ME 231 Manufacturing Processes (MP)

Delivered by
Dr. Muhammad Amjad
Assistant Professor
amjad9002@uet.edu.pk
 Introduction to CASTING

Chapter 10 of MP Groover book

should be consulted over and above
the contents in these slides
 Contents on casting process
1. Casting terminology
2. Types of Moulds and Moulding Processes
3. Desirable Mould Properties
4. Types of patterns
5. Pattern Allowances
6. Heating and Pouring
7. Fluidity
8. Solidification and cooling
9. Defects in Casting
10. Casting processes
 1. Suitability of casting process
▪ Complex shapes with internal cavities and hollow
sections
▪ Surface finish
▪ Size
▪ Cost
▪ Production rate
▪ Simple process---single piece objects
▪ Important engineering properties
▪ Variety of processing materials
 Limitations of casting
▪ limitations on mechanical properties
▪ porosity
▪ poor dimensional accuracy and surface finish for
some casting processes
▪ safety hazards to humans when processing hot
molten metals, and environmental problems.
 2 Casting terminology
▪ Moulding flask
▪ Cope
▪ Drag
▪ Parting line or parting surface
▪ Pattern
▪ Mould
▪ Poring basin
 2 Casting terminology contd…
▪ Sprue
▪ Runner
▪ Gates
▪ Gating system
▪ Riser
▪ Blind
▪ Open
▪ Vents
▪ Core
 3. Types of Moulds
▪ Expendable moulds
▪ Permanent moulds
▪ Sand moulding
▪ Green-sand molds - mixture of sand, clay, and water;
▪ “Green" means mold contains moisture at time of
pouring
▪ Dry-sand mold - organic binders rather than clay
▪ And mold is baked to improve strength
▪ Skin-dried mold - drying mold cavity surface of a
green-sand mold to a depth of 10 to 25 mm, using
torches or heating lamps
 4. Desirable Mold Properties
▪ Strength (Cohesiveness) - to maintain shape and
resist erosion
▪ Permeability - to allow hot air and gases to pass
through voids in sand
▪ Thermal stability (Refractoriness) - to withstand
high temperatures and to resist cracking on contact
with molten metal
▪ Collapsibility - ability to give way and allow casting
to shrink without cracking the casting
▪ Reusability - can sand from broken mold be reused
to make other molds?
 Heating and Pouring
▪ Heating the metal
The heat required is the sum of:
1. Heat to raise temperature to melting point
2. Heat of fusion to convert from solid to liquid
3. Heat to raise molten metal to desired temperature
for pouring
 Heating and Pouring
▪ Pouring the metal

▪ Pouring temperature
▪ Pouring rate
▪ Turbulence
 Heating and Pouring
▪ Fluidity

▪ Pouring temperature
▪ Composition of the alloy
▪ Viscosity
▪ Heat transfer to the surroundings
 Heating and Pouring
▪ Fluidity

Spiral mold test

 Solidification and Cooling
▪ Pure metal
 Solidification and Cooling
▪ Alloy

Phase diagram and cooling curve for a copper nickel alloy system
 Solidification and Cooling
▪ Alloy..

Characteristic grain structure in an alloy casting, showing

segregation of alloying components in the centre of casting.
 Solidification and Cooling
▪ Solidification time

n
V 
TTS = Cm   (Chvorinov’s rule)
 A
Value of Cm depends on the particular conditions of the casting
operation, including
• mold material (e.g., specific heat, thermal conductivity),
• thermal properties of the cast metal (e.g., heat of fusion,
specific heat, thermal conductivity)
• pouring temperature relative to the melting point of the
metal
 Solidification and Cooling
▪ What Chvorinov's rule tells us?

➢ Chvorinov’s rule indicates that a casting with a higher

volume-to-surface area ratio will cool and solidify more
slowly than one with a lower ratio
➢ This principle is put to good use in designing the riser in a
mold

TTS riser> TTS main casting

Solidification and Cooling
 Solidification and Cooling
▪ Shrinkage
▪ Contraction during
▪ Liquid cooling,
▪ phase change from liquid to solid-solidification shrinkage
▪ solid cooling
 Solidification and Cooling
▪ Directional solidification

▪ Chillers
▪ internal chillers
▪ external chillers

• Riser Design
 5. Types of patterns &
6. Pattern Allowances

▪ Click here to go to pattern slides