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By S K Mondal
Sand casting
Sand casting uses ordinary sand as the primary
mould material.
The sand grains are mixed with small amounts of
other materials, such as clay and water, to improve
mouldability and cohesive strength, and are then
packed around a pattern that has the shape of the
desired casting.
The pattern must be removed before pouring, the
mold is usually made in two or more pieces.
An opening called a sprue hole is cut from the top of
the mold through the sand and connected to a
system of channels called runners. Contd.
The molten metal is poured into the sprue hole, flows
through the runners, and enters the mold cavity
through an opening called a gate.
Gravity flow is the most common means of
introducing the metal into the mold.
After solidification, the mold is broken and the
finished casting is removed.
The casting is then fettled by cutting off the ingate
and the feeder head.
Because the mold is destroyed, a new mold must be
made for each casting.
Contd
Sequential steps in making a sand casting
A pattern board is placed between the bottom (drag)
and top (cope) halves of a flask, with the bottom side up.
The contents are shaken from the flask and the metal
segment is separated from the sand, ready for further
processing.
Casting Terms
Flask: A moulding flask is one which holds the sand
mould intact. It is made up of wood for temporary
applications or metal for long-term use.
Contd
Moulding sand: The freshly prepared refractory
material used for making the mould cavity. It is a
mixture of silica, clay and moisture in appropriate
proportions.
5. Rapping allowance
Shrinkage allowance
All metals shrink when cooling except perhaps
bismuth.
Contd
Liquid shrinkage and solid shrinkage
Liquid shrinkage refers to the reduction in volume
when the metal changes temperature from pouring to
solidus temperature in liquid state. To account for this,
risers are provided in the moulds.
Solidification shrinkage refers to the reduction in
volume when metal changes from liquid to solid state
at the solidus temperature. To account for this, risers
are provided in the moulds.
Solid shrinkage is the reduction in volume caused,
when a metal loses temperature in the solid state. The
shrinkage allowance is provided to take care of this
reduction.
Gray CI with a carbon equivalent of 4.3% has
negative shrinkage, that is, it actually expands
upto 2.5% because of graphite precipitation. So,
for this, no riser is needed.
Pattern Allowances
Cast Iron 10 mm/m
Brass, Copper, Aluminium 15 mm/m
Steel 20 mm/m
Zinc, Lead 25 mm/m
GATE-2004
Gray cast iron blocks 200 x 100 x 10 mm are to be
cast in sand moulds. Shrinkage allowance for
pattern making is 1%. The ratio of the volume of
pattern to that of the casting will be
Light in weight
Codes:
(a) 1,3 and 4 (b) 2,3 and 4 (c) 1, 2 and 4 (d) 1, 2 and 3
Types of Pattern
Single Piece Pattern
These are inexpensive and the simplest type of
patterns. As the name indicates, they are made of a
single piece.
Gated Pattern
Gating and runner system are integral with the
pattern. This would eliminate the hand cutting of
the runners and gates and help in improving the
productivity of a moulding.
Types of Pattern
Split Pattern or Two Piece Pattern
This is the most widely used type of pattern for intricate
castings. When the contour of the casting makes its
withdrawal from the mould difficult, or when the depth
of the casting is too high, then the pattern is split into two
parts so that one part is in the drag and the other in the
cope.
Types of Pattern
Cope and Drag Pattern
These are similar to split patterns. In addition to
splitting the pattern, the cope and drag halves of
the pattern along with the gating and riser systems
are attached separately to the metal or wooden
plates along with the alignment pins. They are
called the cope and drag patterns.
Types of Pattern
Match Plate Pattern
The cope and drag patterns along with the
gating and the risering are mounted on a single
matching metal or wooden plate on either side.
Types of Pattern
Loose Piece Pattern
This type of pattern is also used when the
contour of the part is such that withdrawing the
pattern from the mould is not possible.
Types of Pattern
Follow Board Pattern
This type of pattern is adopted for those
castings where there are some portions, which
are structurally weak and if not supported
properly are likely to break under the force of
ramming.
Types of Pattern
Sweep Pattern
It is used to sweep the complete casting by means
of a plane sweep. These are used for generating
large shapes, which are axi-symmetrical or
prismatic in nature such as bell-shaped or
cylindrical.
Types of Pattern
Skeleton Pattern
A skeleton of the pattern made of strips of wood
is used for building the final pattern by packing
sand around the skeleton. After packing the
sand, the desired form is obtained with the help
of a strickle. This type of pattern is useful
generally for very large castings, required in
small quantities where large expense on
complete wooden pattern is not justified.
Cooling Curve
GATE-2016
Heat is removed from a molten metal of mass 2 kg at a
constant rate of 10 kW till it is completely solidified. The
cooling curve is shown in the figure.
Assuming uniform
temperature
throughout the
volume of the metal
during solidification,
the latent heat of
fusion of the metal
(in KJ/kg) is
__________
Fluidity
The ability of a metal to flow and fill a mold is known
as fluidity.
Pouring Temperature
The most important controlling factor of fluidity is the
pouring temperature or the amount of superheat.
Higher the pouring temperature, the higher the fluidity.
Excessive temperatures should be avoided, however. At
high pouring temperatures, metal-mold reactions are
accelerated and the fluidity may be so great as to permit
penetration.
Penetration is a defect where the metal not only fills the
mold cavity but also fills the small voids between the sand
particles in a sand mold.
Core
Used for making cavities and hollow projections.
p 5.0 g / cm 2
T 1min 25 s 1.417 min
501.28
R 70.75
5 1.417
IES 2007
What is permeability? Permeability is more important
in the basic process of sand casting than porosity. Give
one important reason for this feature.
[2 marks]
Collapsibility: At the time of cooling, casting shrinks, and
Because of the high strength of the bond, the core need not
be provided with any other reinforcements.
The sand mixture does not have good shelf life and
therefore should be used immediately after preparation.
GATE 2008 (PI)
In sand casting of a hollow part of lead, a cylindrical core
of diameter 120 mm and height 180 mm is placed inside
the mould cavity. The densities of core material and lead
are 1600 kg/m3 and 11,300 kg/m3 respectively. The net
force (in N) that tends to lift the core during pouring of
molten metal will be
w
Casting yield 100
W
Gating System
Contd
Gating System
Pouring basin: A small funnel shaped cavity at the
top of the mould into which the molten metal is
poured.
Contd
Runner: A runner is commonly a horizontal channel
which connects the sprue with gates, thus allowing the
molten metal to enter the mould cavity. The runners
are of larger cross-section and often streamlined to
slow down and smooth out the flow, and are designed
to provide approximately uniform flow rates to the
various parts of the mould cavity. Runners are
commonly made trapezoidal in cross-section.
Contd
Ingate: A channel through which the molten metal
enters the mould cavity.
Vent: Small opening in the mould to facilitate escape
of air and gases.
Types of Gate or In-gate
Top gate: Causes turbulence in the mould cavity, it is prone
to form dross, favourable temperature gradient towards the
gate, only for ferrous alloys.
Less turbulence.
Sprue Design
Sprue: Sprue is the channel through which the molten
metal is brought into the parting plane where it enters the
runners and gates to ultimately reach the mould cavity.
The molten metal when moving from the top of the cope to
the parting plane gains in velocity and some low-pressure
area would be created around the metal in the sprue.
Since the sand mould is permeable, atmospheric air would
be breathed into this low-pressure area which would then
be carried to the mould cavity.
To eliminate this problem of air aspiration, the sprue is
tapered to gradually reduce the cross section as it moves
away from the top of the cope as shown in Figure below (b).
Contd
The exact tapering can be obtained by the equation of
continuity. Denoting the top and choke sections of The sprue by
the subscriptst and 'c' respectively, we get
Vc
A t Vt A c Vc At Ac
Vt
Contd
Since the velocities are proportional to the square of
the potential heads, as can be derived from
Bernoulli's equation,
hc
At Ac
ht
Where H = actual
sprue height
and ht = h + H
GATE-2007
A 200 mm long down sprue has an area of cross
section of 650 mm2 where the pouring basin meets the
down sprue (i.e. at the beginning of the down sprue).
A constant head of molten metal is maintained by the
pouring basin. The Molten metal flow rate is 6.5 105
mm3/s. Considering the end of down sprue to be open
to atmosphere and an acceleration due to gravity of
104mm/s2, the area of the down sprue in mm2 at its end
(avoiding aspiration effect) should be
(a)650.0 (b)350.0 (c)290.7 (d)190.0
Contd
Gating ratio
Gating ratio is defined as: Sprue area: Runner area:
Ingate area.
For high quality steel castings, a gating ratio of 1: 2: 2 or
1: 2: 1.5 will produce castings nearly free from erosion,
will minimize oxidation, and will produce uniform
flow.
A gating ratio of 1: 4: 4 might favour the formation of
oxidation defects.
Risers and Riser Design
Risers are added reservoirs designed to feed liquid
metal to the solidifying casting as a means of
compensating for solidification shrinkage.
To perform this function, the risers must solidify after
the casting.
According to Chvorinov's rule, a good shape for a riser
would be one that has a long freezing time (i.e., a small
surface area per unit volume).
Live risers (also known as hot risers) receive the last
hot metal that enters the mold and generally do so at a
time when the metal in the mold cavity has already
begun to cool and solidify.
Chvorinovs rule
Total solidification time (ts) = B (V/A) n
where n = 1.5 to 2.0
[Where, B = mould constant and is a function of (mould
material, casting material, and condition of casting]
n = 2 and triser = 1.25 tcasting
2 2
V V
or A 1.25
riser A casting
(b) 20 seconds
(d) 40 seconds
GATE-2013 Same Question (PI)
A cube shaped casting solidifies in 5 min. The
solidification time in min for a cube of the same
material, which is 8 times heavier than the original
casting, will be
(a) v2
(b) v
(c) 1/v
(d) 1/v2
(a) 1 : 2 (b) 2 : 1
Riser h
(c) 1 : 4 (d) 4 : 1
Mold cavity
Modulus Method
It has been empirically established that if the modulus
of the riser exceeds the modulus of the casting by a
factor of 1.2, the feeding during solidification would be
satisfactory.
MR = 1.2 Mc
Modulus = volume/Surface area
[10 - Marks]
GATE-2016
A cylindrical job with diameter of 200 mm and
height of 100 mm is to be cast using modulus
method of riser design. Assume that the bottom
surface of cylindrical riser does not contribute as
cooling surface. If the diameter of the riser is equal
to its height, then the height of the riser (in mm) is
AV Riser
a
According to Caine X= c
Yb
Vriser
Y= and a, b, c are constant.
Vcasting
Table: Constants in Caines Method
Conventional Question IES-2007
Calculate the size of a cylindrical riser (height and
diameter equal) necessary to feed a steel slab
casting of dimensions 25 x 25 x 5 cm with a side
riser, casting poured horizontally into the mould.
For circular plates, the length and width are same as that
of the diameter.
But for cylinders, the width and thickness are same as the
diameter for calculating the shape factor.
But for calculating the riser volume actual casting volume
is to be used.
The other shape of interest is hollow cylindrical shape. In
these the heat removal is restricted , a correction factor k,
needs to be applied to get the effective plate thickness. If T
is the true wall thickness
Core 0.5T T 2T 4T
diameter
Correction 1.17 1.14 1.02 1.00
factor
Shape Factor = (Length+ width)/(k.T)
Example
Calculate the height of cylindrical riser(height=diameter)
necessary to feed the steel slab casting 25 x 25 x 5 with a
side riser, casting poured horizontally into the mold.
Solution:
Shape Factor = (25+25)/5 = 10
From graph-1 at shape factor 10 (riser volume/casting volume)
is 0.47.
Riser Volume(Vr ) = (riser volume/casting volume) x casting
volume
Riser Volume = 0.47 x 25 x 25x 5 =1468.75 cm3
For cylindrical riser of height = diameter
Vr = (.D3 )/4
1468.75= (.D3 )/4
D = 12.32 cm
GATE-2015
The dimensions of a cylindrical side
riser(height = diameter) for a 25 cm x 15 cm x 5
cm steel casting are to be determined. For the
tabulated shape factor values given below, the
diameter of the riser (in cm)________
Shape Factor 2 4 6 8 10 12
tB
2A
Ag 2g
hm hm H
GATE-2012 (PI)
A mould having dimensions 100 mm 90 mm 20 mm is filled
with molten metal through a gate as shown in the figure. For
height h and cross-sectional area A, the mould filling time is t1.
The height is now quadrupled and the cross-sectional area is
halved. The corresponding filling time is t2. The ratio t2/t1 is
1
(a)
2
(b)1
(c ) 2
(d ) 2
Expression for choke area
m
CA mm2
ct 2gH
Contd
hm
H=h- for bottom gate
2
hc2
=h- for parting line gate
2hm
hC
hm
hm hm
Gas defects
Shrinkage cavities
Mold shift.
Gas Defects
A condition existing in a casting caused by the
trapping of gas in the molten metal or by mold gases
evolved during the pouring of the casting.
The defects in this category can be classified into
blowholes and pinhole porosity.
Blowholes are spherical or elongated cavities present
in the casting on the surface or inside the casting.
Pinhole porosity occurs due to the dissolution of
hydrogen gas, which gets entrapped during heating of
molten metal.
Shrinkage Cavities
These are caused by liquid shrinkage occurring during the
solidification of the casting.
To compensate for this, proper feeding of liquid metal is
required. For this reason risers are placed at the
appropriate places in the mold.
Sprues may be too thin, too long or not attached in the
proper location, causing shrinkage cavities.
It is recommended to use thick sprues to avoid shrinkage
cavities.
Molding Material Defects
Cuts and washes,
Scab
Metal penetration,
Fusion, and
Swell
Cut and washes
These appear as rough spots and areas of excess metal, and
are caused by erosion of molding sand by the flowing
metal.
This is caused by the molding sand not having enough
strength and the molten metal flowing at high velocity.
The former can be taken care of by the proper choice of
molding sand and the latter can be overcome by the
proper design of the gating system.
Scab
This defect occurs when a portion of the face of a mould
lifts or breaks down and the recess thus made is filled by
metal.
When the metal is poured into the cavity, gas may be
disengaged with such violence as to break up the sand,
which is then washed away and the resulting cavity filled
with metal.
The reasons can be: - too fine sand, low permeability of
sand, high moisture content of sand and uneven mould
ramming.
Metal penetration
When molten metal enters into the gaps between sand
grains, the result is a rough casting surface.
This occurs because the sand is coarse or no mold wash was
applied on the surface of the mold. The coarser the sand
grains more the metal penetration.
Fusion
This is caused by the fusion of the sand grains with
the molten metal, giving a brittle, glassy appearance
on the casting surface.
The main reason for this is that the clay or the sand
particles are of lower refractoriness or that the
pouring temperature is too high.
Swell
Under the influence of metallostatic forces, the mold
wall may move back causing a swell in the dimension
of the casting. A proper ramming of the mold will
correct this defect.
Inclusions
Particles of slag, refractory materials sand or
deoxidation products are trapped in the casting during
pouring solidification. The provision of choke in the
gating system and the pouring basin at the top of the
mold can prevent this defect
Pouring Metal Defects
The likely defects in this category are
Mis-runs and
Cold shuts
Ans. (d)