Manufacturing Technology

MEC205
Casting Terminology
Types of Pattern
 Metal Casting
“Casting is a process in which molten metal flows by gravity or other
force into a mold(cavity)where it solidifies in the shape of mold
cavity”.
• The term casting also applies to the part made in the process
Steps in casting seem simple:
1. Melt the metal
2. Pour it into a mold
3. Let it freeze
 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
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
 Overview of Casting Technology
•Casting is usually performed in a foundry
•Foundry = factory equipped for making molds, melting and handling
molten metal, performing the casting process, and cleaning the finished
casting
•Workers who perform casting are called foundrymen.
• Mold Contains cavity whose geometry determines part shape
•Actual size and shape of cavity must be slightly oversized to allow for
shrinkage of metal during solidification and cooling
•Molds are made of a variety of materials, including sand, plaster,
ceramic, and metal
 Open Molds and Closed Molds

Open mold Closed mold

Classification of solidification processes
 Two Categories of Casting Processes

1. Expendable mold processes – uses an expendable mold which

must be destroyed to remove casting
– Mold materials: sand, plaster, and similar materials, plus
binders
2. Permanent mold processes – uses a permanent mold which
can be used over and over to produce many castings
– Made of metal (or, less commonly, a ceramic refractory
material
 Sand Casting Mold

•Mold consists of two halves:

Cope = upper half of mold
Drag = bottom half
•Mold halves are contained in a box, called a flask
•The two halves separate at the parting line
 Casting terminology

Cross section of a sand mold

1. Flask 6. Core 11. Sprue
2. Cope 7. Mold cavity 12. Runner 16. Molding sand
3. Drag 8.Riser 13. Gates 17.Chaplet
4. Pattern 9.Gating System 14. Draft 18.Chills
5. Parting line 10. Pouring Cup 15.casting
 Casting terminology

Cross section of a sand mold

1. Flask- A rigid frame that holds the molding aggregate

• It is made of wood for temporary application and more generally of
metal for long term use.
 Casting terminology

Cross section of a sand mold

2. Cope- Upper molding flask
3. Drag- Bottom molding flask
4. Patter
• It is replica of final object to be made.
• Mold cavity is made with the help of pattern. Fig. Pattern
 Casting terminology

Cross section of a sand mold

5. Parting Line-It separates the cope and drag

 Casting terminology

Cross section of a sand mold

6.Core- It is used for making hollow cavities in casting

Product after casting

 Casting terminology

Cross section of a sand mold

7. Mold cavity- combination of the mold material and cores

8. Riser- additional void in the mold that provides additional metal to
compensate for shrinkage
9. Gating system-network of channels that delivers the molten metal to
the mold
 Casting terminology

Cross section of a sand mold

10. Pouring Cup-portion of the gating system that controls the delivery
of the metal.
11. Sprue- vertical portion of the gating system .
•The passage through which molten metal from pouring basin reaches
the mold cavity.
 Casting terminology

Cross section of a sand mold

12. Runner- It is horizontal channels

13. Gates- controlled entrances
•Entry point through which molten metal enters in cavity
 Casting terminology

Cross section of a sand mold

14.Draft-angle or taper on a pattern that allows for easy removal of the

casting from the mold
 Casting terminology

Cross section of a sand mold

15.Casting- It describes both the process and the product when molten
metal is poured and solidified .
16.Facing sand-Facing sand is the sand which covers the pattern all
around it. The remaining box is filled with ordinary floor sand.
17.Molding sand- It is a mixture of silica, clay and moisture in
appropriate proportion
 Casting terminology

Cross section of a sand mold

18.Chaplet- are used to support core inside the mold cavity to take care
of core weight and overcome metallostatic force( force exerted by
liquid).
 Casting terminology

Cross section of a sand mold

18.Chills- Are metallic objects are placed in the mold to increase

cooling rate and to provide uniform cooling rate
 Desirable Mold Properties

Strength ‑ Ability of mold to maintain shape and resist erosion caused

by the flow of molten metal. Depends on grain shape, adhesive quality
of binders
Permeability ‑ to allow hot air and gases to pass through voids in
sand
Thermal stability ‑ ability of sand at the mold surface cavity to resist
cracking and buckling on contact with molten metal
Collapsibility ‑ ability to give way and allow casting to shrink
without cracking the casting .
Flowable-Green sand for moulding must fulfil and pack tightly round
the pattern under pressure.
 Desirable Mold Properties

Plastic behavior -Green sand for moulding should be able of being

deformed slightly without cracking, so that the pattern can be
withdrawn. In other words, it must exhibit
Cohesiveness- Ability of sand particles to stick together
Adhesiveness- The sand particles must be capable of adhering to
another body.
Choice of pattern
Depends on
1. Size of the casting
2. Number of casting to be made
3. Dimensional accuracy required
 Pattern

•Pattern is replica of casting

•A full-sized model of the part, slightly enlarged to account for

shrinkage and machining allowances in the casting

Pattern materials:

1. Wood - common material because it is easy to work, but it warps

2. Metal - more expensive to make, but lasts much longer

3. Plastic - compromise between wood and metal

 Pattern
PROPERTIES OF PATTERN MATERIAL
1. It should be easily shaped, worked, machined and joined.
2. It should be resistant to wear and corrosion.
3. It should be resistant to chemical action.
4. It should be dimensionally stable and must remain unaffected by
variations in temperature and humidity.
5. It should be easily available and economical.
 Pattern
Pattern materials:
Wood - common material because it is easy to work, but it warps
1. Easily available
2. Low weight
3. Low cost
4. It absorbs moisture and hence dimensions will change
5. Lower life
6. Suitable for small quantity production and very large size castings.
7. e.g. pine, mahogany, teak, walnut, and deodar
 Pattern
Pattern materials:
Metal
1. Used for mass production
2. For maintaining closer dimensional tolerances on casting.
3. More life when compared to wooden patterns
4. Few of the material used include CI, Al, Fe, Brass etc. Al is widely
used.
Plastic
5. Low weight
6. Easier formability
7. Do not absorb moisture
8. Good corrosion resistance
 Types of pattern
1. Single piece pattern
2. Split pattern
3. Match plate pattern
4. Gated pattern
5. Cope and drag pattern
6. Loose piece pattern
7. Follow board pattern
8. Sweep pattern
9. Skeleton pattern
Gating system
•It refers to all those elements which are connected with the flow of
molten metal from ladle to mold cavity.
•Various elements of gating system
1. Pouring basin
2. Sprue
3. Runner
4. Riser
5. Gates
Gating system
•Requirements of gating system when designed
1. The mold should be completely filled in the smallest time
possible.
2. The metal should flow smoothly into the mold without any
turbulence.
3. Unwanted materials like slag should not enter the mold cavity.
4. The metal entry should be properly controlled .
5. Metal flow should be maintained such that no mold erosion take
place.
6. Molten metal should reach mold cavity.
Gating system
•Requirements of gating system when designed
7. Design should be economical
Elements of gating system
1. Pouring basin
• Molten metal can not poured directly-> due to mold erosion
• Hence, it is poured is pouring basin which act as a reservoir.
• Pouring basin is able to stop slag with the help of skim core
Gating system
Elements of gating system
1. Pouring basin
•One of the wall of sprue should be
inclined at 45 degree with horizontal.
•Function of basin is to reduce momentum of the liquid
•Basin depth should be 2.5 times than sprue entrance diameter for
smooth flow.
•Metal should be poured steadily
Gating system
Elements of gating system
2. Sprue
• Sprue is inclined channel through which molten metal brought to
parting line ultimately enters the cavity.
• When molten metal flows , it gain velocity and hence smaller area
of cross section to avoid aspiration effect
Gating system
Elements of gating system
2. Sprue
•Exact tapering can be
obtained by continuity
equation

Where A1= Entering area

V1 -Entering velocity of molten metal

A2- exit area of sprue

V2- Exit velocity

Gating system
Elements of gating system
3. Runner
• Located in horizontal plane which connect sprue and gate
• It is trapezoid in cross section.

•For ferrous material the runner us cut in cope and gate in drag to
trap slag.
Gating system
Elements of gating system
4. Gates
• These are opening through which molten metal enters cavity
Types of gate
1. Top gate
2. Bottom gate
3. Parting gate
4. Step gate
Gating system
Elements of gating system
4. Gates
1. Top gate
Molten metal enters cavity from top.
Gating system
Elements of gating system
4. Gates
2. Bottom gate

•Molten metal enters slowly in

cavity
•Used for very deep mold
Gating system
Elements of gating system
4. Gates
3. Side/ Parting Gate
• In this case, metal enters the mould cavity at the same level as the
mould joint or parting line.
• Molten metal enters through the sprue and reaches the parting
surface where the sprue is connected to the runner or gates in a
direction horizontal to the casting
• The arrangement of providing a gate at the parting line allows the
use of devices that can effectively trap any slag, dirt, or sand, which
passes with the metal down the sprue
Gating system
Elements of gating system
4. Gates
4.Step gate-
• Used for heavy castings, where the molten metal enters the mould
cavity through number of ingates arranged in vertical steps.
• Size of ingate is varied from bottom to top, to avoid gradual filling
and sand erosion