Beruflich Dokumente
Kultur Dokumente
TYPES
By WAQAS AHMED
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MANUFACTURING
Therearemanytypesofmanufacturingprocess.
Types
of manufacturing process:
1.
Casting..
2.
Molding..
3.
Forming..
4.
Machining..
5.
Joining..
CASTING& ITS
TYPES!!!
Casting:
Castingisamanufacturingprocessbywhicha
liquidmaterialisusuallypouredintoamold,which
containsahollowcavityofthedesiredshape,and
thenallowedtosolidify.Thesolidifiedpartisalso
knownasacasting,whichisejectedorbrokenout
ofthemoldtocompletetheprocess
Castingmaterialsareusuallymetalsorvariouscold
settingmaterialsthatcureaftermixingtwoormore
componentstogether;examples
are epoxy,concrete,plasterandclay.Castingismostoften
usedformakingcomplexshapesthatwouldbeotherwise
difficultoruneconomicaltomakebyothermethods
categories:-
1.Thoseforwhichanewmoldmustbecreatedfor
casting(theexpandable-moldprocesses)
2.Thosethatemployapermanent,reuseablemold(the
non-expandable-moldprocesses)
Types of casting!!!
Following
Sand casting
Die casting
Lost-foam casting
Centrifugal casting
Most
PATTERNS
WITH
ALLOWANCES
PATTERN
Incasting,apatternisareplicaoftheobjectto
becast,usedtopreparethecavityintowhich
moltenmaterialwillbepouredduringthe
castingprocess
Patternsusedinsandcastingmaybemadeofwood,
metal,plasticsorothermaterials.Patternsaremadeto
exactingstandardsofconstruction,sothattheycanlast
forareasonablelengthoftime,accordingtothequality
gradeofthepatternbeingbuilt,andsothattheywill
repeatablyprovideadimensionallyacceptablecasting.
Types of pattern:-
5.Sweep pattern.
6.Gated pattern.
7.Skeleton pattern
Single
piece pattern:-
Split
piece pattern:-
Loose
piece pattern:-
Match
plate pattern:-
Sweep
pattern:-
Gated
pattern:-
Cope
CORES
Toproducecavitieswithinthecastingsuchas
forliquidcoolinginengineblocksandcylinder
headsnegativeformsareusedtoproducecores
NOW..!!!
SAND CASTING
Sandcasting,alsoknownassandmoldedcasting,isametal
castingprocesscharacterizedbyusingsandas
themoldmaterial.Theterm"sandcasting"canalsorefertoan
objectproducedviathesandcastingprocess.Sandcastingsare
producedinspecializedfactoriescalledfoundries.Over70%of
allmetalcastingsareproducedviaasandcastingprocess
Sandcastingisrelativelycheapandsufficientlyrefractoryevenforsteel
foundryuse.Inadditiontothesand,asuitablebondingagent(usually
clay)ismixedoroccurswiththesand.Themixtureismoistened,typically
withwater,butsometimeswithothersubstances,todevelopstrengthand
plasticityoftheclayandtomaketheaggregatesuitableformolding.The
sandistypicallycontainedinasystemofframesormoldboxesknownas
aflask.Themoldcavitiesandgatesystemarecreatedbycompactingthe
sandaroundmodels,orpatterns,orcarveddirectlyintothesand.
Basic process
Therearesixstepsinthisprocess:
1.Placeapatterninsandtocreateamold.
2.Incorporatethepatternandsandinagatingsystem.
3.Removethepattern.
4.Fillthemoldcavitywithmoltenmetal.
5.Allowthemetaltocool.
6.Breakawaythesandmoldandremovethecasting
Die casting
Diecastingisametalcastingprocessthatischaracterizedby
forcingmoltenmetalunderhighpressureintoamoldcavity.Themold
cavityiscreatedusingtwohardenedtoolsteeldieswhichhavebeen
machinedintoshapeandworksimilarlytoaninjectionmoldduring
theprocess.Mostdiecastingsaremadefromnon-ferrousmetals,
specificallyzinc,copper,aluminium,magnesium,lead,pewterandtin
basedalloysDependingonthetypeofmetalbeingcast,ahot-or
cold-chambermachineisused.
Thecastingequipmentandthemetaldiesrepresentlargecapitalcosts
andthistendstolimittheprocesstohighvolumeproduction.
Manufactureofpartsusingdiecastingisrelativelysimple,involving
onlyfourmainsteps,whichkeepstheincrementalcostperitemlow.It
isespeciallysuitedforalargequantityofsmalltomediumsized
castings,whichiswhydiecastingproducesmorecastingsthanany
othercastingprocess.Diecastingsarecharacterizedbyavery
goodsurfacefinish(bycastingstandards)anddimensional
consistency
Cast
metals:
Themaindiecastingalloysare:zinc,aluminium,magnesium,copper,lead,&tin;
althoughuncommon,ferous
Thefollowingisasummaryoftheadvantagesofeachalloy:
Zinc:theeasiestmetaltocast;highductility;highimpactstrength;easilyplated;economicalfor
smallparts;promoteslongdielife.
Aluminium:lightweight;highdimensionalstabilityforcomplexshapesandthinwalls;good
corrosionresistance;goodmechanicalproperties;highthermalandelectricalconductivity;retains
strengthathightemperatures.
Magnesium :theeasiestmetaltomachine;excellentstrength-to-weightratio;lightestalloy
commonlydiecast.
Copper:highhardness;highcorrosionresistance;highestmechanicalpropertiesofalloysdiecast;
excellentwearresistance;excellentdimensionalstability;strengthapproachingthatofsteelparts.
Leadandtin:highdensity;extremelyclosedimensionalaccuracy;usedforspecialformsof
corrosionresistance.Suchalloysarenotusedinfoodserviceapplicationsforpublichealthreasons.Type
metal,analloyofLead,TinandAntimony(withsometimestracesofCopper)isusedforcastinghand
settypeinletterpressprintingandhotfoilblocking.
Equipment:
Therearetwobasictypesofdiecastingmachines:
Theseareratedbyhowmuchclampingforcetheycan
apply.Typicalratingsarebetween400and4,000st
(2,500and25,000kg)
Hot-chambermachines:
Hot-chambermachines,alsoknownasgooseneckmachines,rely
uponapoolofmoltenmetaltofeedthedie.Atthebeginningofthe
cyclethepistonofthemachineisretracted,whichallowsthemolten
metaltofillthe"gooseneck".Thepneumaticorhydraulicpowered
pistonthenforcesthismetaloutofthegooseneckintothedie.The
advantagesofthissystemincludefastcycletimes(approximately15
cyclesaminute)andtheconvenienceofmeltingthemetalinthe
castingmachine.Thedisadvantagesofthissystemarethathighmeltingpointmetalscannotbeutilizedandaluminiumcannotbe
usedbecauseitpicksupsomeoftheironwhileinthemoltenpool.
Duetothis,hot-chambermachinesareprimarilyusedwithzinc,tin,
andleadbasedalloys
Cold-chambermachines:
Theseareusedwhenthecastingalloycannotbeusedinhotchambermachines;theseincludealuminium,zincalloyswithalarge
compositionofaluminium,magnesiumandcopper.Theprocessfor
thesemachinesstartwithmeltingthemetalinaseparate
furnace.Thenapreciseamountofmoltenmetalistransportedtothe
cold-chambermachinewhereitisfedintoanunheatedshot
chamber(orinjectioncylinder).Thisshotisthendrivenintothedie
byahydraulicormechanicalpiston.Thisbiggestdisadvantageof
thissystemistheslowercycletimeduetotheneedtotransferthe
moltenmetalfromthefurnacetothecold-chambermachine
Dies:
Twodiesareusedindiecasting;oneiscalledthe"coverdiehalf"
andtheotherthe"ejectordiehalf".Wheretheymeetiscalledthe
partingline.Thecoverdiecontainsthesprue(forhot-chamber
machines)orshothole(forcold-chambermachines),whichallows
themoltenmetaltoflowintothedies;thisfeaturematchesupwith
theinjectornozzleonthehot-chambermachinesortheshot
chamberinthecold-chambermachines.Theejectordiecontainsthe
ejectorpinsandusuallytherunner,whichisthepathfromthesprue
orshotholetothemoldcavity.Thecoverdieissecuredtothe
stationary,orfront,platenofthecastingmachine,whiletheejector
dieisattachedtothemovableplaten.Themoldcavityiscutinto
twocavityinserts,whichareseparatepiecesthatcanbereplaced
relativelyeasilyandboltintothediehalves
Theejectordiehalf:
Thecoverdiehalf:
Process:
1.
2.
3.
4.
Advantagesanddisadvantages:
Advantagesofdiecasting:
Excellentdimensionalaccuracy(dependentoncastingmaterial,buttypically0.1mm
forthefirst2.5cm(0.005inchforthefirstinch)and0.02mmforeachadditional
centimeter(0.002inchforeachadditionalinch).
Smoothcastsurfaces(Ra12.5micrometresor0.040.10thou).
Reducesoreliminatessecondarymachiningoperations.
Rapidproductionrates.
Castingoflowfluiditymetals.
Themaindisadvantagetodiecastingistheveryhighcapitalcost.Boththe
castingequipmentrequiredandthediesandrelatedcomponentsareverycostly,
ascomparedtomostothercastingprocesses.Thereforetomakediecastingan
economicprocessalargeproductionvolumeisneeded.Otherdisadvantagesare
thattheprocessislimitedtohigh-fluiditymetals,andcastingweightsmustbe
between30grams(1oz)and10kg(20lb).Inthestandarddiecastingprocess
thefinalcastingwillhaveasmallamountofporosity.Thispreventsanyheat
treatingorwelding,becausetheheatcausesthegasintheporestoexpand,
whichcausesmicro-cracksinsidethepartandexfoliationofthesurfac e
Shell molding
Shell
The
1.
2.
3.
4.
5.
6.
Pattern creation
Mold creation
Mold assembly
Pouring
Cooling
Casting removal
. Examplesofshellmoldeditemsincludegearhousings,cylinder
heads&connectingrods.Itisalsousedtomakehigh-precision
moldingcores
Process:
Theprocessofcreatingashellmoldconsistsofsixsteps:
Finesilicasandthatiscoveredinathin(36%)thermosettingphenolicresinand
liquidcatalystisdumped,blown,orshotontoahotpattern.Thepatternisusually
madefromcastironandisheatedto230to315C(450to600F).Thesandis
allowedtositonthepatternforafewminutestoallowthesandtopartiallycure.
Thepatternandsandaretheninvertedsotheexcesssanddropsfreeofthepattern,
leavingjustthe"shell".Dependingonthetimeandtemperatureofthepatternthe
thicknessoftheshellis10to20mm(0.4to0.8in).
Thepatternandshelltogetherareplacedinanoventofinishcuringthesand.The
shellnowhasatensilestrengthof350to450psi(2.4to3.1MPa).
Thehardenedshellisthenstrippedfromthepattern.
Twoormoreshellsarethencombined,viaclampingorgluingusingathermoset
adhesive,toformamold.Thisfinishedmoldcanthenbeusedimmediatelyor
storedalmostindefinitely.
Forcastingtheshellmoldisplacedinsideaflaskandsurroundedwithshot,sand,
orgraveltoreinforcetheshell.
Advantages
and disadvantages:
Oneofthegreatestadvantagesofthisprocessisthatitcanbe
completelyautomatedformassproduction.Thehighproductivity,
lowlaborcosts,goodsurfacefinishes,andprecisionoftheprocess
canmorethanpayforitselfifitreducesmachiningcosts
.Therearealsofewproblemsduetogases,becauseoftheabsence
ofmoistureintheshell,andthelittlegasthatisstillpresenteasily
escapesthroughthethinshell.Whenthemetalispouredsomeofthe
resinbinderburnsoutonthesurfaceoftheshell,whichmakes
shakingouteasy.
Permanent
mold casting:
Permanentmoldcastingismetalcastingprocessthatemploys
reusablemolds("permanentmolds"),usuallymadefrommetal.The
mostcommonprocessusesgravitytofillthemold,howevergas
pressureoravacuumarealsoused.Avariationonthetypical
gravitycastingprocess,calledslushcasting,produceshollow
castings.Commoncastingmetalsarealuminum,magnesium,
andcopperalloys.Othermaterialsincludetin,zinc,andleadalloys
andironandsteelarealsocastingraphitemolds
Process:
Therearefourmaintypesofpermanentmoldcasting:
1.
gravity,
2.
slush,
3.
low-pressure,
4.
vacuum.
Gravityprocess:
Thegravityprocessbeginsbypreheatingthemoldto150200C(300-400F)toeasetheflowandreducethermal
damagetothecasting.Themoldcavityisthencoatedwith
arefractorymaterialoramoldwash,whichpreventsthecasting
fromstickingtothemoldandprolongsthemoldlife.Anysand
ormetalcoresaretheninstalledandthemoldisclamped
shut.Moltenmetalisthenpouredintothemold.Soonafter
solidificationthemoldisopenedandthecastingremovedto
reducechancesofhottears.Theprocessisthenstartedallover
again,butpreheatingisnotrequiredbecausetheheatfromthe
previouscastingisadequateandtherefractorycoatingshould
lastseveralcastings.Becausethisprocessisusuallycarriedout
onlargeproductionrunworkpiecesautomatedequipmentis
usedtocoatthemold,pourthemetal,andremovethecasting
Slush:
Slushcastingisavariantofpermanentmoldingcasting
tocreateahollowcastingorhollowcast.Intheprocess
thematerialispouredintothemoldandallowedtocool
untilashellofmaterialformsinthemold.The
remainingliquidisthenpouredouttoleaveahollow
shell.Theresultingcastinghasgoodsurfacedetailbut
thewallthicknesscanvary.Theprocessisusuallyused
tocastornamentalproducts,such
ascandlesticks,lampbases,andstatuary,fromlowmelting-pointmaterials.Asimilartechniqueisusedto
makehollowchocolatefigures
forEasterandChristmas
Low-pressure:
Low-pressurepermanentmold(LPPM)castingusesa
gasatlowpressure,usuallybetween3and15psig(20to
100kPag)topushthemoltenmetalintothemoldcavity.
Thepressureisappliedtothetopofthepoolofliquid,
whichforcesthemoltenmetaluparefractorypouring
tubeandfinallyintothebottomofthemold.Thepouring
tubeextendstothebottomoftheladlesothatthe
materialbeingpushedintothemoldisexceptionally
clean.Norisersarerequiredbecausetheapplied
pressureforcesmoltenmetalintocompensatefor
shrinkage.Yieldsareusuallygreaterthan85%because
thereisnoriserandanymetalinthepouringtubejust
fallsbackintotheladleforreuse
Vacuum:
Vacuumpermanentmoldcastingretainsallofthe
advantagesofLPPMcasting,plusthedissolvedgasesin
themoltenmetalareminimizedandmoltenmetal
cleanlinessisevenbetter.Theprocesscanhandlethinwalledprofilesandgivesanexcellentsurfacefinish.
Mechanicalpropertiesareusually10to15%betterthan
gravitypermanentmoldcastings.Theprocessislimited
inweightto0.2to5kg
Advantages
and disadvantages:
Therearethreemaindisadvantages:
high tooling cost,
limited to low-melting-point metals,
short mold life
1.
2.
3.
Investment casting
Investmentcastingisanindustrialprocessbasedonand
alsocalledlost-waxcasting,oneoftheoldestknownmetalformingtechniques.From5,000yearsago,when beeswax
formedthepattern,totodayshigh-technologywaxes,
refractorymaterialsandspecialistalloys,thecastingsallow
theproductionofcomponentswithaccuracy,repeatability,
versatilityandintegrityinavarietyofmetalsandhighperformancealloys.
Theprocessisgenerallyusedforsmallcastings,buthasbeenusedto
producecompleteaircraftdoorframes,steelcastingsofupto300kg
(660lbs)andaluminiumcastingsofupto30kg(66lbs).Itisgenerally
moreexpensiveperunitthandiecastingorsandcasting,buthaslower
equipmentcosts.Itcanproducecomplicatedshapesthatwouldbedifficult
orimpossiblewithdiecasting,yetlikethatprocess,itrequireslittle
surfacefinishingandonlyminormachining..
Processes:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Produce
a master pattern:
Anartistormould-makercreatesanoriginalpattern
fromwax,clay,wood,plastic,steel,oranothermaterial.!!!
Mould
making:
Amould,knownasthemasterdie,ismadeofthemaster
pattern.Themasterpatternmaybemadefromalowmelting-pointmetal,steel,orwood.Ifasteelpatternwas
createdthenalow-melting-pointmetalmaybecast
directlyfromthemasterpattern.Rubbermouldscanalso
becastdirectlyfromthemasterpattern.Thefirststep
mayalsobeskippedifthemasterdieismachined
directlyintosteel.
Produce
Althoughcalledawaxpattern,patternmaterialsalsoincludeplastic
andfrozenmercury.Waxpatternsmaybeproducedinoneoftwo
ways.Inoneprocessthewaxispouredintothemoldandswished
arounduntilanevencoating,usuallyabout3mm(0.12in)thick,
coverstheinnersurfaceofthemould.Thisisrepeateduntilthe
desiredthicknessisreached.Anothermethodisfillingtheentire
mouldwithmoltenwax,andletitcool,untiladesiredthicknesshas
setonthesurfaceofthemould.Afterthistherestofthewaxis
pouredoutagain,themouldisturnedupsidedownandthewax
layerislefttocoolandharden.Withthismethoditismoredifficult
tocontroltheoverallthicknessofthewaxlayer
Assemble
Thewaxpatternisthenremovedfromthemould.Dependingonthe
applicationmultiplewaxpatternsmaybecreatedsothattheycanall
becastatonce.Inotherapplications,multipledifferentwaxpatterns
maybecreatedandthenassembledintoonecomplexpattern.Inthe
firstcasethemultiplepatternsareattachedtoawaxsprue,withthe
resultknownasapatterncluster,ortree;asmanyasseveral
hundredpatternsmaybeassembledintoatree.Foundriesoftenuse
registrationmarkstoindicateexactlywheretheygo.Thewax
patternsareattachedtothesprueoreachotherbymeansofaheated
metaltool.Thewaxpatternmayalsobechased,whichmeans
thepartinglineorflashingarerubbedoutusingtheheatedmetal
tool.Finallyitisdressed,whichmeansanyotherimperfectionsare
addressedsothatthewaxnowlookslikethefinishedpiece.
Investment:
Theceramicmould,knownastheinvestment,isproducedbythree
repeatingsteps:coating,stuccoing,andhardening.Thefirststep
involvesdippingtheclusterintoaslurryoffinerefractorymaterial
andthenlettinganyexcessdrainoff,soauniformsurfaceis
produced.Thisfinematerialisusedfirsttogiveasmoothsurface
finishandreproducefinedetails.Inthesecondstep,thecluster
isstuccoedwithacoarseceramicparticle,bydippingitinto
afluidisedbed,placingitinarainfall-sander,orbyapplyingby
hand.Finally,thecoatingisallowedtoharden.Thesestepsare
repeateduntiltheinvestmentistherequiredthickness,whichis
usually5to15mm
De
wax:
Theinvestmentisthenallowedtocompletelydry,whichcantake16
to48hours.Dryingcanbeenhancedbyapplyingavacuumor
minimizingtheenvironmentalhumidity.Itisthenturnedupsidedownandplacedinafurnaceorautoclavetomeltoutand/or
vaporizethewax.Mostshellfailuresoccuratthispointbecausethe
waxesusedhaveathermalexpansioncoefficientthatismuchgreater
thantheinvestmentmaterialsurroundingit,soasthewaxisheatedit
expandsandinducesgreatstresses.Inordertominimizethese
stressesthewaxisheatedasrapidlyaspossiblesothatthesurfaceof
thewaxcanmeltintothesurfaceoftheinvestmentorrunoutofthe
mold,whichmakesroomfortherestofthewaxtoexpand.Incertain
situationsholesmaybedrilledintothemoldbeforehandtohelp
reducethesestresses.Anywaxthatrunsoutofthemoldisusually
recoveredandreused.
Burnout
& preheating:
Themoldisthensubjectedtoaburnout,whichheatsthemold
between870C&1095Ctoremoveanymoistureandresidual
wax,andtosinterthemold.Sometimesthisheatingisalsousedas
thepreheat,butothertimesthemoldisallowedtocoolsothatitcan
betested.Ifanycracksarefoundtheycanberepairedwithceramic
slurryorspecialcements.Themoldispreheatedtoallowthemetal
tostayliquidlongertofillanydetailsandtoincreasedimensional
accuracy,becausethemoldandcastingcooltogether
Pouring:
Theinvestmentmoldisthenplacedcup-upwardsintoatubfilled
withsand.Themetalmaybegravitypoured,butiftherearethin
sectionsinthemolditmaybefilledbyapplyingpositiveair
pressure,vacuumcast,tiltcast,pressureassistedpouring,
orcentrifugalcast
Removal:
Theshellishammered,mediablasted,vibrated,waterjeted,or
chemicallydissolved(sometimeswithliquidnitrogen)toreleasethe
casting.Thesprueiscutoffandrecycled.Thecastingmaythenbe
cleaneduptoremovesignsofthecastingprocess,usually
bygrinding
Advantages
of Investment casting:
Averysmoothsurfaceisobtainedwithnopartingline.
Dimensionalaccuracyisgood.
Certainunmachinablepartscanbecasttopreplanned
shape.
Disadvantages
of Investment casting:
Thisprocessisexpensive,isusuallylimitedtosmall
casting,andpresentssomedifficultieswherecoresare
involved.
Holescannotbesmallerthan1/16 in.(1.6mm)and
shouldbenodeeperthanabout1.5timesthediameter.
Investmentcastingsrequireverylongproduction-cycle
timesversusothercastingprocesses.
Thisprocessispracticallyinfeasibleforhigh-volume
manufacturing,duetoitshighcostandlongcycletimes.
Applications:
Investmentcastingisusedintheaerospaceandpower
generationindustriestoproduceturbinebladeswith
complexshapesorcoolingsystems
Lost-foam casting
Lost-foamcasting(LFC)isatypeofevaporativepatterncastingprocessthatissimilartoinvestment
castingexceptfoamisusedforthepatterninstead
ofwax.
Thisprocesstakesadvantageofthelowboilingpointof
foamtosimplifytheinvestmentcastingprocessby
removingtheneedtomeltthewaxoutofthemold
Process:
First,apatternismadefrompolystyrenefoam,whichcanbedonemanydifferentways.Forsmall
volumerunsthepatterncanbehandcutormachinedfromasolidblockoffoam;ifthegeometryis
simpleenoughitcanevenbecutusingahot-wirefoamcutter.Ifthevolumeislarge,thenthe
patterncanbemass-producedbyaprocesssimilartoinjectionmolding.Pre-expandedbeadsof
polystyreneareinjectedintoapreheatedaluminummoldatlowpressure.Steamisthenappliedto
thepolystyrenewhichcausesittoexpandmoretofillthedie.Thefinalpatternisapproximately
97.5%airand2.5%polystyrene.Pre-madepouringbasins,runners,andriserscanbehotgluedto
thepatterntofinishit.
Next,thefoamclusteriscoatedwithceramicinvestment,alsoknownastherefractorycoating,via
dipping,brushing,sprayingorflowcoating.Thiscoatingcreatesabarrierbetweenthesmoothfoam
surfaceandthecoarsesandsurface.Secondlyitcontrolspermeability,whichallowsthegascreated
bythevaporizedfoampatterntoescapethroughthecoatingandintothesand.Controlling
permeabilityisacrucialsteptoavoidsanderosion.Finally,itformsabarriersothatmoltenmetal
doesnotpenetrateorcausesanderosionduringpouring.Afterthecoatingdries,theclusterisplaced
intoaflaskandbackedupwithun-bondedsand.Thesandisthencompactedusingavibration
table.Oncecompacted,themoldisreadytobepoured.Automaticpouringiscommonlyusedin
LFC,asthepouringprocessissignificantlymorecriticalthaninconventionalfoundrypractice.
Thereisnobake-outphase,asforlost-wax.Themeltispoureddirectlyintothefoam-filledmould,
burningoutthefoamasitpours.Asthefoamisoflowdensity,thewastegasproducedbythisis
relativelysmallandcanescapethroughmouldpermeability,asfortheusualoutgassingcontrol
Advantages
and disadvantages:
Thiscastingprocessisadvantageousforverycomplexcastingsthat
wouldregularlyrequirecores.Itisalsodimensionallyaccurate,
maintainsanexcellentsurfacefinish,requiresnodraft,andhasno
partinglinessonoflashisformed.Ascomparedtoinvestment
casting,itischeaperbecauseitisasimplerprocessandthefoamis
cheaperthanthewax.Risersarenotusuallyrequiredduetothe
natureoftheprocess;becausethemoltenmetalvaporizesthefoam
thefirstmetalintothemoldcoolsmorequicklythantherest,which
resultsinnaturaldirectionalsolidificationFoamiseasyto
manipulate,carveandglue,duetoitsuniqueproperties
Thetwomaindisadvantagesarethatpatterncostscanbehighfor
lowvolumeapplicationsandthepatternsareeasilydamagedor
distortedduetotheirlowstrength.
Ifadieisusedtocreatethepatternsthereisalargeinitialcost.
Centrifugal casting
Centrifugalcastingorroto-castingis
acastingtechniquethatistypicallyusedtocastthinwalledcylinders.Itisnotedforthehighqualityofthe
resultsattainable,particularlyforprecisecontroloftheir
metallurgyandcrystalstructure.Unlikemostother
castingtechniques,centrifugalcastingischieflyusedto
manufacturestockmaterialsinstandardsizesforfurther
machining,
Process:
Incentrifugalcasting,apermanentmoldisrotatedcontinuously
aboutitsaxisathighspeeds(300to3000rpm)asthemoltenmetal
ispoured.Themoltenmetaliscentrifugallythrowntowardsthe
insidemoldwall,whereitsolidifiesaftercooling.Thecastingis
usuallyafine-grainedcastingwithaveryfine-grainedouter
diameter,owingtochillingagainstthemouldsurface.Impurities
andinclusionsarethrowntothesurfaceoftheinsidediameter,
whichcanbemachinedaway.
Castingmachinesmaybeeither horizontal or verticalaxis.Horizontalaxismachinesarepreferredforlong,thincylinders,
verticalmachinesforrings.
Castingscanbemadeinalmostanylength,thickness&diameter.
Differentwallthicknessescanbeproducedfromthesamesizemold.
Eliminatestheneedforcores.
Resistanttoatmosphericcorrosion,atypicalsituationwithpipes.
Mechanicalpropertiesofcentrifugalcastingsareexcellent
Onlycylindricalshapescanbeproducedwiththisprocess.
Materials:
Typicalmaterialsthatcanbecastwiththisprocess
areiron, steel, stainless steels, glass, and alloys
of aluminum, copper & nickel.
Twomaterialscanbecasttogetherbyintroducingasecond
materialduringtheprocess.
Applications:
WHY CASTING..!!!!!
Advantages
of Casting:
5. Accuracy:
Castingcanbemadewithhairlikeprecisionprovided
propermoldingandcastingtechniqueisemployed.
6. Fibrous Structure:
Onlycastinghavethisadvantage.Castingleaves
componentwithitssolidfibrousstructurewhichinherit
greatcompressivestrength.So,componentsubjectedto
compressivestrengtharemadewithcastingegICengine
cylinder.
7. Control Over Grain Size:
Grainsizeofcastcomponentcanbeeasilycontrolledby
controllingcoolingratewhichinturncanbeusedto
modifytheproperties.
8. Low Cost:
Casingisoneofcheapestmethodformassproduction.
Disadvantages
of Casting:
ThoughcastingischeapestforMASSProduction,it
becomesnoneconomicalincaseofJOBproduction.
Sandcastingleavesroughsurfacewhichneeds
machininginmostofcases.Itaddsupthecostin
production.
Insandcasting,poordimensionalaccuracyisachieved.
Castproductsaresuperiorforcompressiveloadsbutthey
areverypoorintensileorshockloads.(Theyarebrittle).
FINALLY THATS
ALL !!!!!!