advance casting processs

8/10/2019 Advance casting Processs

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Prikshit Gothwal

2014PPE5067Production(M Tech.)


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Casting

ExpandableMould

Vacuum

Casting

ExpandablePatternCasting

Ceramic

Casting

PermanentMould

Squeeze

Casting

Die

Casting

ContinuousCasting

Classification of Casting Processes


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Evaporative Pattern Casting Process

It is a type of casting process that uses a pattern made from amaterial that will evaporate when the molten metal is poured intothe molding cavity.

Most common evaporative pattern material Polystyrene foam

The two major evaporative-pattern casting processes are

1) Lost Foam Casting Uses unbounded sand,

2) Full Mold Casting Uses bounded sand,


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History

H.F. Shroyer patented the foam patterns for metal casting onApril 15, 1958.

M.C. Flemming in 1964, used unbounded sand with the process. This is known today as lost foam casting (LFC).


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Steps : [1]


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Application

It is used for making automotive components (cylinder heads,engine blocks, inlet manifolds, heat exchanger ,crank shaft) It is used in marine, aerospace and construction industries


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Limitations:

Since every casting requires a new pattern, it is a costly processThere is a limitations on the minimum section thickness of the

patternQuality of the casting fully depends upon the quality of the

patternAs the sand is unbounded, during pouring, because of thedifference of the evaporation rate of the metal and flow rate ofthe metal, sand falls down in the cavity generated. Hence,defective casting.


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Vacuum mould Casting

The Vacuum molding (V process) makes use of dry sand, plasticfilm and a negative vacuum pressure as a means for binding. To bind sand use vacuum 250 450 mm Hg Plastic film

[1]


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Steps


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Process Parameters in VMC

Ishikawa Cause and Effect diagram

[1]


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VMC Specification

Tolerances One side of parting line .010" up to 1".

Over 1" add .002"/in.

Surface Finish 125-150 RMS

Draft Required Nil

Minimum Section Thickness 2.5 mm


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Application Medical devices Computers Instrumentations Electronic Enclosures


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Process Steps

[1]


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Process Parameters

Ishikawa Cause and Effect diagram

[1]


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Metal Mould Casting

Instead of using sand as the mold material, a metal is used as a mold.

Cast iron or Meehanite (a dense cast iron) is used as the mold materialand the cores are made from metal or sand. Cavity surfaces are coatedwith a thin layer of heat resistant material such as clay or sodium silicate

Common casting metals are aluminium, magnesium, and copper alloys.Other materials include tin, zinc, and lead alloys and iron and steel.


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Advantages: 1) Reusable Mold

2) Good Surface Finish3) Good Dimension Accuracy4) High Production Rates5) Directional Solidification

Disadvantages:1) High tooling cost2) Limited to low-melting-point metals3) Short mold life4) Not economical for small production runs5) Intricate shape cannot be cast


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Specifications: Tolerances : 0.4 mm for first 25mm

0.02 mm for each additional centimeter

Surface Finish : 2.5-7.5 m RMS

Draft : 2 - 3 Wall Thickness: 3-50 mm

Part Size Range : 100 g to 75 kg


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Continuous Casting

Molten metal solidifies into semifinished goods as billet,bloom or slab

In this process liquid metal will be stored in tundish & it will allowthrough a die.

The input to the die is a liquid metal & output is a solid crust on towhich water is spray to cool the material at the faster rate


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Calculate the casting distance (L) where the product is fully-solidified

(i.e. no liquid core remaining); solving for "L":

[13]


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Casting Parameter:

Casting temperatures depend on the alloy and the partgeometry. The starting point is normally 6 to 55 C above theliquidus temperature.

Tooling temperatures ranging from 190 to 315 C are normallyused

Pressure levels of 50 to 140 MPa are normally used

Lubrication For aluminum, magnesium, and copper alloys, agood grade of colloidal graphite spray lubricant has provedsatisfactory when sprayed on the warm dies prior to casting


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Advantages:

Offers a broader range of shapes and components than othermanufacturing methods

Little or no machining required post casting process

Low levels of porosity

Good surface texture

Fine micro-structures with higher strength components

No waste material, 100% utilization


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Limitations & Disadvantages:

Costs are very high due to complex tooling

No flexibility as tooling is dedicated to specific components

Process needs to be accurately controlled which slows the cycle timedown and increases process costs.

High costs mean high production volumes are necessary to justifyequipment investment

Can be affected by premature chemical reaction, air entrapment andfailure to fill the cavity resulting in reject components.


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C i Sh ll C i


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Ceramic Shell Casting

Mold is made from ceramic material

Ceramics can withstand higher temperatures


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Advantages:

1) Excellent Surface Finish (1.2 to 3.0 m )

2) Tight dimensional tolerances

3) Machining can be reduced or completely eliminated

4) High melting point alloy can be cast, almost any metal can be cast

5) Almost unlimited intricacy


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Limitations:

1) Costly patterns and moulds

2) Labour costs can be high

3) Limited size

Common Metals:

Ferrous and high-temperature nonferrous metals are mostcommon; can be used with alloys of aluminum, copper,

magnesium, titanium and zinc


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R id P i T h l


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Rapid Prototyping Technology

Rapid prototyping (RP) is a technology wherein the physical modeling

of a design is done using a specialized machining technology

Steps:

1. Creation of the CAD model of the (part) design2. Conversion of the CAD model into Standard Tessellation Language

(STL) format3. Slicing of the STL file into thin sections4. Building part layer by layer

5. Post processing/finishing/joining.

A li ti


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Application

1. It is mainly used in modeling, Product Design and Development,

2. Reverse Engineering applications,3. Short Production Runs and Rapid Tooling,4. In medical applications, RPT is used to make exact models

resembling the actual parts of a person, through computer scanneddata, which can be used to perform trial surgeries,

5. RP techniques are used to make custom-fit masks that reducescarring on burn victims,

6. Selective laser sintering (SLS) has been used to produce superiorsocket knees,

7. Very tiny, miniature parts can be made by electrochemicalfabrication,

8. In jewelry designs, crafts and arts .

Ad t


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Advantages:Process is independent of (workpice) feature

No blanks are required.

Toolless processEasily automation

Disadvantages:In view of high equipment cost, very few organizations can invest in

these new machines.

Currently, RPT is more limited to modeling, specimen making and

designing.The RPT is at present limited to making of paper and plastic type

products only.


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Video

F t d l t
http://d/adv%20casting/Rapid_Prototype_Aesthetic_Extrusion_Process.flvhttp://d/adv%20casting/Rapid_Prototype_Aesthetic_Extrusion_Process.flv


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Future developments:

As the Rapid Prototyping Technology gets further advanced, it can

lead to substantial reduction in build-up time for manufacturing. Further improvement in laser optics and motor control can improvethe accuracy.

The development of new materials and polymers so that they are less prone to curing and temperature induced warpages.

Much anticipated development is the introduction of non-polymericmaterials including metals, ceramics, composites and powder metallurgy.

Developments in ceramic composites can further increase the range ofrapid prototyping.

Currently, the size is also a restriction; capability for larger parts shall be expected in the near future.

References:


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References:

1) http://nptel.ac.in 2)http://www.engineershandbook.com 3)http://thelibraryofmanufacturing.com 4)http://www.engineershandbook.com/MfgMethods/ 5)http://www.mccannsales.com/book/vprocess.pdf 6)http://petersonenterprises.com/processesproducts/casting/v-

process-castings 7)http://www.keytometals.com/page.aspx?ID=CheckArticle&site=kts&NM=361 8)http://www.keytometals.com/page.aspx?ID=CheckArticle&site=kt

n&NM=172 9)http://www.efunda.com/processes/metal_processing/ceramic_mold.cfm
http://nptel.ac.in/http://www.engineershandbook.com/http://thelibraryofmanufacturing.com/http://www.engineershandbook.com/MfgMethods/http://www.mccannsales.com/book/vprocess.pdfhttp://petersonenterprises.com/processesproducts/casting/v-process-castingshttp://petersonenterprises.com/processesproducts/casting/v-process-castingshttp://www.keytometals.com/page.aspx?ID=CheckArticle&site=kts&NM=361http://www.keytometals.com/page.aspx?ID=CheckArticle&site=kts&NM=361http://www.keytometals.com/page.aspx?ID=CheckArticle&site=ktn&NM=172http://www.keytometals.com/page.aspx?ID=CheckArticle&site=ktn&NM=172http://www.efunda.com/processes/metal_processing/ceramic_mold.cfmhttp://www.efunda.com/processes/metal_processing/ceramic_mold.cfmhttp://www.efunda.com/processes/metal_processing/ceramic_mold.cfmhttp://www.efunda.com/processes/metal_processing/ceramic_mold.cfmhttp://www.keytometals.com/page.aspx?ID=CheckArticle&site=ktn&NM=172http://www.keytometals.com/page.aspx?ID=CheckArticle&site=ktn&NM=172http://www.keytometals.com/page.aspx?ID=CheckArticle&site=kts&NM=361http://www.keytometals.com/page.aspx?ID=CheckArticle&site=kts&NM=361http://petersonenterprises.com/processesproducts/casting/v-process-castingshttp://petersonenterprises.com/processesproducts/casting/v-process-castingshttp://petersonenterprises.com/processesproducts/casting/v-process-castingshttp://petersonenterprises.com/processesproducts/casting/v-process-castingshttp://petersonenterprises.com/processesproducts/casting/v-process-castingshttp://www.mccannsales.com/book/vprocess.pdfhttp://www.engineershandbook.com/MfgMethods/http://thelibraryofmanufacturing.com/http://www.engineershandbook.com/http://nptel.ac.in/


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10) Continuous Casting of Steel: Basic Principles By Bruce Kozak,& Joseph Dzierzawski

11)Ch-11, Kalpakjian, Serope; Schmid, Steven(1995), Manufacturing Engineering and Technology (3thed.),Pearson, ISBN 0-201-53846-6

12) Squeeze casting by M.R. Ghomashchi*, A. Vikhrov

13) http://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspx
http://en.wikipedia.org/wiki/International_Standard_Book_Numberhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20Info/Continuous%20Casting%20of%20Steel%20-%20Basic%20Principles.aspxhttp://www.steel.org/Making%20Steel/How%20Its%20Made/Processes/Processes%20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advance casting processs

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