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Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
casting 60% Permanent mold casting 11% Die casting 9% Investment casting 7% Centrifugal casting 7% Shell mold casting 6%
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Mold Features
The following is a gravity casting system. 2 principles of fluid flow are relevant to gating design: Bernoullis theorem and the law of mass continuity.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Gray cast iron Ductile iron (nodular iron) White cast iron Malleable iron Compacted-graphite iron Cast steels Cast stainless steels
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Aluminum-based alloys Magnesium-based alloys Copper-based alloys Zinc-based alloys High-temperature alloys
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Components of Casting
Path: Sprue -> Well -> Runner -> Mold cavity Riser: Compensate volume loss due to shrinkage Location of riser? Core: Make holes Core print Draft: Prevent collapse of sand
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Sand Casting
Types of sand molds 3 types: green-sand, cold-box, and no-bake molds. Green molding sand is mixture of sand, clay, and water and is inexpensive. In skin-dried method, castings has high strength, better accuracy and surface finish. In no-bake mold process, a synthetic liquid resin is mixed with the sand and hardened in room temperature.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Sand Casting
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Shell-mold casting
Can produce castings with close dimensional tolerances Good surface finish Low cost.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Shape Material
Conserve Material
Consolidation
Alting,Leo. Manufacturing Processes Reference Guide. 1994 April 2003 Horacio Elizondo
Capabilities
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
FIGURE 5.20 Schematic illustration of the expendable-pattern casting process, also known as lost-foam or evaporative-pattern casting.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Source:
Schematic illustration of investment casting (lost wax process). Castings by this method can be made with very fine detail and from a variety of metals. Source: Steel Founders' Society of America.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Shape Material
Conserve Material
Consolidation
Alting,Leo. Manufacturing Processes Reference Guide. 1994 April 2003 Horacio Elizondo
Capabilities
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Investment Casting
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Continuous-Casting
(a) The continuous-casting process for steel. Note that the platform is about 20 m (65 ft) above ground level. Source: American Foundrymen's Society. (b) (b) Continuous strip casting of nonferrous metal strip. Source: Courtesy of Hazelett Strip-Casting Corp.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Shape Material
Conserve Material
Consolidation
Alting,Leo. Manufacturing Processes Reference Guide. 1994 April 2003 Horacio Elizondo
Capabilities
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
FIGURE 5.24
FIGURE 5.23 The pressure casting process, utilizing graphite molds for the production of steel railroad wheels. Source: Griffin Wheel Division of Amsted Industries Incorporated.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Shape Material
Conserve Material
Consolidation
Alting,Leo. Manufacturing Processes Reference Guide. 1994 April 2003 Horacio Elizondo
Capabilities
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
FIGURE 5.25 Schematic illustration of the cold-chamber die-casting process. These machines are large compared to the size of the casting, because high forces are required to keep the two halves of the die closed under pressure.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Die Casting
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Centrifugal Casting
FIGURE 5.26 Schematic illustration of the centrifugal casting process. Pipes, cylinder liners, and similarly shaped hollow parts can be cast by this process.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Semicentrifugal Casting
FIGURE 5.27 (a) Schematic illustration of the semicentrifugal casting process. Wheels with spokes can be cast by this process. (b) Schematic illustration of casting by centrifuging. The molds are placed at the periphery of the machine, and the molten metal is forced into the molds by centrifugal forces.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Rotor Microstructure
FIGURE 5.22 Microstructure of a rotor that has been investment cast (top) and conventionally cast (bottom). Source: Advanced Materials and Processes, October 1990, p. 25. ASM International.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Q ! A1v1 ! A2 v2
Q = volumetric rate of flow A = cross-sectional area of the liquid stream v = velocity of the liquid
h2 h1
v ! c 2 gh
v ! c 2g h x
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
vD Re ! L
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Example 1
V = 1,040 m/s
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Example 5.2
The desired volume flow rate of the molten metal into a mold is 0.01 m3/min. The top of the sprue has a diameter of 20 mm and its length is 200 mm. What diameter should be specified at the bottom of the sprue in order to prevent aspiration? What is the resultant velocity and Reynolds number at the bottom of the sprue if the metal being cast is aluminium and has a viscosity of 0.004 N-s/m2 Solution Since d1 = 0.02 m
T 2 T 2 A1 ! d ! 0.002
! 3.14 10 4 m 2 4 4
1Top, 2 bottom
The metal volume flow rate is Q= 0.01 m3/min = 1.66710-4 m3/s Therefore
Assuming no frictional losses, and recognizing that the pressure at the top and bottom of the sprue is atmospheric Thus,
2 p2 v2 p1 v12 h1 ! h2 f Vg 2 g Vg 2 g 2 patm 0.531
patm v2 ! 0 0.2 Vg 29.81
Vg 29.81
2
v2 ! 1.45 m/s
Q ! A2 v2
T 2 A2 ! d 4
A2 ! 1.15 v 10 4 m 2
T 2 ! d 4
d ! 12 mm
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
v = velocity of the liquid D = diameter of the channel = density n = viscosity of the liquid. As stated above, this magnitude is typical for casting molds, representing a mixture of laminar and turbulent flow An Re value of up to 2000 represents laminar flow An Re Between 2000 and 20,000 it is a mixture of laminar and turbulent flow and is generally regarded as harmless in gating systems for casting Re values in excess of 20,000 represent severe turbulence.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Heat transfer
Heat flow depends on casting material and the mold and process parameters. Temperature distribution in the mold-liquid metal interface is shown below.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Solidification time (t) for a conducting mold (Biot # =hl/k < 0.17)
H = latent heat for the process = Hf + Ci T Hf = latent heat of solidification (fusion) V = volume A = area h = heat transfer coefficient C = specific heat = density
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, 2008 , Additional references in the last slide
Cooling time (t) for a solid object for a small Biot number (Biot # =hl/k < 0.17)
t!
casting
ln
old
casting ,initil
elting _ po int
casting , final
V t ! K A
t = cooling time K = a constant V = volume A = area
2 Amold tf ! Agate 2 g
For no aspiration
total
htotal hmold
Abotto
.of . spreue
Material
Density ( ) (kg/m3)
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Melting point Latent heat of Specific heat (C) Viscosity (oC) solidification (kJ/kg-oC) (L) (mPa-s) (fusion) (Hf) (kJ/kg)
660 1453 1083 1251 396 297 384 220 211 1.05 0.73 1.38 0.52 0.34 1.3 --1.04 2.1 5.25
Magnesium 650
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Solidification time
Solidification time is a function of the volume of a casting and surface area (Chvorinovs rule).
Volume Solidification time ! Surface Area
n
C = constant n=2
Effects of mold geometry and elapsed time on skin thickness and its shape are show.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Solidification time w
! 4.84
Shrinkage
Shrinkage in casting causes dimensional changes. Cracking is a result of: Contraction of the molten metal Contraction of the metal during phase change Contraction of the solidified metal
1. 2. 3.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Melting has a direct bearing on the quality of castings. Fluxes are inorganic compounds that refine the molten metal by removing dissolved gases and various impurities. The metal charge may be composed of commercially pure primary metals, which can include remelted or recycled scrap.
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid,
Casting Alloys
Source : Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Materials,5 Schmid, P.P.P File Prepared by the author and publisher and other sources
Bibliography (References) . Manufacturing Processes for Engineering Materials,5rd Edition., S. Kalpakjian and S. Schmid, Prentice Hill 2008 Materials and Processes in Manufacturing, 10th Edition, E. Paul DeGarmo, J. T. Black, Ronald A. Kohser,2007. Manufacturing Engineering & Technology , Serope Kalpakjian , 6th Edition, Prentice Hall,2009. TECNOLOGI CO DE MONTERREY Mechanical Manufacturing, Professor Arturo Molina , October 2004. E. Paul DeGarmo et al, Materials And Processes in Manufacturing, Wiley Publishing Company 2003. John E. Schey, Introduction To Manufacturing Processes McGraw-Hill Book Company,1988. Courtney, T. H., Mechanical Behavior of Materials, N. Y., McGraw-Hill, 1990. E., George E. and George F., The Testing of Engineering Materials, McGrraw-Hill Book Company. 1982. Hardness Tests, Metals Park, Ohio: ASM International, 1987. Harmer E., George E. and George F., The Testing of Engineering Materials, McGrraw-Hill Book Company. 1982. Halmshaw R. Non-Destructive Testing, Edward Arnold, 1991. Courtney, T. H., Mechanical Behavior of Materials, N. Y., McGraw-Hill, 1990. Jonathan S. Colton , Manufacturing Processes and Engineering, Georgia Institute of Technology, 2009. Pohlandt K., Material Testing for Metal forming Industry, N.Y Springer 1989. Lawrence E. Doyle, Manufacturing Process And Materials For Engineers, Prentice-Hall, Third Edition. T.T. EL-Midany & M.A. Mansour , Manufacturing Technology, King Abdulaziz University. S.F. Kvav et al., Machine Tool Operations, McGraw-Hill Book Company. Geoffrey Boothroyd, Fundamentals of Metal Machining and Machine Tools, McGraw-Hill Book Company. Cold and Hot Forging Fundamentals and Applications, Taylan Altan ,al, ASM,2007. Fundamentals of Metal Forming ,Robert H. Wagoner,Jean-Loup,Wiley,1997. Metal Forming ,Willam F. Hosford Robert M. ,second Edition, PTR, 1993.