MANUFACTURING TECHNOLOGY-I ME8351

UNIT-I

METAL CASTING PROCESSES

 Manufacturing’ is derived from the Latin,
manus = hand and factus = made,
that is, the literal meaning is “made by hand”.

 ‘Manufacturing’ means the making of goods and

articles by hand and/or by machinery.

 ‘Manufacturing Technology’ or “Production

Technology” can be defined as the study of the
various processes required to produce parts and to
assemble them into machines and mechanisms.
 SAND CASTING
 MELTING FURNACES
 Sand moulds
– Blast
 Type of patterns
– Pattern materials – Cupola
– Pattern allowances  SPECIAL CASTING PROCESSES
 Moulding sand – Shell
– Types – investment casting
– Properties – Ceramic mould
– Testing – Lost Wax process
 Core making – Pressure die casting
– Types – Centrifugal casting
– Applications
– CO2 process
 Moulding machines
– Stir Casting
– Types
(Working principle)
– Application
 DEFECTS IN SAND CASTING
Cold curing CO2 Process
 To make good Quality castings
in large numbers.
 Binder – Pure dry silica sand +
Sodium silicate liquid
 Moisture content – Should not
exceed 3 %
 Additives – Sawdust about
1.5%, Asbestos powder – up to
5%, Graphite powder –
deformable & collapsible
 CO2 gas is passed through the core for 30 sec
at 140 KN/m2.

 CO2 + Sodium silicate = Sodium carbonate +

Silica jell

 Silica jell binds the sand.

(MOULDING) SAND TESTING METHODS
1. Moisture content test
2. Clay content test
3. Grain fitness test
4. Permeability test
5. Strength test
6. Deformation or Toughness test
7. Hot strength test
8. Refractoriness test
9. Mould hardness test
 (CORE) SAND TESTING METHODS
1. Green strength test
2. Baked strength test
3. Retained strength test
4. Core strength test
5. Moisture content test
 MOULDING
Moulding is the process of making a mould
cavity by packing prepared moulding sand
around the pattern and removing the pattern
from the mould to form the mould cavity.

Types:
1. Green sand mould
2. Dry sand mould
3. Loam sand mould
 MOULDING METHODS
1. Bench Moulding
2. Floor Moulding
3. Pit Moulding
4. Sweep Moulding
5. Plate Moulding
JOLTING MACHINE
SQUEEZING MACHINE
SAND SLINGER
 MELTING FURNACE
1. Cupola – CI 4. Pot
2. Open hearth – Steel 5. Electric
3. Crucible – Non-Ferrous a) Direct arc
a) Pit type b) Indirect arc
b) Coke fired stationary c) Induction
c) Oil fired tilting
CUPOLA FURNACE
CRUCIBLE - PIT FURNACE
CRUCIBLE - CFS FURNACE
CRUCIBLE - OFT FURNACE
ELECTRIC – DA FURNACE
ELECTRIC – IDA FURNACE
INDUCTION FURNACE
 SPECIAL CASTING PROCESSES
1. Shell Mould Casting

2. Investment Casting

3. Ceramic Mould Casting

4. Lost Wax Process

5. Pressure Die Casting

1) Hot chamber Die Casting

2) Cold chamber Die Casting

6. Gravity Die Casting

7. Centrifugal Casting

8. Continuous Casting process

SHELL MOULD CASTING
 5 to 10% - Phenolic resin mixed with fine dry silica
(Mixer – dry oil or presence of alcohol)
 No water
 230 – 600◦C
 Release Agent – Silicone (sprayed over pattern)
 Thickness of shell – time of contact of the mixture
with the heated pattern (Ex: 20-30 sec, 6 mm)
 Then the mould is heated in an Oven at 300◦C for 15-
60 sec.
 After cooling &Solidification, the shells are broken or
shaken away from the castings.
 Brake drums, Bushings, Cams, Cam shaft, rollers etc.,
INVESTMENT CASTING
 PRESSURE DIE CASTING
PDC - HOT CHAMBER
PDC - COLD CHAMBER
GRAVITY DIE CASTING
(Permanent mold casting)
CENTRIFUGAL CASTING
CONTINUOUS CASTING PROCESS
 OTHER CASTING METHODS

• LOST WAX PROCESS

• CERAMIC MOULD CASTING
 DEFECTS
1. Shrinkage 9. Shift
2. Blow holes 10. Cold Shut
3. Scab 11. Inclusions
4. Swell 12. Fins
5. Hard Spots 13. Dress
6. Run out 14. Rat tail
7. Honey combing 15. Blister
8. Cracks
 INSPECTION METHODS
1. Visual Inspection

2. Pressure Test
3. Magnetic Particle Inspection

4. Dye-Penetrant Inspection

5. Radiographic Inspection
6. Ultrasonic Inspection

7. Thermography Inspection