METAL

CASTING

GAUTAM M AGASTI

INTRODUCTION
INTRODUCTION TO
TO METAL
METAL CASTING
CASTING
1. Is one of the versatile forms of
production Process.
2. No limit to size & shape of article
produce.
3. Production cost is considerably low.
4. metal casting is using it as a way to
create sculptures or other artistic
endeavors.

OBJECTIVES
General Objectives:The students will be able to
Understand metal casting process.
Specific objectives:The students will be able to
Define pattern ,moulding ,casting.
Explain different types of pattern allowance in
casting process.
Explain sand moulding process.

PATTERN

A pattern is model of the object to be manufactured.

Patterns materials: Wood , Wax, Plastic, metals & alloys.
Patterns may be made as one-piece or multiple-piece (split,
match plate).

PATTERN ALLOWANCES
Metals shrink in size when there is a
change from liquid to solid state.
Casting require surface finish.
Casting tend to warp or distort during
cooling stage.
Shrinkage

Finishing

Draft

NEXT

Shrinkage allowance: allowance given on the

pattern size for avoiding any change in
dimensions of casting.
For grey cast iron 7 10.5mm/ m, steel
20mm/ m , aluminium 18mm/ m
Finishing allowance: allowance given on
pattern for machining rough surface of
casting.
Standard allowance for ferrous metal is 3 mm
& nonferrous metal is 1.5 mm.

 Draft allowance:is the taper allowed on the

vertical faces of a pattern for easy removal
of pattern without damaging the mould
cavity surface.
A draft of 3-6 mm per/m is generally
adopted.
For pattern used in machine moulding,
normally one degree taper is given.

MOULDING
Is process of making cavity of desire
shape & size on a medium(moulding
sand)
Types of moulds are:
Green sand
Cold box
No bake moulds

GREEN SAND MOULDING

The "Green" sand process uses only water ,
silica sand and clay to make the mould.
The sand costs are lower than other
moulding processes making green sand an
economical casting method.
Permeability of the green sand mould can
be properly controlled for avoiding casting
defects.

steps in
metal casting process

Six steps in metal casting process are :

1) Place a pattern in sand to create mould.
2) Incorporate the gating system.
3) Remove the pattern.
4) Fill the mould cavity with molten metal.
5) Allow the metal to cool.
6) Break away the sand mould & remove
the casting.

SAND MOULDING PROCESS

metal pattern

moulding
board.
1) Place metal pattern on the moulding board. Sprinkle
them with parting dust. Simple Baking Soda works
well as parting dust and it's cheap.

Drag

2) Place a frame, called the "drag"

around the pattern, then start
adding sand

bottom board

Once the "drag" is full, level the sand with the

top of the frame using the other board or
"bottom board" that will also be used to cover
the drag.

Then hold onto both boards and turn

the flask over so the "bottom board"
really is on the bottom.

(4) Remove

the moulding board.

PIPE

SPRUE

Add a "sprue" or the hole through which your molten

metal will be poured.use a pipe to mould the sprue.

cope

Latch

drag
Place the pipe back in place to from the sprue. Then
set on the top frame or the "cope". Latch the frame in
place if you have latches.

Tamping

Add more sand and again gently tamp it in around the

part as well as the pipe to from the sprue.

Flatten off the sand level the the top edge of the
frame or "cope" and also form a funnel cup

Gently remove the pipe that was forming the

sprue. Then place the "molding board" on top.

top frame

Unlatch the frames and carefully lift off the top frame or
"cope" and set it on its side. You should be able to rest it
on its top, but less movement is better.

Using a couple of knife blades, delicately lift the part/s

from the bottom frame or "drag". Be careful to lift the
part/s straight up so as not the disturb the sand .

Using a knife or blade carve out the "gating"

system that will allow the metal to flow into the
part and the air to flow out.
gating
system

CASTING
Casting involves pouring of the molten
metal into cavity of desire shape & size &
allowing it to solidify.
The metal is melted in a furnace & poured
in the cavity.
After solidification is completed, the
casting is removed & cleaned.

Time to melt some metal. This is flower pot

furnace,. Wait until the melt begins to glow
orange.

Pour the he flask with molten metal. Don't pour

too slowly or the metal will harden too quickly in
the gate, coking the part off.

After 5 minutes the flask can be

opened for inspection.

Final Parts next to original after

the being brushed off.

Two sets of casting ( bronze & aluminium)

THANK
YOU