s Some casting processes are net shape; others are near net shape s Can produce very large parts s Some casting methods are suited to mass production
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5 Disadvantages of Casting s Different disadvantages for different casting processes: b Limitations on mechanical properties b Poor dimensional accuracy and surface finish for some processes; e.g., sand casting b Safety hazards to workers due to hot molten metals b Environmental problems 11.3 Casting Terminology s Pattern- approximate duplicate of the part to be cast s Molding material- material that is packed around the pattern to provide the mold cavity s Flask- rigid frame that holds the molding aggregate s Cope- top half of the pattern s Drag- bottom half of the pattern s Core- sand or metal shape that is inserted into the mold to create internal features
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6 Casting Terminology s Mold cavity- combination of the mold material and cores s Riser-additional void in the mold that provides additional metal to compensate for shrinkage s Gating system- network of channels that delivers the
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ch11 - Chapter 11: Fundamentals of Casting 11.1...

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