1. 2. 3. 4. 5.

Basic permanent mold process Slush casting Low pressure casting Vacuum permanent mold casting Die casting- (a) hot chamber die casting (b) cold chamber die casting

1) Flask molding 2) Flaskless molding using master flask

Ramming can be done through different methods: a) Hand ramming b) Jolting action c) Using pneumatic pressure d) Slinging action

1) Strength
2) Collapsibility 3) Thermal stability

4) Reusability
5) Permeability

% by volume : 1) 90% sand 2) 3% water 3) 7% clay 4) Organic resin 5) Inorganic binders

1. Green sand mold 2. Dry sand mold uses organic binders

rather than clay 3. Skin dried mold drying green sand mold upto a depth of 10-25 mm.

1) Shell molding

2) Vacuum molding or V-process

3) Expanded poly-styrene process 4) Investment casting

5) Plaster mold and ceramic mold casting

1) Plaster mold- Gypsum (CaSO4 + 2H2O)

2) Ceramic mold- ZrO2 , Al2O3 , carbides,

nitrides etc.

Cupola furnace 2. Electric arc melting: (a) direct arc type (b) Indirect type 3. Crucible furnace 4. Reverberatory or air furnace
1.

Types of Ladles

 Ferrous casting

alloys- Cast iron and steel

Non-ferrous casting alloys- Mg, Al, Sn, Cu, Zn alloys

Geometric simplicity
Thin sections Corners Draft Use of cores Dimensional tolerances Surface finish

Machining allowance

1. Flat rolling 2. Shape rolling

1. 2.

3.
4. 5. 6. 7. 8. 9.

10.
11.

Soaking and soaking pit Draft =d Reduction= r Spreading No slip point or neutral point Forward slip=s Max draft Force =F Contact length =L Torque =T Power =P

1.

Thread rolling

2. Ring rolling
3.

Gear rolling

4. Roll piercing

Open die forging or upset forging 2. Impression die forging 3. Closed die forging or flash-less forging
1.

1.

Gravity drop hammer

2. Power drop hammers

1.

Mechanical presses

2. Hydraulic presses

3.

Screw presses

1. 2.

3.
4. 5. 6. 7. 8.

Upsetting or heading Swaging Radial forging Roll forging Orbital forging Hubbing Isothermal and hot-die forging Trimming