Академический Документы
Профессиональный Документы
Культура Документы
1. INTRODUCTION
CENTRIFUGAL CASTING
2. CLASSIFICATION
CENTRIFUGAL CASTING
CENTRIFUGAL CASTING
Mold
2)
Roller track
3)
End plate
4)
Spinning pot
5)
Cooling track
6)
Spout
7)
Housing
Process Details: Molten metal can be introduced into the mold at one end, at both ends, or
through channel of variable length. Pouring rate widely according to the size of the
casting being produced and the metal being used. For example, a pouring rate of 1.1 t
2.2 tons/min. has been used to cast6 alloy steel tubes of 500mm in outside diameter
with 50mm thick walls. Pouring rates that are too slow can result in gas porosity while
high rates slow solidification are one of the main causes of longitudinal cracking.
Cast temperatures: The degree of superheat required to produce a casting is a function of the
metal or alloy being poured. The following empirical formula has been suggested as
general guideline to determine the degree of super heat.
L = 2.4 T + 110
CENTRIFUGAL CASTING
Where the length of spiral fluidity (in mm) and T is the degree of superheat
(in degrees centigrade) Mold Temperatures Initial mold temperatures vary over a
wide range according to the metal being cast, the mold thickness, and the wall
thickness of tube being cast. Initial mold temperature does not affect the structure of
the resultant casting as greatly as the process parameters discussed above do.
CENTRIFUGAL CASTING
Speed of rotation: Generally the mold is rotated at a speed that creates a centrifugal force ranging
from 75 to 120g speed of rotation is varied during the casting process.
The cycle can be divided into three parts: At the time of pouring, the mold I rotating at a speed sufficient to throw the molten
metal against the mold wall.
As the metal reaches the opposite end of the mold, the speed of rotation is
increased. Speed of rotation is held constant for a time after pouring the time at
constant aped varies with mold type, metal being cast, and required wall thickness.
The ideal speed of rotation causes rapid adhesion of the molten metal to the
mold wall with minimal vibration. Such conditions tend to result in a casting with a
uniform structure.
As the molten metal enters the mold a pressure gradient is established across
the tube thickness by centrifugal acceleration.
Too low a speed of rotation can cause sliding and result in poor surface finish.
Too high speed of rotation can generate vibrations, which can result in circumferential
segregation.
CENTRIFUGAL CASTING
Mold
2)
Adapter table
3)
Funnel
4)
Spinner machine
Process details: Casting Inside Diameters: When making castings on a vertical centrifugal casting machine, the inside
diameter (bore) of the casting will be tapered in accordance with the following
formula.
n =264
h
r12 r22
Where n is speed of rotation, r1 is the inside radius at the top of the casting, r2
is the inside radius at the bottom of the casting and h is casting height.
CENTRIFUGAL CASTING
CENTRIFUGAL CASTING
Speed of rotation: To establish a temperature gradient of the molten metal from the outside
diameter towards the centre of rotation. It is usually necessary for the mold to be
spinning when the metal is poured. In some cases, in order to eliminate defects such
as erosion and dirt in sand molds, it is desirable to pour at a slow speed of rotation.
However, true centrifugal castings having a wall section of 12.7mm or less must be
poured at spinning speed because the metal in this thin section.
Nomographs are available for determining the proper speed of rotation
for centrifugal casting. Equation used to calculate spinning speed.
G = 0,0000142Dn
Where g is the centrifugal force, D is the inside diameters of the casting, and n is the
speed of ration.
CENTRIFUGAL CASTING
5. POURING TECHNIQUES
10
CENTRIFUGAL CASTING
11
CENTRIFUGAL CASTING
6. SOLIDEFICATION
12
CENTRIFUGAL CASTING
7. MOLDS
Molds used in centrifugal casting: Molds consist of four parts, the shell the casting spout, roller tracks and end
heads. The mold assembly is placed on interchangeable carrying rollers that enable
the use of different mold diameters and fine adjustments. Molds are cooled by a water
spray, which can be divided into severed streams for selective cooling.
Different types of molds are generally used according to the geometry and
quantity of castings needed and the characteristic of the metal or allow being cast.
Expendable Molds: Expendable molds lined used in centrifugal cooling, especially for producing
relatively few casting. A single mold case can be used with different thickness of sand
linings to produce tubes of various diameters within a limited range.
Green Sand Molds: Green sand is commonly used as the liner in expendable molds. Various
mixtures and binders are used for example, a mixture of 60% silica sand and 40%
calcined and crushed asbestos or sand bound with resin.
Dry Sand molds: a) Dry sand molds can also be employed in this cases, the sand is pressed
down around a pattern having the same dimensions as the casting. Hardening is
sometimes accomplished with carbon dioxide.
Permanent Molds: The most common materials for permanent molds are steel, copper and
graphite.
13
CENTRIFUGAL CASTING
Steel Molds: It is used to cast large quantities and for some casting alloys that require
specific solidification conditions. Steel molds are sensitive to thermal shock, alumina
or circonial base mold sprays are used to lesser thermal shocks to the mold and to
improve the mold surface, Mold coatings are also important in regulating the
solidification rates of some casting materials.
Copper Molds: These are sometimes used for their high thermal conductivity. Their relatively
high cost and the difficulty of calculating the correct dimensions of these molds limit
their field of application.
Graphite Molds: Because of their relatively low cast, graphite molds can be an economical
alternative to sand in the production of small quantities of parts. Graphite is the mold
material of choice in the casting of 80% a bronze, high phosphorus brass, and other
copper alloys. Graphite has excellent thermal conductivity and resistance to thermal
shock.
14
CENTRIFUGAL CASTING
8. MOLD DESIGN
Metal Mold Design: Machining allowances for casting depend of melting practices, the condition
and thickness of the mold insulation coating, the volumetric shrinkage of the metal
being cast, and the susceptibility of the metal to causing defects such as dross
formation.
With minimum allowances, the mold can be refashioned to allow for more
machining allowance as determined by experience and the specific melting practices
used, Patternmakers shrinkage is the shrinkage allowance built into the pattern to
compensate for the change in dimensions caused by the contraction of the cast metal
as it cools. This shrinkage allowance is the factor with which the mold maker is
concerned.
Mold wall Thickness: Wall thickness may vary depending on the specific equipment and application
involved. Mold wall thickness is independent of casting wall thickness for watercooled steel molds.
End Plate Thickness: End plate thicknesses depend on casting wall thickness and end plate material.
Commonly used and end plate material are ASTM A 36, steel, 1015 steel, or 1018
steel plate.
End Plate Recess: The end plate recess in the mold provides an effective to prevent leakage of
the molten metal from the mold. The amount of end plate recess used depends on
mold inside diameter and can be as high as the mold inside diameter plus 25mm (1
in.) for mold inside diameters of 150mm (6 in.) or more.
College Of Engineering Pandharpur
15
CENTRIFUGAL CASTING
End Plate Mold Lock Design: Various removable end plates are shown in Fig. These end plate types are
recommended for all vertical molds. Preferred end plate types are those shown in Fig
(a), (b) and (c). Mold end plate diametric clearance fit into the mold recess diameter
should be a minimum of 1.2 mm. This clearance is effective for end plates upto about
380 mm (15 in.) in diameter. On large end plates, clearances as large as 2.5 mm. (3/ 32
in.) may be necessary for easy removal and assembly. The standard draft angle of 3 0
will permit easy removal and assembly.
End Plate Wedge and Pin Design: Wedges for holding the end plate secure in the mold are principally of two
different types: the tapered wedge and the tapered pin. The maximum allowable stress
for tapered wedges and pins is 69 Mpa.
Mold Adapter Tables: A mold adapter table is usually furnished or required with a vertical
centrifugal casting machine to facilitate attachment of the molds to the machine. Also
furnished or required with the mold adapter table is a mold centering boss or index
boss/plug for aligning and centering the mold so that it is concentric with the spinner
shaft of the machine.
16
CENTRIFUGAL CASTING
17
CENTRIFUGAL CASTING
9. DEFECTS
Segregation Banding: It occurs only in true centrifugal casting, generally where the casting wall
thickness exceeds 50to 75 mm. It rarely occurs in thinner-wall castings. Banding can
occur in both horizontal and vertical centrifugal castings. Bands are annular
segregated zones of low melting constituents, such as eutectic phases and oxide or
sulfide inclusions.
Causes: a) Banding has been found when some critical level of rotational speed is attained,
and it has been associated with very low speeds, which can produce sporadic of
molten metal.
b) Vibration is the principle cause and that during solidification a zone of low melting
liquid exits immediately adjustment to the main crystal growth, nucleation can occur
and it disturbed by vibration banding result.
c) If there are irregularities in the flow of the liquid metal as it enters the rotating
mold.
Raining: In a horizontal Machine, raining can occur if the mold is rotated at too low
speed or if the metal is poured into the mold too fast. In this phenomenon, the metal
actually rains or falls the top of the mold to the bottom.
Vibration Defects: Vibration can cause a laminated casting. It can beheld to a minimum by proper
mounting, careful balancing of the molds, and frequent inspection of rollers, bearing,
and other vital parts.
18
CENTRIFUGAL CASTING
10. APPLICATIONS
Applications: The flexibility of the centrifugal casting process, in terms of both materials
and the wide range of part sizes that can be produced, has led to the application of
centrifugally cast parts in many industries. Some of the most common applications are
outlined briefly in this section.
Iron and Steel industry: Centrifugally cast parts are used in the production of iron and steel for
continuous casting rollers, rolling mill rolls, furnace rollers, special pipelines, winding
spools, and other applications.
Petroleum production: Off shore production platforms in the oil and gas industry use centrifugally
cast tubes in various application. Hot extruded bimetallic tubes are used in pipelines
and gathering systems.
Other Applications: Other applications for centrifugally cast tubes include hydraulic cylinders,
rollers for glass production, pipelines for the transport of abrasive materials, rollers in
the pulp and paper industry, tubes for the chemical processing industry, foundation
piles, and building columns. Gears, disked wheels, propellers and pulleys also
produced by centrifugal casting.
19
CENTRIFUGAL CASTING
11. CONCLUSION
20
CENTRIFUGAL CASTING
12. REFERENCES
1. ASM HANDBOOK
CASTINGS
MATERIALS
VOL 15
2. BLACK AND KOSHER
ELEMENTS OF WORKSHOP
TECHNOLOGY
VOL 1: Manufacturing.
21