Ain Shams University.

Faculty of Engineering.
Mechanical Engineering Department.

Manufacturing Technology II.

Casting process procedure.

Submitted by: Omar Mohammed Abd-ulhammed.

Class No. : Five.

Second Year of Mechanical Engineering.

Submitted to: Eng. Hesham Ahmed.

Under supervision of: Prof. Tarek Moussa.

 Abstract:
In industries, many different processes or manufacturing methods are used to be able to select the technically
In addition, economically best manufacturing sequence for a product, it is necessary to have a broad
Fundamental knowledge of the possibilities and limitations of the various manufacturing processes, including
Work materials used and geometries, surface finishes & tolerances required.

Production or manufacturing can be simply defined as value addition processes by which raw materials of low
Utility and value due to its inadequate material properties and poor or irregular size, shape and finish are
Converted into high utility and valued products with definite dimensions, forms and finish imparting
Some functional ability. Manufacturing Process deals with the conversion of raw materials to final product or
Useful material (output or finished product or component).

Manufacturing Processes refers to science and technology of manufacturing products effectively, efficiently,
Economically and environment-friendly through:
• Application of any existing manufacturing processes and system.
• Proper selection of input materials, tools, machines and environments.
• Improvement of the existing materials and processes.
Development of new materials, systems, processes and technique all such manufacturing processes, systems,
Techniques have to be:
 Technologically acceptable.
 Economically viable.
 Technically feasible.
 Eco – friendly.

Classification of Manufacturing Processes:

 Shaping or forming : : manufacturing a solid product of definite size and shape from a given
Material taken in three possible states:

o Solid state – e.g., forging, rolling, extrusion, drawing.

o Liquid or semi-liquid state – e.g., casting, injection molding.

 Joining process: Welding, brazing, soldering.

 Removal process: Machining.
 Casting:
Casting, one of the oldest manufacturing processes, dates back to 4000 B.C. when copper arrowheads were
Made.
Casting processes basically involves the introduction of molten metal into a mold cavity, where upon
Solidification, the metal takes on the shape of the mold cavity.
Simple and complicated shapes can be made from any metal that can be melted.
Example of cast parts: frames, structural parts, machine components, engine blocks, valves, pipes,……

Advantages of Casting Process:

● Any intricate shape & shape can be cast, both internal & external.
● Rapid cooling provides small grain size and good strength to casting.
● Any metal or alloy that can be heated to the liquid state can be cast.
● It is the easiest and quickest way from drawing to the production.
● Some methods are highly suitable for mass production.
● Some operations capable of producing parts to net shape require no further machining (only for
Finishing).

Limitations of Casting Process:

 Limitation on mechanical properties.
 Poor dimensional accuracy and surface finish.
 Removal of pattern of the thin & small parts is very difficult.
 Safety hazards to humans & environmental problems.
 Internal defects cannot be completely eliminated.

Steps involved in Casting Process:

 Pattern Making.

 Sand mixing & preparation.

 Core making.

 Melting.

 Pouring.

 Finishing.

 Testing.

 Heat Treatment.

 Re-testing.
Casting process procedure:
First prepare all required tools for the operation:-
 Mold Box – is a combination of two halves; upper half is called cope and lower half drag.
 Pattern - made of wood or metal, is a replica of the final product and is used for preparing mold cavity.
 Core – is an obstruction (made of either sand or metal) positioned in the mold does not permit molten metal to f
occupied by core, thereby making holes or hollow cavities inside a casting

Second preforming the casting process:-

a) Putting the lower half of pattern in the drag & turn them upside down.
b) Felling the drag with casting sand to fell all the space around the pattern.
c) Removing the excess sand and flatting the lower surface of sand to be with the drag in the same plane.
d) Putting powder material above the separating surface between the drag and cope to facilitate
The removal of cope from drag after the process is finished.
e) Placing the other half of pattern in the cope & repeat step (b) & (c).
f) Immersing two circular short rods to make the holes for the riser & gating system.
g) Removing each half pattern from the drag & the cope after a mold cavity created.
h) Exposing the cope & the drag to heat to evaporate any moisture in casting sand.
i) For hollow patterns use a core made from sand and place it in the mod cavity.
j) Placing the cope above the drag and locking them by a locating pin.
k) Starting to pour the molten metal in the gate tunnel until seeing the metal from the riser tunnel to
Make sure that the cavity is felled with the molten metal.
l) Waiting for metal solidification in the cavity