MANUFACTURING PROCESESS

UNIT-1

CASTING PROCESSES

Prof S.A.Shimple
Assistant Professor
Department of Mechanical Engineering,
TSSM's PVPIT, Bavdhan
 Casting process
Casting is a manufacturing process that involves pouring molten metal into a mold to
create a solid part. The solidified part is called a casting

Steps in the casting process

1.Pattern making: Create a replica of the part to be

cast. This replica is called the pattern.

2.Mold making: Use the pattern to create a mold cavity.

3.Pouring: Pour the molten metal into the mold cavity.

4.Cooling: Allow the molten metal to cool and solidify into

the desired shape.

5.Ejecting: Remove the solidified casting from the mold.

 Patterns

A pattern
. in casting is a replica of the object to be cast. It's used to create a mold
cavity that's filled with molten metal to produce the casting

Patterns may be in two or three pieces, where as casting are in a single

piece.

A pattern is required even if one object has to be cast.

The quality of casting and the final product will be effected to a great
extent by the planning of pattern.
 Functions of Patterns
A Pattern prepares a mould cavity for the purpose
of making a casting.

 A Pattern may contain projections known as core prints if

the casting requires a core and need to be made hollow.

Risers, runners and gates may form a part of the pattern.

Patterns properly made and having finished and smooth

surfaces reduce casting defects.

Properly constructed patterns minimize overall cost of the

casting.
 Selection of Pattern Materials
• No. of castings to be produced.
• Metal to be cast.
• Dimensional accuracy & surface finish.
• Shape, complexity and size of casting.
• Casting design parameters.
• Type of molding materials.
• The chance of repeat orders.
• Nature of molding process.
• Position of core print.
Casting Pattern Allowances
Draft allowances: draft allowances create a taper for removing casting patter without
any distortion. And the accurate angle of taper depends on the type of mold and surface,
and the complexity of the casting pattern.
Shrinkage allowance: usually the casting pattern has a bigger size of the mold, because
most metal material contracts when it cools. The shrinkage allowance compensates for
the cooling shrink of metal, and the precise parameter of the allowance depends on the
metal material.
Distortion allowance: casting patterns have a special design for avoiding the expected
cooling distortion. We call it a distortion allowance.
Machining allowance: excess material in the finishing stage for compensating some
loss materials.
Single piece pattern,
Split pattern,
Gated pattern,
Multi piece pattern,
Match plate pattern,
Skeleton pattern,
Sweep pattern,
Lose piece pattern,
Cope and drag pattern,
Shell pattern.
 Molding sand,
Molding sand, also known as foundry sand, is a sand mixture used to create molds
for casting metal. It's made from silica sand, clay, water, and other additives.

How it's used

When moistened, compressed, oiled, or heated, molding sand packs well and
holds its shape
It's used to prepare the mold cavity in the sand casting process

Ingredients
•Silica sand: The most common sand used because it's abundant, cheap, and has a
fine grain size
•Clay: Acts as a binder to hold the sand grains together
•Water: Activates the clay bond
•Organic additives: Give the sand specific properties like cohesiveness,
permeability, and refractoriness
 Molding sand properties
Molding sand has many properties, including:

Refractoriness
The ability to withstand high temperatures without breaking down, which helps produce
sound castings.
Cohesiveness
The ability of the sand to hold its particles together, which helps retain the shape of the
mold.
Plasticity
The ability of the sand to flow into all parts of the mold and retain its shape.
Porosity
Also known as permeability, this is the ability of the sand to allow gases to pass through.
Flow ability
The ability of the sand to be compacted into a uniform density and to take on the shape of
the pattern in the mold.
Adhesiveness
The ability of the sand to stick to the sides of the mold.
 core
A core is an insert used in the casting process to create internal cavities and complex
shapes. Cores are often made of sand and a bonding agent.

How cores are used

Cores are placed in the mold before the mold halves are joined.
During pouring and cooling, the core shapes the interior of the part.
Cores can be broken up and poured out of the part after it hardens.

Types of cores
Solid: Creates interior cavities
Hollow: Allows the metal to fill other sections
Intricate: May have interior angles and geometries to create
complex holes and passages Horizontal core.
Vertical core.
Balanced core.
Drop Core.
Horizontal core rests in mould along the parting line between cope and drag.

Vertical core rest in cope and drag part of the mould.

Vertical cores have a high taper at the top and a small taper at the bottom of
the core.
It is called a vertical core as it is placed and rested in a mould vertically.
A balanced core is a core in which only one side of the core is available for making holes
in the casting.
While another side of the core is deep inside the molding sand supporting the entire
core.
A core is balanced by making the core longer and core prints support the core.

The core used for producing cavities which are

not in line with the parting surface is called a
drop core. Drop cores are in the drag section of
the mould.
 gating system
Mold is used for producing a casting. Molten metal is conveyed into the mold cavity
by using Gating system. In casting process, gating system plays an important role to
produce a high quality casting. A poorly designed gating system results in casting
defects. A gating system controls mould filling process. The main function of gating
system is to lead molten metal from ladle to the casting cavity ensuring smooth,
uniform and complete filling.

Runner: The passageway for molten metal from the machine nozzle to the mold cavity.
Pouring basin: A conical or tapered hollow portion that helps direct the flow of molten
metal.
Riser: A reservoir that prevents cavities due to metal shrinkage.
Gate: The entry point for liquid metal to enter the cavity.
Ingate: The last point where molten metal enters the cavity.
Pouring cup: Minimizes splash and turbulence when metal flows through the sprue.
Pouring Cup – It is the funnel-shaped opening, made at the top of the mold. The main
purpose of the pouring basin is to direct the flow of molten metal from ladle to the sprue.
Spruce – It is a vertical passage connects the pouring basin to the runner or ingate. It is
generally made tapered downward to avoid aspiration of air. The cross section of the sprue
may be square, rectangular, or circular.
Spruce Well – It is located at the base of the sprue. It arrests the free fall of molten metal
through the sprue and turns it by a right angle towards the runner.
Runner – It is a long horizontal channel which carries molten metal and distribute it to the
ingates .It will ensure proper supply of molten metal to the cavity so that proper filling of
the cavity takes place.
 Cleaning and Finishing of casting
Castings are cleaned and finished using a variety of methods, including grinding,
sandblasting, shot blasting, and electroplating. The process ensures that the casting
has the desired surface finish and dimensional accuracy.

Cleaning and finishing methods

Grinding
Also called fettling, this is the initial cleaning of castings after they leave the sand mold. It
removes excess sand, cuts away runners, and smooth rough spots.
Sandblasting
Removes residual materials, such as mold release agents or oxidation, from the surfaces.
Shot blasting
Prepares castings for further treatment. It is widely used in many industries, such as the
automotive, aerospace, rail, and marine industries.
Bead blasting
Removes scale and other impurities, leaving behind a uniform surface.
Electroplating
Deposits a layer of metal onto the surface using an electric current. This enhances corrosion
resistance, wear resistance, and aesthetic appeal.
1. Shift or Mismatch : The defect caused due to misalignment of upper
and lower part of the casting and misplacement of the core at parting
line.
Cause :
(1) Improper alignment of upper and lower part during mold preparation.
(2) Misalignment of flask (a flask is type of tool which is used to contain a
mold in metal casting. it may be square, round, rectangular or of any
convenient shape.)
Remedies
(i) Proper alignment of the pattern or die part, molding boxes.
(ii) Correct mountings of pattern on pattern plates.
(iii) Check the alignment of flask.
2. Swell :
It is the enlargement of the mold cavity because of the molten metal
pressure, which results in localised or overall enlargement of the casting.
Causes
(i) Defective or improper ramming of the mold.
Remedies
(i) The sand should be rammed properly and evenly.
3. Blowholes:
When gases entrapped on the surface of the casting due to solidifying metal, a
rounded or oval cavity is formed called as blowholes. These defects are always
present in the cope part of the mold.
Causes :
(i) Excessive moisture in the sand.
(ii) Low Permeability of the sand.
(iii) Sand grains are too fine.
Remedies :
(i) The moisture content in the sand must be controlled and kept at desired level.
(ii) High permeability sand should be used.
(iii) Sand of appropriate grain size should be used.
4. Drop:
Drop defect occurs when there is cracking on the upper surface of the sand and sand
pieces fall into the molten metal.
Causes :
(i) Soft ramming and low strength of sand.
Remedies :
(i) Sand of high strength should be used with proper ramming (neither too hard nor
soft).
 Purpose of Special Casting
Casting in sand Mould is economical and give good results for many
applications where dimensional accuracy and surface finish requirement
are not to stringent(hard) and casting wall thickness are not to small

Casting in sand Mould is economical and give good

results for many applications where dimensional
accuracy and surface finish requirement are not to
stringent(hard) and casting wall thickness are not to
small
 Purpose of Special Casting

Casting in sand Mould is economical and give good

results for many applications where dimensional
accuracy and surface finish requirement are not to
stringent(hard) and casting wall thickness are not to
small
 Types of Special Casting Process
• Shell Mould casting
• Investment Casting
• Die Casting
1.Cold Chamber Die casting
2.Hot Chamber Die Casting
• Centrifugal casting
1.True Centrifugal Casting
2. Semi Centrifugal Casting
3. Centrifuge Casting
• Continuous casting
 Shell Mould Casting
• Shell mold casting is a metal casting process that creates a
thin-walled mold shell around a reusable metal pattern. This
shell is then filled with molten metal to produce the desired
part.
Investment Casting ( Lost Wax Process)
• The lost wax process, also known as investment casting, is a
technique for creating metal objects by pouring molten metal into
a mold. The mold is made from a wax pattern that is then melted
out.
Steps
1.Create a wax pattern: The wax pattern can be carved, hand formed, or reproduced
from a mold.
2.Coat with ceramic: The wax pattern is coated with a ceramic material.
3.Heat to remove the wax: The coated pattern is heated, causing the wax to melt and
flow out of the mold.
4.Pour molten metal: Molten metal is poured into the mold.
5.Cool and break away the ceramic shell: After the metal has cooled, the ceramic
shell is broken away to reveal the cast metal part.
Uses
•Jewelry: The lost wax process is used to create jewelry.
•Dentistry: The lost wax process is used in dentistry.
•Art: The lost wax process is used to create sculptures and other art.
•Engineering and manufacturing: The industrial form of the lost wax process, called
investment casting, is used to create precision metal parts.
 Steps in investment casting
• Preparation of dies for making wax pattern
• Preparation of wax pattern and gating systems
• Assembly if wax pattern
• Pre-coating
• Investment
• Removal of wax
• Preheating the mould and pouring
• Cleaning
• Inspection
 Centrifugal Casting
centrifugal casting is a metal casting process that uses a spinning mold to create
cylindrical products like pipes, tubes, rings, and wheels. The process involves pouring
molten metal into a spinning mold, which uses centrifugal force to distribute the metal
along the inner diameter of the mold.

True Centrifugal Casting

• Centrifugal casting is done by pouring molten metal into rotating mould
• The centrifugal force acting on the mould helps in feeding and positioning the metal in the
mould.
• Mould rotation is continued till after the metal is solidifies.
How it works
•Molten metal is poured into a spinning mold
•Centrifugal force distributes the metal along the inner diameter of the mold
•The metal solidifies from the outside in
What it's used for
•Centrifugal casting is used to make pipes, tubes, rings, wheels, pulleys, and other
cylindrical products
Benefits
•Centrifugal casting can produce consistent and reproducible components with
dimensional accuracy
•It can produce components with a uniform grain structure
•It can produce components with a superior metallurgical structure and weldability
 Semi Centrifugal Casting

Semi-centrifugal casting is a casting technique that uses a rotating mold to create

solid castings with rotational symmetry. It's a variation of true centrifugal casting,
but it produces solid castings instead of hollow ones

How it works
•Molten metal is poured into a mold through a
central sprue.
•The mold rotates, which pushes the molten
metal into the mold's cavities.
•The metal solidifies, with the material around the
axis being denser than the material away from
the axis.
•The casting is machined to remove the material
around the axis, making room for the axis on
which the component will spin.
 Centrifuging / Centrifuge Casting

• Centrifuge casting is employed to force metal

under pressure in to moulds of small casting or
castings not symmetrical about any axis of
rotation.
• The Mould are made around a central axis of
rotation to balance each other.
• The metal is poured along this axis of rotation
through a central gate and made to flow in to
mould cavities.
• Centrifuging helps in proper feeding of casting
resulting in clean, close grained casting.
  Die Casting
Die casting is a permanent mold casting procedure, in which the mold is
made of metal and large number of castings are produced from it.
Mold:The mold is made of
special die steels.

Die: The mold made of metals is

called “die”.These steels have
very high melting point and must
resist very high temperatures
 COLD CHAMBER DIE CASTING

Cold chamber die casting is a process that uses a separate furnace to melt metal and
then force it into a mold. It's used to create a variety of shapes and components,
including intricate and large parts

How it works
1.Melt metal in a separate furnace
2.Transfer molten metal to the cold
chamber machine
3.Force the metal into the mold cavity using
a hydraulic or mechanical piston
4.Hold pressure on the metal while it
solidifies
5.Eject the part once it's solidified
Advantages
•Strength: Cold chamber die-cast parts are stronger and heavier than plastic injection moldings
•Precision: The separate furnace allows for precise control over the metal during injection
•Cost-effective: A practical process that can create a wide range of shapes
Disadvantages
•Complex geometries: It can be difficult to produce parts with thin walls or undercuts
Applications
•Cold chamber die casting is often used to mass produce magnesium castings
•It's also used for alloys with high melting points, such as aluminum and some magnesium alloys
 HOT CHAMBER DIE CASTING

Hot chamber die casting is a manufacturing process that creates metal

parts by injecting molten metal into a mold. It's a cost-effective method
for producing high-volume quantities of small, intricate parts
How it works
1.A furnace melts metal, usually zinc, magnesium, or other alloys with low melting points
2.A feeding system, called a "gooseneck", connects the furnace to the casting machine
3.A plunger forces the molten metal through the gooseneck and into the die cavity
4.The metal solidifies in the die
5.The plunger is withdrawn, and the machine opens to eject the completed part
6.The process repeats
Advantages
•Fast cycle times
Cost-effective
•Versatile
Disadvantages
•Limited size and complexity: The size and complexity of the parts that can be produced is
limited by the design of the die
•Limited to low-melting point metals: Aluminum can't be used because it picks up iron from the
molten pool
 Continuous casting
 This process essential consist of pouring molten
metal into the upper opening of a vertical mould
open at the both ends, cooling it rapidly with
water and removing the solidifies product
continuously from the other end.
 In continuous Casting Process water jacket is
used to instant cooling
 The molten metal is fed to the mould from near
the bottom of the furnace so that the impurities
and slag are left out .As the metal flow into the
mould it is rapidly cooled by the water
circulating in the cooling water jacket
surrounding the mould.
 The Solidifies casting is pulled out at a controlled
speed by withdrawing rolls.
 A cut off station may be provided to cut the metal
into required length by sawing or flame cutting
How it works
1.The metal is melted and poured into a tundish, which is a container that leads to
the mold.
2.The molten metal moves through the mold, which is cooled with water.
3.The metal casting moves outside the mold using rollers that bend and straighten
it.
Advantages
•Cost-effective
Produces long products
What it's used for
•Continuous casting is used to make copper alloys, such as bronze and aluminum
bronze.