THE MAKING OF METALLIC BODY

In metalworking, casting involves pouring liquid metal into a mold, which contains a hollow
cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is also
known as a casting, which is ejected or broken out of the mold to complete the process. Casting
is most often used for making complex shapes that would be difficult or uneconomical to make
by other methods.
Casting processes have been known for thousands of years, and widely used for sculpture,
especially in bronze, jewellery in precious metals, and weapons and tools. Traditional techniques
include lost-wax casting, plaster mold casting and sand casting.
The modern casting process is subdivided into two main categories: expendable and nonexpendable casting. It is further broken down by the mold material, such as sand or metal, and
pouring method, such as gravity, vacuum, or low pressure.
Some general mechanical terms:Foundry:-The place where jobs are prepared by melting and pouring the molten metals into
mould.
Mould:-It is a cavity so prepared that it can be used to make castings by pouring molten metal
into it.
Pattern:-It is a model of anything which is used to prepare moulds by placing it into sands.
MOLD CASTINGS
Furnace
In Kalsi Metal Works PVT.LTD,they are having a Cupola furnace which is used to melt the
metals for reshaping as desired parts of motor of different sizes such as end rings, top cover,
stator core ,stator outer body etc. are made in this department.
Furnace installed in this industry is Furnace,is a type of crucible furnaces .these are the most
commonly used furnace in foundries. In this furnace whole melting of metal is carried out inside
a melting pot, called Crucibles
Cupola furnace
A cupola or cupola furnace is a melting device used in foundries that can be used to melt cast
iron, ni-resist iron and some bronzes. The cupola can be made almost any practical size. The size
of a cupola is expressed in diameters and can range from 1.5 to 13 feet (0.5 to 4.0 m). The

overall shape is cylindrical and the equipment is arranged vertically, usually supported by four
legs. The overall look is similar to a large smokestack.
The bottom of the cylinder is fitted with doors which swing down and out to 'drop bottom'. The
top where gases escape can be open or fitted with a cap to prevent rain from entering the cupola.
To control emissions a cupola may be fitted with a cap that is designed to pull the gases into a
device to cool the gases and remove particulate matter.
The shell of the cupola, being usually made of steel, has refractory brick and plastic
refractory patching material lining it. The bottom is lined in a similar manner but often a clay and
sand mixture ("bod") may be used, as this lining is temporary. Finely divided coal ("sea coal")
can be mixed with the clay lining so when heated the coal decomposes and the bod becomes
slightly friable, easing the opening up of the tap holes The bottom lining is compressed or
'rammed' against the bottom doors. Some cupolas are fitted with cooling jackets to keep the sides
cool and with oxygen injection to make the coke fire burn hotter.
To begin a production run, called a 'cupola campaign', the furnace is filled with layers of coke
and ignited with torches. Some smaller cupolas may be ignited with wood to start the coke
burning. When the coke is ignited, air is introduced to the coke bed through ports in the sides
called tuyeres.
When the coke is very hot, solid pieces of metal are charged into the furnace through an opening
in the top. The metal is alternated with additional layers of fresh coke. Limestone is added to act
as a flux. As the heat rises within the stack the metal is melted. It drips down through the coke
bed to collect in a pool at the bottom, just above the bottom doors. During the melting process
a thermodynamic reaction takes place between the fuel and the blast air. The carbon in the coke
combines with the oxygen in the air to form carbon monoxide. The carbon monoxide further
burns to form carbon dioxide. Some of the carbon is picked up by the falling droplets of molten
metal which raises the carbon content of the iron. Silicon carbide and ferromanganese briquettes
may also be added to the charge materials. The silicon carbide dissociates and carbon and silicon
enters into the molten metal. Likewise, the ferromanganese melts and is combined into the pool
of liquid iron in the 'well' at the bottom of the cupola. Additions to the molten iron such
as ferromanganese, ferrosilicon, Silicon carbide and other alloying agents are used to alter the
molten iron to conform to the needs of the castings at hand.
The operator of the cupola is known as the "cupola tender" or "furnace master". During the
operation of a tapped cupola (cupolas may vary in this regard) the tender observes the amount of
iron rising in the well of the cupola. When the metal level is sufficiently high, the cupola tender
opens the "tap hole" to let the metal flow into a ladle or other container to hold the molten metal.
When enough metal is drawn off the "tap hole" is plugged with a refractory plug made of clay.

The cupola tender observes the furnace through the sight glass or peep sigh in the tuyeres. Slag
will rise to the top of the pool of iron being formed. A slag hole, located higher up on the
cylinder of the furnace, and usually to the rear or side of the tap hole, is opened to let the slag
flow out. The viscosity is low (with proper fluxing) and the red hot molten slag will flow easily.
Sometimes the slag which runs out the slag hole is collected in a small cup shaped tool, allowed
to cool and harden. It is fractured and visually examined. With acid refractory lined cupolas a
greenish colored slag means the fluxing is proper and adequate. In basic refractory lined cupolas
the slag is brown.

Equipments used for casting

Metal used :- Cast iron at 1260 0C
Moulding Boxes
Mold boxes are also known as molding flasks. Open molding boxes are made with the hinge at
one corner and a lock on the opposite corner. They are also known as snap molding boxes which
are generally used for making sand molds. A snap molding is made of wood and is hinged at one
corner. It has special applications in bench molding in green sand work for small nonferrous
castings. The mold is first made in the snap flask and then it is removed and replaced by a steel
jacket. Thus, a number of molds can be prepared using the same set of boxes. As an alternative to
the wooden snap boxes the cast-aluminum tapered closed boxes are finding favor in modern
foundries. They carry a tapered inside surface which is accurately ground and finished. A solid
structure of this box gives more rigidity and strength than the open type. These boxes are also
removed after assembling the mould. Large molding boxes are equipped with reinforcing cross
bars and ribs to hold the heavy mass if sand and support gaggers. The size, material and
construction of the molding box depend upon the size of the casting.

Open molding box

Ladle
It is similar in shape to the crucible which is also made from graphite or steel shell lined with
suitable refractory material like fire clay. It is commonly used to receive molten metal from the

melting furnace and pour the same into the mold cavity. Its size is designated by its capacity.
Small hand shank ladles are used by a single foundry personal and are provided with only one
handle.

Ladle
Molding Sand
Molding Sand is a mixture of silica sand with the coal powder along with batanoute ,dextrin
powder Silica sand in form of granular quarts is the main constituent of molding sand having
enough refractoriness which can impart stability and permeability to molding and core sand. But
along with silica small amounts of iron oxide, alumina, lime stone, magnesia, soda and potash
are present as impurities. The chemical composition of silica sand gives an idea of the impurities
like lime, magnesia, alkalis etc. present. The presence of excessive amounts of iron oxide, alkali
oxides and lime can lower the fusion point to a considerable extent which is undesirable. To
remove these impurities and to minimize the effect of these impurities, doping is made and to
provide strength to sand .
Shovel
It consists of an steel pan fitted with a long wooden handle.It is used in mixing, tempering and
conditioning the foundry sand by hand. It is also used for moving and transforming the molding
sand to the container and molding box or flask. It should always be kept clean.

Shovel
Strike off bar
It is a flat bar having straight edge and is made of wood or iron.It is used to strike off or remove
the excess sand from the top of a molding box after completion of ramming thereby making its
surface plane and smooth. Its one edge is made beveled and the other end is kept perfectly
smooth and plane.

Strike off bar

DESIGN CONSIDERATIONS IN PATTERN MAKING
The following considerations should always be kept in mind while designing a pattern:
1. Parting line should be selected carefully, so as to allow as small portion of the pattern as far as
possible in the cope area.
2. The thickness and section of the pattern should be kept as uniform as possible.
3. Sharp corners and edges should be supported by suitable fillets or otherwise rounded of. It will
facilitate easy withdrawal of pattern, smooth flow of molten metal and ensure a sound casting.
4. Surfaces of the casting which are specifically required to be perfectly sound and clean should
be so designed that they will be molded in the drag because the possible defects due to loose
sand and inclusions will occur in the cope.
5. As far as possible, full cores should be used instead of cemented half cores for reducing cost
and for accuracy.
6. For mass production, the use of several patterns in a mound with common riser is to be
preferred.
7. The pattern should have very good surface finish as it directly affects the corresponding finish
of the casting.
8. Shape and size of the casting and that of the core should be carefully considered to decide the
size and location of the core prints.
9. Proper material should always be selected for the pattern after carefully analyzing the factors
responsible for their selection.
10. Wherever there is a sharp corner, a fillet should be provided, and the corners maybe rounded
up for easy withdrawal of patterns as well as easy flow of molten metal in the mould.
PATTERN LAYOUT
After deciding the molding method and form of pattern, planning for the development of
complete pattern is made which may be in two different stages. The first stage is to prepare
layout of the different parts of the pattern. The next stage is to shape them. The layout
preparation consists of measuring, marking, and setting out the dimensions on a layout board

including needed allowances. The first step in laying out is to study the working drawing
carefully and select a suitable board of wood that can accommodate at least two views of the
same on full size scale. The next step is to decide a working face of the board and plane an
adjacent edge smooth and square with the said face. Select a proper contraction scale for
measuring and marking dimensions according to the material of the casting. Further the layout is
prepared properly and neatly using different measuring and making tools specifying the locations
of core prints and machined surfaces. Finally on completion of the layout, check carefully the
dimension and other requirements by incorporating all necessary pattern allowances before
starting construction of the pattern.
PATTERN CONSTRUCTION
On preparing the pattern layout, the construction for making it is started by studying the layout
and deciding the location of parting surfaces. From the layout, try to visualize the shape of the
pattern and determine the number of separate pieces to be made and the process to be employed
for making them. Then the main part of pattern body is first constructed using pattern making
tools. The direction of wood grains is kept along the length of patterns far as possible to ensure
due strength and accuracy. Further cut and shape the other different parts of pattern providing
adequate draft on them. The prepared parts are then checked by placing them over the prepared
layout. Further the different parts of the pattern are assembled with the main body in proper
position by gluing or by means of dowels as the case may be. Next the relative locations of all
the assembled parts on the pattern are adjusted carefully. Then, the completed pattern is checked
for accuracy. Next all the rough surfaces of pattern are finished and imparted with a thin coating
of shellac varnish. The wax or leather fillets are then fitted wherever necessary. Wooden fillets
should also be fitted before sanding and finishing. The pattern surface once again prepared for
good surface and give final coat of shellac. Finally different parts or surfaces of pattern are
colored with specific colors mixed in shellac or by painting as per coloring specifications.

Metal Making by metal casting

The hot molten metal obtained from furnace is obtained in ladle upto caryable capacity of
workers to handle the ladle carefully it is transported to cavity cell manually by workers and it is
poured in the mold slowly-slowly in the mould as iot is poured in the mould the gases present in
the sand of mold burns out as burns flame through the openings provided by rimmers if they are
not provided then the mould will burst out due such a high pressure
Then the desired piece is isolated for 1-2 days allowing it to cool down and attain the shape of
the mould . after the time the sand should be remove carefully without damaging the the piece.
Die-casting
Die casting means casting of the metallic part by making is die where die is a mould cavity of the
shape of metal to make
Die casting is a metal casting process that is characterized by forcing molten metal under high
pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which
have been machined into shape and work similarly to an injection mold during the process. Most
die
castings
are
made
from
non-ferrous metals,
specificallyzinc, copper, aluminium, magnesium, lead, pewter and tin based alloys. Depending
on the type of metal being cast, a hot- or cold-chamber machine is used.
The casting equipment and the metal dies represent large capital costs and this tends to limit the
process to high volume production. Manufacture of parts using die casting is relatively simple,
involving only four main steps, which keeps the incremental cost per item low. It is especially
suited for a large quantity of small to medium-sized castings, which is why die casting produces
more castings than any other casting process. Die castings are characterized by a very
good surface finish (by casting standards) and dimensional consistency.