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CONSIDERATION FOR
INVESTMENT CASTING
Introduction
Solid mould
In the solid mould process the pattern is placed into a container and
mould material poured around the pattern and allowed to solidify to make
the solid block.
Pattern materials
moulded
of
either
wax
or
plastic.
features
casting are:
Intricate shape
Close tolerances
Small size
of
investment
Contoured
surfaces,
undercuts,
other
Typical
examples
of
such
mechanical
General design
considerations
Fluidity
Shrinkage
Resistance
to hot
tearing
Castability
rating
Carbon steels
1040 (G10400)
B+
1050 (G10500)
B+
Alloy steels
2345(G23450)
A-
4130(G41300)
A-
Nickel alloys
Monel (QQ-N288-A)
(N04020)
B+
Inconel 600
(AMS 5665)
(N06600)
B+
Fluidity
Shrinkage
Resistance
to hot
tearing
Castability
rating
Cobalt alloys
Cobalt 21
(R30021)
A-
Cobalt 31
(R30031)
A-
Aluminum Alloys
A 356 (A13560)
A+
C 355 (A33550)
Tool steels
A-2 (T30102)
B+
H-13 (T20813)
B+
B+
Copper alloys
Gunmetal
(C90500)
Detail design
recommendations
The following important design guidelines are
recommended for investment casting.
Low-carbon steel
1.8
High-carbon steel
1.5
Low-alloy steel
1.5
1.0
1.5
Cobalt-base alloys
0.75
Nonferrous metals
Aluminum
1.0
Beryllium copper
0.75
Brass
1.0
Bronze
1.5
Detail design
recommendations
Radii:
Even though use of sharp corners is possible by this method,
generous radii are preferred. Better quality and more accurate
parts can be produced by providing ample fillets and radii. A
minimum of 0.75mm fillet radius need to be furnished. However, a
radius of 1.5 to 3 mm is preferable.
Curved surfaces:
Both concave and convex surfaces are possible to
cast in this category. Generally concave surfaces
can be cast with greater accuracy.
Parallel sections:
Parallel sections can be classified into two
geometric categories namely: forks or yokes and
clamp or pinch collars.
Figure 5: Recommended minimum slot widths W for clamps and pinch collars
are 1.5 mm for ferrous metals and 1.0 mm for non-ferrous metals.
Figure 6: Keys and keyways should have a width to-depth ratio of 1:1 or
Holes:
Whenever holes are to be incorporated a
minimum size (diameter) must be greater than or
equal to 1.5mm and 2.2 mm for nonferrous and
ferrous alloys respectively are to be used.
Blindholes:
In general, blind holes are not recommended for
casting. If it is inevitable, the depth of the hole
should not exceed the diameter.
Through holes:
Tolerances for blind holes and through holes are same.
L/D ratio should not exceed 4:1 and 5:1 for ferrous
and copper & aluminum respectively.
Ceramic cores:
In the design of pattern mould, if any intricate internal
configuration (example internal thread) has to be
made with a ceramic core then provision must be
provided in the mould to support the ceramic core the
Draft:
To remove wax pattern from the mould a small amount
of draft is provided to the pattern. The recommended
values lie in the range between 1/4 to 1/8 .
Screw threads:
Both internal and external threads can be
investment
casted.
But
it
is
not
usual
recommended practice.
Undercuts:
Even though undercuts doesnt create any problem
to the casting operation but has significant effect in
pattern moulding operation and hence this has to be
avoided.
Dimensional factors:
The most significant factor influencing the dimensional
accuracy of investment casting is the shrinkage of the
materials used. Some degrees of shrinkage are there
in all levels: wax pattern, investment material and cast
material. The normal shrinkage allowance provided for
shell mould and flask mould method are 1.6 to 1.7 %
and 1.1% respectively.
Pattern
and
pattern-mould
dimensional
variations
Recommended tolerances(mm)
Normal
Tight
Up to 6
0.4
0.08
613
0.4
0.10
1325
0.4
0.13
2550
0.4
0.18
50100
0.8
0.40
100150
1.1
0.60
Over 150
1.5
0.80