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Group no.

7
Furqan Hameed

11013386-031

Bilal Abdul Mateen

11013386-036

Farhan Ghos Butt 11013386-014


Ibrar Hussain

11013386-040

Muhammad Furqan

11013386-045

Metal Casting Process

Objective
History
Definition of casting
Basic features
Types of moulds
Categories of casting process
Further classification of Expendable and

Permanent mould casting

It is oldest
manufacturing
process.

Casting process
Castingis amanufacturingprocess by

which a liquid material is usually poured


into amold, which contains a hollow cavity
of the desired shape, and then allowed to
solidify.
The solidified part is also known as a

casting, which is ejected or broken out of


the mold to complete the process.

Casting process
Casting materials are usually metals.
Almost all metals can be cast.

Casting is most often used for making


complex shapes that would be otherwise
difficult to make by other methods.

Basic Features
Pattern: A pattern is made of wood or metal, is a replica of

the final product and is used for preparing mould cavity


Riser: A column of metal placed in the mold to feed the

casting as it shrinks and solidifies. Also known as a "feed


head."
Runner: The channel through which the molten metal is
carried from the sprue to the gate.
Cores: A separated part of the mold, made of sand and
generally baked, which is used to create openings and
various shaped cavities in the casting.
Gate: A channel through which the molten metal enters the

casting cavity.

Parting Line: Joint where mold separates to permit


removal of the pattern and which shows how and
where to open the mold.
Sand: A sand which binds strongly without losing its
permeability to air or gases.
Chaplet: A metal support used to hold a core in place
in a mold. Not used when a core print will serve.
Binders: Materials used to hold molding sand together.
Pouring basin: Filling the mold with molten metal.
Shrinkage: The decrease in volume when molten
metal solidifies.
Mould: The mould contains a cavity whose geometry
determines the shape of cast part.
Mould material should posses refractory characteristics
and with stand the pouring temperature

Types of moulds
The various casting processes are classified according
to these different moulds
open mould
closed mould

Types of moulds
Open mould
in which the liquid metal is simply
poured until it fills the open cavity. (fig. a)

Closed mould

the closed mold is provided to permit the


molten metal to flow from outside the mold cavity.
(fig. b)
the closed mold is more important categories in
production casting operation.

Open and Closed Mould

Casting process video:

Categories of casting process


Casting process divide onto two broad categories

according to types of mold used;


o Expandable mould casting
o Permanent mould casting

Expandable mould casting


Expandable mould means that :
the mold in which the molten metal is solidifies
must be break or destroyed to remove the casting.
Or
After solidification of molten metal the mold is break to
remove the desired casting. (sand casting)
Expandable mould materials:
the mold are made out of sand, plaster, and
similar materials.

Classification of casting
processes

Expandable mold casting

Expandable mold casting:


1.permanent pattern:
SAND CASTING

Common features

Schematicillustrationofsandcastingshowingvariousfeatures.

Sand Casting
Advantages

Disadvantages

Recommended
Application

Least Expensive in
small quantities (less
than 100)

Dimensional
accuracy inferior to
other processes,
requires larger
tolerances

Use when
strength/weight
ratio permits

Ferrous and non ferrous metals may


be cast
Possible to cast very
large parts.
• Least
expensive tooling

Castings usually
exceed calculated
weight
Surface finish of
ferrous castings
usually exceeds 125
RMS

Tolerances,
surface finish and
low machining
cost does not
warrant a more
expensive process

Sand casting process video:

Expandable mold casting:


Expendable pattern:
INVESTMENT CASTING:
Use gravity to fill the mold.
Mold is destroyed to remove casting
Metal flow is slow
Walls are much thicker than in die casting.
Cycle time is longer than die casting because of

inability of mold material to remove heat.


The investment casting process uses expendable
patterns made of investment casting wax.

Investment Casting
Advantages

Disadvantages

Recommended
Application

Close dimensional
tolerance

Costs are higher


than Sand,
Permanent Mold or
Plaster process
Castings

Use when
Complexity
precludes use of
Sand or
Permanent Mold
Castings

Complex shape, fine


detail, intricate core
sections and thin
walls are possible
Ferrous and nonferrous metals may
be cast
As-Cast" finish (64 125 RMS)

The process cost is


justified through
savings in
machining or
brazing
Weight savings
justifies increased
cost

Investment casting video:

Permanent mold casting


o In permanent mold casting, the mold
is reused many times.
o The molds are commonly made of
steel or cast iron.
o The Metals commonly cast in the
permanent mold casting include
aluminum, magnesium and copperbased alloys( brass , bronze)

Permanent mold casting

Types permanent mold


casting
Two
basic
two
types
permanent mold casting
under
o Die casting
o Centrifugal casting

of
as

Die casting:
o Die casting is permanent-mold casting
process in which the molten metal is
injected into mold cavity under high
pressure. The pressure is maintained
during solidification, after which the
mold is opened and part is removed.
o Typical pressures are 7 to 350 MPa.
o The molds used in this casting
operation is called dies; hence the
name die casting

Die casting:

Die casting machines:


Two

types
of
die
machines that as under

o Hot chamber die casting


o Cold chamber die casting

casting

Die casting video:

Hot chamber die casting:


In hot chamber die- casting machines, the
molten metal is poured into a heated chamber
from an external melting container, and piston is
used to inject the molten metal under a high
pressure into die cavity.
o Typically injection pressures are 7 to 35 mpa.
o This process only used for the low-melting-point
metals.(zinc,tin
,lead
and,
sometimes
magnesium)
o

Cold chamber die-casting :


o In which the molten metal poured into an

unheated chamber, and piston is used to


inject the liquid metal under a high
pressures into the die cavity
o Injection pressures used in these machine
are typically 14 to 140 mpa.

Centrifugal casting:
o In centrifugal casting the mold is rotated

at high speed so that the centrifugal force


is produced that distributes the molten
metal to the outer regions of the cavity.
o Examples of parts made by this process
include pipes, tubes bushing and rings.

Centifugal casting video:

Advantages of permanent mold


casting
o High production rates possible.
o Close tolerance is possible for small

parts.
o Good surface finish.
o Thin sections are possible.
o Rapid solidification.

Limitation of permanent mold


casting
Only used for low melting point metals.
o More intricate shapes are not achieved
o Mold is expensive.
o

Note:(More

intricate shapes are not


achieved by the permanent mold casting)

Selecting the Right Metal


Casting Process
For any Metal Casting Process, selection of right alloy, size,

shape, thickness, tolerance, texture, and weight, is very


vital.
Views of the Tooling Designer; Foundry / Machine House
needs, customer's exact product requirements, and
secondary operations like painting, must be taken care of
before selecting the appropriate Metal Casting Process.
Tool cost.
Economics of machining versus process costs.
Adequate protection / packaging, shipping constraints,

regulations of the final components, weights and shelf life of


protective coatings also play their part in the Metal Casting
process.

thanks

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QUESTION
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