Prikshit Gothwal

2014PPE5067
Production(M Tech.)

Content
Introduction
Classification
Advance Casting Processes
a) Evaporative pattern casting
b) Vacuum mould casting
c) Hybridization of EPC & VMC
d) Metal mould casting
e) Continuous casting
f) Squeeze casting
g) Ceramic shell casting
Rapid Prototyping Technology
References

Introduction:
Casting is a manufacturing process in which molten liquid metal allow to
solidify in pre-defined mould cavity. The solidified part is also known as
a casting.
Casting is most often used for making complex shapes that would be
otherwise difficult or uneconomical to make by other methods

Classification of Casting Processes

Casting

Expandable
Mould

Vacuum
Casting

Expandable
Pattern
Casting

Permanent
Mould

Ceramic
Casting

Squeeze
Casting

Continuous
Casting

Die
Casting

Evaporative Pattern Casting Process

It is a type of casting process that uses a pattern made from a
material that will evaporate when the molten metal is poured into
the 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,

History
H.F. Shroyer patented the foam patterns for metal casting on
April 15, 1958.
M.C. Flemming in 1964, used unbounded sand with the
process. This is known today as lost foam casting (LFC).

Steps:

[1]

Parameters in EPC

Ishikawa Cause and Effect diagram

[1]

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

Advantages:
In the EPC process, no cores are required making it the most
advantageous.
No requirement for binders or other additives, as it is a binder
less process
Complete sand reclamation is possible using very simple and
inexpensive techniques
Sand shake out is easy as the sand is unbounded
Since the pattern used in EPC process is one piece, hence no
parting line and since cores are eliminated, hence no core
prints. Also, no mismatch, core shift because of the mentioned
reasons
Improved casting quality. Close tolerances are possible
The EPC is an environmentally favorable process

Limitations:
Since every casting requires a new pattern, it is a costly process
There is a limitations on the minimum section thickness of the
pattern
Quality of the casting fully depends upon the quality of the
pattern
As the sand is unbounded, during pouring, because of the
difference of the evaporation rate of the metal and flow rate of
the metal, sand falls down in the cavity generated. Hence,
defective casting.

Vacuum mould Casting

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

[1]

Steps

Process Parameters in VMC

Ishikawa Cause and Effect diagram

[1]

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

Application

Medical devices
Computers
Instrumentations
Electronic Enclosures

Advantages
Zero Degree Draft
Excellent Dimensional Tolerance
Smooth Surface Finish
Thin-wall Capabilities;
Excellent Reproduction of Details
Low Tooling Costs
Unlimited Pattern Life
User-friendly Patterns; easy revisions to patterns,
no metal tooling; good for prototypes
Short Lead Times
Patterns have a long life
Low Cleaning / Finishing Cost

Hybrid Evaporative Pattern Casting Process

EPC

VMC

VAEPC

Vacuum Assisted Evaporative Pattern Casting Process

(VAEPC)
Need
One of the limitations of EPC process is that the sand, which is free
flowing, falls on the unfilled casting before the final solidification
Vaporizes rate of pattern is higher than flowing metal

so sand falls in cavity

produce defective casting

This problem has been overcome by combining the process sequence of EPC and
vacuum molding process i.e., by VAEPC

Process Steps

[1]

Process Parameters

Ishikawa Cause and Effect diagram

[1]

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 material
and the cores are made from metal or sand. Cavity surfaces are coated
with 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.

Advantages:
1)
2)
3)
4)
5)

Reusable Mold
Good Surface Finish
Good Dimension Accuracy
High Production Rates
Directional Solidification

Disadvantages:
1)
2)
3)
4)
5)

High tooling cost

Limited to low-melting-point metals
Short mold life
Not economical for small production runs
Intricate shape cannot be cast

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

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

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

(i.e. no liquid core remaining); solving for "L":
[13]

Squeeze Casting
Squeeze casting as liquid-metal forging, is a process by which molten
metal solidifies under pressure within closed dies positioned between the
plates of a hydraulic press.
The process was introduced in the United States in 1960

Casting Parameter:
Casting temperatures depend on the alloy and the part
geometry. The starting point is normally 6 to 55C above the
liquidus temperature.
Tooling temperatures ranging from 190 to 315C are normally
used
Pressure levels of 50 to 140 MPa are normally used

Lubrication For aluminum, magnesium, and copper alloys, a

good grade of colloidal graphite spray lubricant has proved
satisfactory when sprayed on the warm dies prior to casting

Advantages:
Offers a broader range of shapes and components than other
manufacturing 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

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 time
down and increases process costs.
High costs mean high production volumes are necessary to justify
equipment investment
Can be affected by premature chemical reaction, air entrapment and
failure to fill the cavity resulting in reject components.

Applications
Create complex internal features Both ferrous and non-ferrous
materials can be produced using this method
Light alloy castings can be produced in complex 3D shapes which are
stronger than plastic equivalents
Application in automotive industry in producing aluminium front
steering knuckles, chassis frames
Making of High capacity propellers for boat-engine . piston, made by
squeeze casting car rim

Ceramic Shell Casting

Mold is made from ceramic material
Ceramics can withstand higher temperatures

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

Limitations:
1) Costly patterns and moulds

2) Labour costs can be high

3) Limited size

Common Metals:
Ferrous and high-temperature nonferrous metals are most
common; can be used with alloys of aluminum, copper,
magnesium, titanium and zinc

Applications:
1)Aerospace and rocket components.
2)Vanes and blades for gas turbines.
3)Surgical instruments

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) design
2. Conversion of the CAD model into Standard Tessellation Language
(STL) format
3. Slicing of the STL file into thin sections
4. Building part layer by layer
5. Post processing/finishing/joining.

Application
1.
2.
3.
4.

5.
6.
7.
8.

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

Reverse Engineering applications,
Short Production Runs and Rapid Tooling,
In medical applications, RPT is used to make exact models
resembling the actual parts of a person, through computer scanned
data, which can be used to perform trial surgeries,
RP techniques are used to make custom-fit masks that reduce
scarring on burn victims,
Selective laser sintering (SLS) has been used to produce superior
socket knees,
Very tiny, miniature parts can be made by electrochemical
fabrication,
In jewelry designs, crafts and arts.

Advantages:
Process is independent of (workpice) feature
No blanks are required.
Toolless process
Easily 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.

Video

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 improve
the 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-polymeric
materials including metals, ceramics, composites and powder metallurgy.
Developments in ceramic composites can further increase the range of
rapid prototyping.
Currently, the size is also a restriction; capability for larger parts shall
be expected in the near future.

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/vprocess-castings
7)http://www.keytometals.com/page.aspx?ID=CheckArticle&site=kt
s&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_mol
d.cfm

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

& Joseph Dzierzawski
11)Ch-11,
Kalpakjian,
Serope;
Schmid,
Steven
(1995), Manufacturing Engineering and Technology (3th
ed.),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/Pro
cesses/Processes%20Info/Continuous%20Casting%20of%20Steel%2
0-%20Basic%20Principles.aspx