Академический Документы
Профессиональный Документы
Культура Документы
Scrap meetings are held daily. Managers of all the major departments
attend these meetings. They gather castings that have been identified as
scrap by inspector. The defect is circled with chalk. An effort is made to
analyze the cause of the defect, and the manager whose department was
responsible for it is directed to take corrective action to eliminate that
specific defect in future castings.
NITC
Repairability
FINS OR FLASH ON CASTINGS -AsMetallic Projections
NITC
Cavities
Possible Causes
Damage to the casting while hot due to rough handling or excessive
temperature at shakeout.
Remedies
Care in shakeout and in handling the casting while it is still hot;
Sufficient cooling of the casting in the mold;
For metallic molds; delay knockout, assure mold alignment, use
ejector pins
Defective Surface
Possible Causes
Oxide films which lodge at the surface, partially marking the
paths of metal flow through the mold.
Remedies
Increase mold temperature;
Lower the pouring temperature;
Modify gate size and location (for permanent molding by
gravity or low pressure);
Tilt the mold during pouring;
In die casting: vapor blast or sand blast mold surfaces which
are perpendicular, or nearly perpendicular, to the mold
parting line.
Incomplete Casting
Possible Causes
Insufficient quantity of liquid metal in the ladle;
Premature interruption of pouring due to workmans error.
Remedies
Have sufficient metal in the ladle to fill the mold;
Check the gating system;
Instruct pouring crew and supervise pouring practice.
Incorrect Dimensions or Shape
Distorted casting. Inadequate thickness, extending over
large areas of the cope or drag surfaces at the time the
mold is rammed.
Possible Causes
Rigidity of the pattern or pattern plate is not sufficient to
withstand the ramming pressure applied to the sand. The
result is an elastic deformation of the pattern and a
corresponding, permanent deformation of the mold
cavity. In diagnosing the condition, the compare the
surfaces of the pattern with those of the mold itself.
Remedy
Assure adequate rigidity of patterns and pattern plates,
especially when squeeze pressures are being increased.
Inclusions or Structural Anomalies
Possible Causes
Combinations formed as intermetallics between the melt and metallic impurities
(foreign impurities);
Charge materials or alloy additions which have not completely dissolved in the
melt;
Exposed core wires or rods;
During solidification, insoluble intermetallic compounds form and segregate,
concentrating in the residual liquid.
Remedies
Assure that charge materials are clean; eliminate foreign metals;
Use small pieces of alloying material and master alloys in making up the charge;
Be sure that the bath is hot enough when making the additions;
Do not make addition too near to the time of pouring;
For nonferrous alloys, protect cast iron crucibles with a suitable wash coating
INCLUSIONS (FOREIGN PARTICLES) IN CASTINGS
NITC
DESIGN CONSIDERATIONS
NITC
Poor casting practices, lack of control of process
variables- DEFECTIVE CASTINGS
TO AVOID DEFECTS-
Basic economic factors relevant to casting operations to
be studied.
General guidelines applied for all types of castings to be
studied.
DESIGN CONSIDERATIONS
NITC
CORNERS, ANGLES AND SECTION THICKNESS
Sharp corners, angles, fillets to be avoided
Cause cracking and tearing during solidification
Fillet radii selection to ensure proper liquid metal flow-
3mm to 25 mm.
Too large- volume large & rate of cooling less
Location with largest circle inscribed critical.
Cooling rate less
shrinkage cavities & porosities result-
Called HOT SPOTS
NITC
DESIGN MODIFICATIONS TO AVOID DEFECTS-
NITC
LARGE FLAT AREAS TO BE AVOIDED-
WARPING DUE TO TEMPERATURE GRADIENTS
ALLOWANCES FOR SHRINKAGE TO BE PROVIDED
PARTING LINE TO BE ALONG A FLAT PLANE-
GOOD AT CORNERS OR EDGES OF CASTING
DRAFT TO BE PROVIDED
PERMISSIBLE TOLERANCES TO BE USED
MACHINING ALLOWANCES TO BE MADE
RESIDUAL STRESSES TO BE AVOIDED
NITC
DESIGN MODIFICATIONS TO AVOID DEFECTS-
AVOID SHARP CORNERS TO REDUCE STRESS
CONCENTRATIONS
NITC
DESIGN MODIFICATIONS TO AVOID DEFECTS-
MAINTAIN UNIFORM CROSS SECTIONS TO AVOID HOT
SPOTS AND SHRINKAGE CAVITIES
NITC
DESIGN MODIFICATIONS TO AVOID DEFECTS-
NITC
DESIGN MODIFICATIONS TO AVOID DEFECTS-
SECTION THICKNESS UNIFORMITY MAINTAINED
THROUGHOUT PART
NITC
DESIGN MODIFICATIONS TO AVOID DEFECTS
NITC
DESIGN MODIFICATIONS TO AVOID DEFECTS-
USE OF METAL PADDING (CHILLS)
NITC
INSPECTION OF CASTINGS
SEVERAL METHODS
VISUAL
OPTICAL
- FOR SURFACE DEFECTS
SUBSURFACE AND
INTERNAL DEFECTS
THROUGH
NDTs & DTs
PRESSURE TIGHTNESS OF
VALVES BY SEALING THE
OPENING AND
PRESSURISING WITH WATER
EXERCISE
PROCESS FLOW CHART
RECEIPT OF ORDER
(REVIEW)
ARE THE TERMS ACCEPTED? NO COMMUNICATE-
NEGOTIATE
YES
PREPARE WORK ORDER
WORK ORDER TO Q.C, INSPECTION, PLANNING, METHODS,
PRODUCTION AND DESPATCH
PRODUCTION PLAN
METHOD DRAWING, QA DATA, PATTERN PLAN
MOULDING
WORK ORDER, CORE MAKING, HEAT CONFORMATION
MELTING AND POURING
FOR THESE, LAB TEST REPORTS
KNOCK OUT
STAGE ISPECTION- NOT OK, REJECT
OK, SHOT BLASTING, GAS CUTTING/ARC CUTTING
ASTM STANDARDS
HEAT TREATMENT
ROUGH FETTLING, FINISH FETTLING,
INSPECTION
NDT- CUSTOMER REPORT, NOT OK,
WELDING & RECTIFICATION
WELDING LOG SHEET
RE-INSPECTION, NOT OK-
REJECT
MACHINE - IF REQUIRED
STRESS RELIEF
HYDRAULIC TESTS Etc.
TEST CERTIFICATE DESPATCH
DOCUMENTS, PACKING, Etc. Etc.
Largest Vertically Parted Mold Machine Built for
Denmark.
DISA Group (with U.S. headquarters in Oswego, Illinois)
NEWS FROM NET
www.moderncasting.com/info