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Traditional Manufacturing Processes

Casting Forming Sheet metal processing Powder- and Ceramics Processing Plastics processing Cutting Joining Surface treatment

Casting

Refractory mold pour liquid metal solidify, remove finish

VERSATILE: complex geometry, internal cavities, hollow sections VERSATILE: small (~10 grams) very large parts (~1000 Kg) ECONOMICAL: little wastage (extra metal is re-used)

ISOTROPIC: cast parts have same properties along all directions

Different Casting Processes


Process Sand Shell mold Expendable pattern Plaster mold Ceramic mold Investment Permanent mold Die Centrifugal Advantages many metals, sizes, shapes, cheap better accuracy, finish, higher production rate Wide range of metals, sizes, shapes complex shapes, good surface finish complex shapes, high accuracy, good finish complex shapes, excellent finish good finish, low porosity, high production rate Excellent dimensional accuracy, high production rate Large cylindrical parts, good quality Disadvantages poor finish & tolerance limited part size patterns have low strength non-ferrous metals, low production rate small sizes small parts, expensive Costly mold, simpler shapes only costly dies, small parts, non-ferrous metals Expensive, few shapes Examples engine blocks, cylinder heads connecting rods, gear housings cylinder heads, brake components prototypes of mechanical parts impellers, injection mold tooling jewellery gears, gear housings gears, camera bodies, car wheels pipes, boilers, flywheels

Sand Casting

History of metal casting Late 20th Century


Early 1970s The Semi-Solid Metalworking (SSM) process is conceived of at Massachusetts Institute of Technology. It combines aspects of casting with aspects of forging. 1971 The Japanese develop V-Process molding. This method uses unbonded sand and a vacuum. 1972 The first production Austempered Ductile Iron (ADI) component is produced by Wagner Castings Company. 1976 Compacted graphite iron (CGI), an iron with elongated graphite particles with rounded edges and roughened surfaces, is developed in the U.K. It has characteristics of both gray and ductile iron.

1982 The Warm Box binder system was introduced. 1993 First foundry application of a plasma ladle refiner (melting and refining in one vessel) occurs at Maynard Steel Casting Company in Milwaukee, WI. 1995 Babcock and Wilcox, Barberton, OH, patent a lost foam vacuum casting process to produce stainless steel castings with low carbon content. 1996 Cast metal matrix composites were first used in a production model automobile in the brake rotors for the Lotus Elise. 1997 Electromagnetic casting processes developed by Argonne and Inland Steel Corporation. Electromagnetic edge containment greatly reduces cost and energy expenditures in steel production

Recent advances in sand casting technology


After 5000 years of technological advances, metal casting plays a greater part in our everyday lives and is more essential than it has ever been. There are various developments in sand casting technology which include advanced permanent molding, flexible machines for metal mold casting, improved molding and solidification practices for sand casting, rapid prototyping, Computer modeling and simulation Advanced casting processes are rapidly being adopted. These include lost foam castings in volume production, continuous castings, advanced semi permanent mold casting, semisolid casting(SSM) and no bake Sand Castings

Lost foam casting


Lost foam casting (LFC) is a type of investment casting process that uses foam patterns as a mold. The method takes advantage of the properties of foam to simply and inexpensively create castings that would be difficult to achieve using other casting techniques.

Variations and Developments


Continuous casting Lost foam molding 3D Printing of Investment tooling Direct printing with metal droplets Uniform metal spray

Continuous casting

ref AISI

Steel from the electric or basic oxygen furnace is tapped into a ladle and taken to the continuous casting machine. The ladle is raised onto a turret that rotates the ladle into the casting position above the tundish. Referring to Figure 2, liquid steel flows out of the ladle (1) into the tundish (2), and then into a water-cooled copper mold (3). Solidification begins in the mold, and continues through the First Zone (4) and Strand Guide (5). In this configuration, the strand is straightened (6), torch-cut (8), then discharged (12) for intermediate storage or hot charged for finished rolling.
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3D Printing of Investment cast tooling

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Shell and part (Turbine blade)

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Microcasting of droplets

CMU

MIT

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Environmental Issues
Smelting Energy Off-gassing see AFS webpage on green sand emissions;
http://www.afsinc.org/environmental.html

Cooling water Waste sand disposal Off shore locations

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Metal Smelting; reducing oxides and sulfides to metal..

http://www.steel.org/learning/howmade/blast_furnace.htm
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Environmental loads by manufacturing sector


Carbon Dioxide and Toxic Materials per Value of Shipments
5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0

Weight/Dollars

CO2 (metric ton/$10,000)

Toxic Mat'ls (lb/$1000)

Primary Metal

Fabricated Metal

Manufacturing industries

Transportation

Plastics and Rubber

Petroleum and Coal

Chemicals

Machinery

Electronic

EPA 2001, DOE 2001

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Vacuum casting and molding


Similar to investment casting, except: fill mold by reverse gravity Easier to make hollow casting: early pour out

3D Printing of Investment tooling:The Technology Used for Creating 3D Printed Concept Models 1. Fused Deposition Modeling (FDM) Technology 2. PolyJet 3D Printing Technology

No Bake Sand Casting


No Bake is a casting process that uses chemical binders to bond the molding sand. The sand is then transported to the mold fill station in preparation for filling of the mold. A mixer is then used to blend sand with the chemical binder and the catalyst. When the sand exits the mixer, the binder begins the hardening process. After the compaction process, a rollover process is used to remove the mold from the pattern box. The mould is then readied for handling the molten metal. After a shakeout process, the molded sand is taken away from the casting. Then various procedures follow including the finishing and the sand can be reclaimed by thermal means. In the No-Bake resin sand casting process, sand molds are created using a wood, metal, or plastic pattern. Sand is mixed with a plastic binder in a high-speed mixer. This sand is deposited into box containing the pattern and all essential gating, risers and chills for pouring. The sand mixture sets up hard in a few minutes and the mold is removed from the pattern. Cores for forming internal passages in the castings are made using the same process. Cores are carefully placed into the molds. The molds are then closed and are ready for pouring.

Conclusion:
As there is a growth in technology , there is an advancement in each and every stage of casting process which proportionally reduces the cost and time of manufacturing with an improved quality of a product.

References:1. Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003), Materials and Processes in Manufacturing (9th ed.), Wiley, ISBN 0-471-65653-4. 2. Todd, Robert H.; Allen, Dell K.; Alting, Leo (1994), Manufacturing Processes Reference Guide, Industrial Press Inc., ISBN 0-8311-3049-0. 3. Rao, T. V. (2003), Metal Casting: Principles and Practice, New Age International, ISBN 978-81-224-0843-0. 4. Campbell, John (2003), Casting (2nd ed.), Butterworth-Heinemann, ISBN 0-7506-479066

TYPES OF MOLDING PROCESS


1 Expendable Mold 1.1 Permanent Pattern 1.1.1 Sand Casting 1.1.2 Plaster Molding 1.2 Expendable Pattern 1.2.1 Lost Foam 1.2.2 Lost Wax (investment casting) 1 Permanent Mold 1.1 Die 1.1.1 Hot Chamber 1.1.2 Cold Chamber 1.1.3Thixotropic

Mold prepertation =) metal heating =) pouring =) cooling =) processing

Expandable mold

permanent pattern
SAND CASTING

SAND CASTING

The set of channels through which a molten metal flows to the mold cavity is called gating system.
Typical gating system consists of a pouring cup and a sprue receiving the poured melt, runner a channel through which the melt is supplied to the gates through which the molten metal enters the mold cavity.

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