ME8352 – MANUFACTURING

TECHNOLOGY - 1

UNIT -1
METAL CASTING PROCESSES
SYLLABUS
 TOPICS
1. INTRODUCTION TO CASTING PROCESSES
2. PATTERNS
3. MOULD MATERIALS
4. SAND PREPARATION, CONDITIONING & TESTING
5. CORE
6. MOULDS
7. METAL MELTING FURNACES
8. HAND MOULDING MATERIALS
9. MOULDING MACHINES
10. CASTING PROCESSES
11. CLEANING OF CASTING
12. CASTING DEFECTS AND REMEDIES
13. INSPECTION OF CASTING
14. METALS FOR CASTING
 1. INTRODUCTION TO CASTING
PROCESSES
1. Casting Definition
2. Need
3. Steps involved in casting processes
4. Advantages & Applications of metal casting
processes
 2. Patterns
1. Pattern definition
2. Pattern making
1. Functions of a pattern
3. Pattern materials
1. Material for making pattern
4. Pattern Allowances
1. Types of allowance used in patterns
5. Types of Patterns
6. Pattern Colours
 3.Mould Materials
1. Moulding Sand
2. Types of moulding sand
3. Characteristic of moulding sand
4. Constituents of moulding sand
 4. Sand Preparation , conditioning
and Testing
1. Sand preparation & conditioning
2. Sand testing
1. Moisture content test
2. Clay content test
3. Permeability test
4. Grain Fineness test
5. Compression strength Test
 5.CORE
1. Core sand and its ingredients
2. Core making
3. Types of Cores
4. Core Boxes
5. Core prints
6. Chaplets
 6.MOULDS
1. Steps involved in mould Making
2. Moulding processes
1. Floor moulding
2. Bench moulding
3. Pit moulding
4. Green sand moulding
5. Dry sand moulding
6. Loam moulding
7. Shell moulding
8. Carbon-dioxide moulding
3. Gating system
1. Pouring Cups and Basins
2. Sprue
3. Runner
4. Gates
5. Riser or Feeder head
 7.METAL MELTING FURNACES
1. Selection of Furnaces
2. Types of Furnaces
1. Crucible furnace
2. Cupola Furnace
 8. HAND MOULDING MATERIALS
1. Shovel 12. Vent wire
2. Hand riddle 13. Trowels
3. Rammers 14. Draw screws and rapping
4. Slicks plates
5. Lifters & cleaners 15. Smoothers and corner slicks
6. Draw spike 16. Mallets
7. Bellow 17. Sprue pin
8. Sprue cutter 18. Gate cutter
9. Swab 19. Brush and dust bag
10. Gaggers 20. Clamps , cotters and wedges
11. Strike off bars 21. Nails and wire pieces
22. Spray – gun and sprit levels
 9. Moulding Machine
1. Squeeze moulding machine
2. Jolt moulding machine
3. Jolt – sqeezing and moulding machine
4. Sand slinger
 10.Casting Processes
1. Permanent mould casting
2. Slush Casting
3. Pressure Die – Casting
4. Comparison between Hot chamber and Cold
Chamber Die Casting
5. Centrifugal Casting
6. Investment casting
7. Continuous Casting
8. Ceramic Mould Casting
9. Stir Casting
 11.Cleaning of Casting
1. Removal of dry sand cores
2. Removal of gates, risers, runners etc
3. Removal of unwanted metal projections
4. Removal of adhering sand and oxide, scale
from the casting surface.
12. Casting Defects and Remedies
1. Blow holes
2. Porosity
3. Shrinkage
4. Hot tears
5. Misrun
6. Cold shut
7. Scabs
8. Mis match
9. Core shift
 13. INSPECTION OF CASTINGS
1. DESTRUCTIVE TESTING METHODS
2. NON – DESTRUCTIVE TESTING METHODS
 14. METALS FOR CASTING
1. FERROUS CASTING ALLOYS
2. NON- FERROUS CASTING ALLOYS
 1. INTRODUCTION TO CASTING
PROCESSES
1. Casting Definition
2. Steps involved in casting processes
3. Advantages & Applications of metal casting
processes
 CASTING DEFINITION
• Casting and Founding is the processes of
producing metal or alloy component parts
• The parts of desired shape are formed by
pouring the molten metal or alloy into in to a
prepared mould and then allowing the metal
or alloy to cool and solidify
• This solidified piece of metal or alloy is called
casting
2. Steps involved in casting processes

1. Pattern making
2. Sand mixing and preparation
3. Core making
4. Melting
5. Pouring
6. Finishing
7. Testing
 3. Advantages and applications of
metal casting
1. Advantages
1. Most versatile manufacturing processes
2. It provides great freedom of design in terms of shape ,
size and quality etc.
3. Provides better vibration damping capacity
4. Complex shapes can be easily formed by wucing casting
2. Applications
1. Automobile components
2. Ship components
3. Machine tool structures
4. Pump body casing
5. Valve body casing etc
 2. Patterns
1. Pattern definition
2. Pattern making
1. Functions of a pattern
3. Pattern materials
1. Material for making pattern
4. Pattern Allowances
1. Types of allowance used in patterns
5. Types of Patterns
6. Pattern Colours
 PATTERN
• A pattern is defined as a model or replica of
the of the object to be cast
Mould cavity
Sprue & Riser needs
 Pattern Making
• A pattern is slightly larger than casting to
match the accuracy of casting size during
cooling of molten metal
• These pattern are mainly made up of wood
and the model for the pattern shape is done
by machining the pattern material to attain
the correct desired shape
 Functions of a Pattern
• To prepare a mould cavity of appropriate size and
shape
• To produce seats for the cores in the mould in
which cores can be placed for producing cavity in
the casting, such seats in the mould are called
core prints
• To establish the parting line and parting surface in
the mould
• To minimize the casting defects
• It should minimize the over all casting cost
 Pattern Materials
• Selection of material for Pattern :
1. Based on number of casting to be made, here
the metal pattern are used for large quantity of
production
2. Degree of accuracy
3. Method of moulding by machine or hand
4. Types of casting method – sand casting or
investment casting
5. Shape , size and complexity
6. Casting design parameters
7. Types of moulding material to be used
 Pattern Materials
1. Wood
2. Metal
3. Plastic
4. Plaster
5. Wax
 Pattern Allowances
1. Shrinkage allowance
2. Machining allowance
3. Drafter or taper allowance
4. Distortion allowance
5. Rapping or shake allowance
 Pattern Allowances
1. Shrinkage or Contraction allowance
– After pouring molten metal in to the mould cavity
and during cooling the molten metal tends to shrink
due to its metallurgical and mechanical properties
– To satisfy these the pattern is produced just larger
than the real size of the component to be casted its is
called as shrinkage allowance
 Pattern Allowances
2. Machining or Finish allowance
– It is the amount of dimension on a casting which is made
over sized to provide stock for machining
– A casting may require machining all over or on certain
specific portions
– Such portions or surface on the pattern are given
adequate allowance in addition to the shrinkage
allowance
 Pattern Allowances
3. Draft or taper allowance
– These allowances are given to all the vertical faces of
the pattern for their easy removal from sand without
damaging the mould
– This slightly inward or out ward on the vertical faces
is known as draft
– It can be expressed in degree or mm/ meter
 Pattern Allowances
4. Distortion or chamber allowance
– The tendency of distortion is not common in all the
castings
– The casting will distort
• If it is irregular in shape
• It is or U or V shape
• The arms having unequal thickness
 Pattern Allowances
5. Rapping or shake allowance
– When a pattern is to be taken from the mould it
should be rapped or shaked , so that the pattern
gets adjoined from the sand.
– Due to this the mould may get enlarged, for this a
negative allowance is provided on the pattern
 Types of Patterns
1. Single piece or Solid Pattern
2. Two Piece or Split pattern
3. Loose piece pattern
4. Cope and Drag pattern
5. Gated pattern
6. Match Plate pattern
7. Sweep Pattern
8. Skeleton Pattern
9. Segmental pattern
10. Follow board pattern
11. Lagged – up pattern
 1. Single piece or Solid Pattern
• It is the simplest of all the pattern
• It is of single solid piece with desired shape of the
component
• It is generally used for making large sized simple casting
1. Single piece or Solid Pattern
 1. Two piece or Split Pattern
• Patterns of complicated shape castings cannot be made
in one piece because of the difficulties associated with
the moulding operations
• Such patterns are made in two pieces , called as split
pattern or two piece pattern
1. Two piece or Split Pattern
 3. Loose piece pattern
• Some patterns embedded in the moulding sand cannot
be withdrawn, hence such patterns are made with one
or more loose pieces for their easy removal from the
moulding box
3. Loose piece pattern
 4. Cope and Drag Pattern
• It is another form of Split pattern
• The pattern is split about a suitable surface or line
 5. Gated Pattern
• To increase the strength and reduce the tendency to
wrap, gated patterns are generally made of metals.
• By using gated patterns number of casting can be made
at a time, hence they are used in mass production
system
5. Gated Pattern
 6. Match plate pattern
• These patterns are made up of two pieces. One piece is
mounted on onside and the other on the other side of
the plate, called as match plate
• The plate can carry one pattern or group of pattern
mounted in the same way on its two sides
6. Match plate pattern
 7.Sweep pattern
• This pattern is just a form made on a board which
sweeps the casting shape into the sand all around
the circumference
7.Sweep pattern
 8. Skeleton pattern
• When the casting size is very large, but easy to shape and few are to
be made , then it is not economical to make a large solid pattern of
that size.
• in such cases, a pattern consisting of a wooden frame and strips is
made which is called as skeleton pattern
• It is filled with loam sand and rammed
• A Strickle is used for giving the desired shape to the sand and for
removing the extra sand
8. Skeleton pattern
 9. Segmental pattern
• The working principle of segmental pattern is
equal to seep pattern
 10. Follow Board Pattern
• A follow board is a wooden board and is used for
supporting a pattern which is thin and fragile.
• With the support of follow board the thin weak pattern
is rammed and after ramming the follow board is
removed from the thin weak pattern
 11. Lagged up pattern
• Cylindrical work pieces such as cylinders , pipes or
columns are built up with lag (Stave) constructions
 Pattern Colours
1. To identify quickly the main pattern body and
different pattern parts
2. To indicate the type of the metal to be cast
3. To identify loose pieces , core prints etc.
4. To visualise machined surfaces, etc.
An American Colour Scheme
• Red – Cast surfaces to be maintained
• Black – Surfaces to be left un machined
• Yellow – Core Prints seat
• Red Strips on Yellow base – Loose piece and seatings
• Clear or no colour – Parting surfaces
• Black Strips on yellow base – Supports or stop offs
• Yellow strips on black background – Core prints for
machined castings
 Mould material
• It is one of which a mould is made
• The mould material should be such that the
cavity of the mould retains its shape till the
metal has solidified
• Casting can be done permanent mould ( made
up of ferrous metal and alloys ) or temporary
refractory moulds ( made of resin and sands)
 Moulding Sand
• Sand is the most widely used mould material for
casting ferrous and non ferrous metals from few
grams to tons
• The main reason for this is that , the sand fulfills
service requirements at reasonable cost than the
other materials
• When the sand is properly mixed with other
elements , it constitutes one of the best materials
for the mould
• The source of moulding sand are river beds,
lakes, sea and desert
 Types of moulding sand
1. Natural sand
2. Synthetic sand
3. Special sands
1. Green sand
2. Loam sand
3. Core sand
4. Parting sand
5. Facing sand
6. Backing sand
 Characteristics of Moulding sand
1. Flowability or plasticity
2. Green strength
3. Dry strength
4. Permeability or porosity
5. Refractoriness
6. Adhesiveness
7. Cohesiveness
8. Thermal stability
9. Collapsibility
 Constituents of Moulding sand
1. Sand
2. Binder
3. Additives
1. Coal dust
2. Sea coal
3. Corn flour or cereals
4. Silica flour
5. Wood flour
6. Pitch
7. Fuel oil
4. Water
 4. Sand Preparation , conditioning
and Testing
1. Sand preparation & conditioning
2. Sand testing
1. Moisture content test
2. Clay content test
3. Permeability test
4. Grain Fineness test
5. Compression strength Test
 Function of sand preparation and
conditioning
• To develop optimum properties in the
moulding sand
• To obtain even distribution of sand grains
through out the bond
• To add suitable amount of water to activate
clay binders
• To deliver sand at the suitable temperature
• To remove impurities from the moulding sand
 Steps involved in preparation of sand
1. Remove all impurities
2. Mix the sand with hand or Muller machine
3. Temper the moulding sand ingredients
4. Treat the sand by aeration process which
separate sand grains into individual particles
5. Finally cool the sand
Mullers
Muller working
 Sand Tester
1. Moisture Content test
2. Clay content test
3. Permeability test
4. Grain fineness test
5. Mould hardness test
6. Refractoriness test
7. Compression strength test
Moisture content test
Grain fineness test
Compression strength test
 5.CORE
1. Core sand and its ingredients
2. Core making
3. Types of Cores
4. Core Boxes
5. Core prints
6. Chaplets
 Core
• It is a sand shape or form which makes the
contour of a casting for which no provision has
been made in the pattern for moulding
 Functions of Core
• It provides a means of forming the main
internal cavity for hollow casting
• Provides external under cut features
• It is used to increase the strength of the
mould
• It can be used as a part of gating assembly
 Characteristics of core
• Strength
• High permeability
• High refractoriness
• Smooth surface
• High collapsibility
 Core sand and its ingredients
• Sand mixture
• Consist of 1% core oil , 1% cereal and 2.5 to 6% water
• Core sand ingredients
1. Granular refractories
2. Core binders
3. Water
4. Additives
 Core making
1. Core sand preparation
2. Core making
3. Core backing
4. Finishing of cores
5. Setting the cores
 Types of cores
1. Horizontal core
2. Vertical core
3. Hanging over core
4. Balanced core
5. Ram up core
6. Kiss core
7. Drop core
 Core Boxes
1. Half core box
2. Dump core box
3. Split core box
4. Strickle core box
5. Gang core box
6. Loose piece core box
7. Left and right hand core boxes
 Core boxes
Half core box Dump core box
 Core boxes
Split core box Strickle core box
 Core boxes
Gang core box Loose piece core box
Left and right hand core boxes
Core Prints
Chaplets
Types of Chaplets
 6.MOULDS
1. Steps involved in mould Making
2. Moulding processes
1. Floor moulding
2. Bench moulding
3. Pit moulding
4. Green sand moulding
5. Dry sand moulding
6. Loam moulding
7. Shell moulding
8. Carbon-dioxide moulding
3. Gating system
1. Pouring Cups and Basins
2. Sprue
3. Runner
4. Gates
5. Riser or Feeder head
Steps involved in moulding
 Moulding processes

1. Floor moulding
2. Bench moulding
3. Pit moulding
4. Green sand moulding
5. Dry sand moulding
6. Loam moulding
7. Shell moulding
8. Carbon-dioxide moulding
 Moulding processes
Shell moulding
Carbon dioxide moulding
Gating System
 Gates
• Parting line gates
• Top gates
• Bottom gates
• Side gates
Gates
 Selection of furnaces
• Initial furnace cost
• Cost of the fuel
• Type of metal to be melted
• Melting and pouring temperature required
• Quantity and of metal to be melted
• Degree of cleanliness or pollution
• Speed of melting etc
 Types of furnace
• Furnace of batch melting
– Crucible furnace
• Pit furnace
• Oil fired furnace
• gas fired furnace
– Electric furnace
• Direct arc furnace
• Indirect Arc Furnace
• Induction Furnace
• Furnace of continuous melting
– Blast Furnace
– Cupola Furnace
 Crucible Furnace
1. Pit furnace
2. Oil fired furnace
3. gas fired furnace
1. Pit furnace
2. Oil fired Furnace
3. Coke fired Furnace
 Electrical Furnace
1. Direct arc furnace
2. Indirect Arc Furnace
3. Induction Furnace
1. Direct Arc Furnace
2. In -Direct Arc Furnace
3. Induction Furnace
 8. HAND MOULDING MATERIALS
1. Shovel 12. Vent wire
2. Hand riddle 13. Trowels
3. Rammers 14. Draw screws and rapping
4. Slicks plates
5. Lifters & cleaners 15. Smoothers and corner slicks
6. Draw spike 16. Mallets
7. Bellow 17. Sprue pin
8. Sprue cutter 18. Gate cutter
9. Swab 19. Brush and dust bag
10. Gaggers 20. Clamps , cotters and wedges
11. Strike off bars 21. Nails and wire pieces
22. Spray – gun and sprit levels
 9. Moulding Machine
1. Squeeze moulding machine
2. Jolt moulding machine
3. Jolt – sqeezing and moulding machine
4. Sand slinger
1.Squeeze moulding machine
2.Jolt moulding machine
3. Jolt – sqeezing and moulding
machine
4. Sand slinger
 10.Casting Processes
1. Permanent mould casting
2. Slush Casting
3. Pressure Die – Casting
4. Centrifugal Casting
5. Investment casting
6. Continuous Casting
7. Ceramic Mould Casting
8. Stir Casting
1. Permanent mould casting
2. Slush casting
 11.Cleaning of Casting
1. Removal of dry sand cores
2. Removal of gates, risers, runners etc
3. Removal of unwanted metal projections
4. Removal of adhering sand and oxide, scale
from the casting surface.
12. Casting Defects and Remedies
1. Blow holes
2. Porosity
3. Shrinkage
4. Hot tears
5. Misrun
6. Cold shut
7. Scabs
8. Mis match
9. Core shift
 13. INSPECTION OF CASTINGS
1. DESTRUCTIVE TESTING METHODS
2. NON – DESTRUCTIVE TESTING METHODS