Workshop Practice (Theory) :ESC-

104
Lecture-2
Presented By:
Jagdip Chauhan
Assistant Professor
Mechanical Engineering Department
Guru Jambheswar University of Science & Technology, Hisar
Casting:
Foundry or casting is the process of producing metal or alloy
parts of desired shapes by pouring the Molten metal/alloy
into a prepared mould or cavity and then allowing the
metal/alloy to cool and solidify. The solidified piece of
metal/alloy is known as Casting.
 Metal casting processes:
• Casting is one of the oldest manufacturing processes. It is the first step in
making most of the products.
• Steps:
- Making mould cavity
- Material is first liquefied by proper heating in a suitable furnace.
- Liquid is poured into a prepared mould cavity
- Allowed to solidify
- Product is taken out of the mould cavity, trimmed and made to shape.
• We should concentrate on the following for a successful casting operation:
(i) Preparation of moulds by patterns
(ii) Melting and pouring of the liquefied metal
(iii) Solidification and further cooling to room temperature
(iv) Defects and inspection
casting terms:
• Flask: A metal or wood frame, without a fixed top or bottom, in which
the mould is formed. Depending upon the position of the flask in the
moulding structure, it is referred to by various names such as drag –
lower moulding flask, cope – upper moulding flask, cheek – intermediate
moulding flask used in three-piece moulding.
casting terms:
• Pattern: It is the replica of the final object to be made. The mould cavity
is made with the help of a pattern.
• Parting line: This is the dividing line between the two moulding flasks
that makes up the mould.
• Moulding sand: Sand, which binds strongly without losing its
permeability to air or gases. It is a mixture of silica sand, clay, and
moisture in appropriate proportions.
• Facing sand: The small amount of carbonaceous material sprinkled on
the inner surface of the mould cavity to give a better surface finish to the
castings.
casting terms:
• Core: A separate part of the mould, made of sand and generally baked,
which is used to create openings and various shaped cavities in the castings.
• Pouring basin: A small funnel-shaped cavity at the top of the mould into
which the molten metal is poured.
• Sprue: The passage through which the molten metal, from the pouring basin,
reaches the mould cavity. In many cases, it controls the flow of metal into
the mould.
• Runner: The channel through which the molten metal is carried from the
sprue to the gate.
• Gate: A channel through which the molten metal enters the mould cavity.
casting terms:

• Chaplets: Chaplets are used to support the cores inside the

mould cavity to take care of their own weight.
• Riser: A column of molten metal placed in the mould to feed
the castings as it shrinks and solidifies. Also known as “feed
head”.
• Vent: Small opening in the mould to facilitate the escape of air
and gases.
Steps in making sand castings:
• The basic steps in making sand castings are:
• (i) Pattern making, (ii) Core making, (iii) Moulding, (iv) Melting and pouring, (v)
Cleaning
• Pattern: Replica of the part to be cast and is used to prepare the mould cavity. It is the
physical model of the casting used to make the mould. Made of either wood, metal, or
wax.
• The mould is made by packing some readily formed aggregate material, such as
moulding sand, surrounding the pattern. When the pattern is withdrawn, its imprint
provides the mould cavity. This cavity is filled with metal to become the casting.
• If the casting is to be hollow, additional patterns called ‘cores’, are used to form these
cavities.
Steps in making sand castings:
• Core making: Cores are placed into a mould cavity to form the interior surfaces of
castings. Thus the void space is filled with molten metal and eventually becomes the
casting.
• Moulding: Moulding is nothing but the mould preparation activities for receiving
molten metal. It usually involves:
• (i) preparing the consolidated sand mould around a pattern held within a supporting
metal frame, (ii) removing the pattern to leave the mould cavity with cores.
• Mould cavity is the primary cavity. The mould cavity contains the liquid metal and it
acts as a negative of the desired product.
• The mould also contains secondary cavities for pouring and channeling the liquid
material in to the primary cavity and will act as a reservoir, if required.
Steps in making sand castings:

• Melting and Pouring: The preparation of the molten metal for casting is
referred to simply as melting. The molten metal is transferred to the pouring
area where the moulds are filled.
• Cleaning: Cleaning involves the removal of sand, scale, and excess metal from
the casting. Burned-on sand and scale are removed to improve the surface
appearance of the casting. Excess metal, in the form of fins, wires, parting line
fins, and gates, is removed. Inspection of the casting for defects and general
quality is performed.
PATTERN:
A pattern is an essential tool for the Casting Process. It is used for molding a cavity
in the molding sand mixture such that the formed cavity is looked the same as the
casting product.
The selection of material for pattern depends on different factors that include the
number of casting, quality of casting, and the degree of finish.

• Functions of Pattern:
These are some functions of a Pattern:

1. It is used for preparing a mold cavity which is used for Casting any parts.
2. Some accurate patterns can minimize the production cost of a product because
no further machining is required.
3. It reduces casting defects.
MATERIALS USED FOR PATTERN:
Some key factors are in mind before choosing a material for the pattern:
1. The materials used in the pattern should be cheap in cost and easily available in
the market.
2. The material should have a good surface finish.
3. The material should have withstood high temperatures and does not change its
shape at high temperatures.

• Generally, we use 5 different types of material to make the pattern and those are:

1. Wood
2. Metals
3. Plaster of Paris
4. Plastics
5. Wax
MATERIALS USED FOR PATTERN:
Wood:
As we all know woods are easily available, and the price is quite low so it is satisfied some
basic criteria which I mentioned above.
Also, there are some advantages to using wood in patterns and those are:
1.Wood is light in weight
2.Easily Available in the market
3.You can make any shape using wood
4.Woods gives a good surface finish
• However, wood is attracted to moisture and sometimes it can change shape at high
temperatures or after drying out from moisture, this is an important con of using wood as
a pattern.
• Not only this reason woods are very weak in strength, and it wears out quickly due to
their low resistance to sand abrasion.
For these above reasons, it is not used for very big product casting.
• Generally, pines deodar, walnut, teak’s are used for making a pattern.
MATERIALS USED FOR PATTERN:
Metals:
In metals, cast iron, brass, aluminum are generally used in patterns. It gives a
smooth surface finish, this is the only reason that metals are used in large
production casting workshops.
These are some advantages of using Metal Pattern:
1.Smooth surface finish can be obtained by metal patterns.
2.Deformation is less.
3.Closer dimensional tolerance.
Although there are some disadvantages of using this type of pattern like it is
a little bit costlier, heavy, sometimes rusting effect occurred on the surfaces
of the metals.
MATERIALS USED FOR PATTERN:
Plaster of Paris:
It is generally used if you need to set up the pattern quickly. The main advantage of this
pattern is it can easily be cast into intricate shapes.
However, it is not for repetitive usage as it is fragile.
Plastics:
Different types of plastics are nowadays used in patterns because of their lighter weight,
strength, and dimensionally stability, and also for a cheap cost.
Thermoplastics and polystyrene are commonly used for making patterns, and
Thermosetting plastics such as phenolics and epoxies are also used in a pattern.
There are a few advantages of using patterns and those are:
1.Light in weight.
2.Cheap in price.
3.It possesses good compressive strength.
4.No tension of rusting or moisture absorbing.
However, they are a little weak in strength and not good abrasion-resistant.
MATERIALS USED FOR PATTERN:
Wax:
A wax pattern is used in the investment casting process. By using this pattern
we get a high degree of accuracy and have an excellent surface finish.

However it needs little care handling otherwise it can be broken, and it is

used in small casting.
 Q&A

I am done
Thank You