Beruflich Dokumente
Kultur Dokumente
Casting Forming Sheet metal processing Powder- and Ceramics Processing Plastics processing Cutting Joining Surface treatment
Casting
VERSATILE: complex geometry, internal cavities, hollow sections VERSATILE: small (~10 grams) very large parts (~1000 Kg) ECONOMICAL: little wastage (extra metal is re-used)
Sand Casting
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
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.
10
11
12
Microcasting of droplets
CMU
MIT
13
Environmental Issues
Smelting Energy Off-gassing see AFS webpage on green sand emissions;
http://www.afsinc.org/environmental.html
14
http://www.steel.org/learning/howmade/blast_furnace.htm
15
Weight/Dollars
Primary Metal
Fabricated Metal
Manufacturing industries
Transportation
Chemicals
Machinery
Electronic
16
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
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
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.