Introduction To Casting Processes

by Stead Fast Engineers Pvt Ltd

part 2

one of the leading Induction

heating system manufactures

Design, Materials and

Economics

Design Considerations in
Casting
Design of the part
Casting process and
material
Locate parting line
Locate design gates
Locate mold features
such as sprue,
screens and risers

Design Consideration of Cast

Parts

Corners, angles,
section thickness
Avoid sharp
corners angles
and fillets
Stress raisers,
cracking, and
tearing
Sections should be
blended smoothly

Design Consideration of Cast

Parts

Design Consideration of Cast

Parts
Flat Areas
Large flat areas may
warp during cooling
Poor surface finish from
uneven flow in pouring
Resolve with ribs, and
serrations
Circles and Rounds
Lower cooling rate in
circles induces hot spots
Shrinkage cavities and
porosity

Design Consideration of Cast

Parts
Shrinkage
to avoid cracking
during the cooling
process there should
be shrinkage
allowance
Staggered ribs,
change the
intersection
geometry
Patternmakers
Shrinkage Allowance
10-20 mm/m

Design Consideration of Cast

Parts
Draft
Used to enable easy
removal of pattern
without damage to mold
Range from 5 to
15mm/m

Angles of 0.5 to 2
Dimensional Tolerances

As wide as possible
within limits of good
performance
Letters and markings

Locating the Part Line

Part line
separates upper
and lower mold

Flat plane, along

corners or edges
This will
avoid
flash at the
parting lines

Locating and Designing

Gates
Gates

Connections between
runners and the part
Multiple gates
preferred
Feed into thick
sections of the
castings
Runners
Distribution channel
for molten metal from
the sprue into the
gates

Casting Alloys
Nonferrous Alloys
Aluminum,
magnesium, copper,
zinc, tin, lead
Good electrical
conductivity and
resistant to corrosion
Most of these alloys
share characteristics
of good machinability
and can all be
welded

Casting Alloys
Ferrous alloys
Cast irons
Largest quantity of all
metals cast
Good wear resistance,
hardness and
machinability
Cast Steels
Material used under
extreme heat conditions
Railroad, mining and
construction

Casting Economics
Cost
Depends on materials,
equipment, and labor
Preparations require raw
materials, time and effort
Melting, pouring, heating,
cleaning, inspections
Equipment cost lowers
with large # of castings
Solutions to alleviate
unneeded cost are being
looked into
Rapid prototyping

Molten Metal Pour

Solidification

Solidification
Temperatures

Dimensional Change

Pinholes

Blowhole

Scab

Pinholes

Rough Surface

Thank you