Professional Documents
Culture Documents
1. Sand Casting
2. Other Expendable Mold Casting Processes
3. Permanent Mold Casting Processes
4. Foundry Practice
5. Casting Quality
6. Metals for Casting
7. Product Design Considerations
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Two Categories of Casting
Processes
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Overview of Sand Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
▪ Sand casting weighing over 680 kg (1500 lb) for an
air compressor frame (photo courtesy of Elkhart
Foundry).
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Class Activity 1!
https://padlet.com/mat_utie/casting1
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Making the Sand Mold
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Sand Casting Production
Sequence
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Class Activity 2!
https://padlet.com/mat_utie/casting2
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Types of Patterns
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Core
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Core in Mold
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Desirable Mold Properties
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Foundry Sand
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Binders Used with
Foundry Sand
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Types of Sand Mold
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Buoyancy in a
Sand Casting Operation
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Whole semester
Project/Assignment
▪ Shell Molding
▪ Vacuum Molding
▪ Expanded Polystyrene Process
▪ Investment Casting
▪ Plaster Mold and Ceramic Mold Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Shell Molding
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in Shell Molding
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in Shell Molding
▪ (3) Box is
repositioned so
loose uncured
particles drop
away
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in Shell Molding
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in Shell Molding
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in Shell Molding
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in Shell Molding
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Shell Molding: Advantages and
Disadvantages
▪ Advantages:
▪ Smoother cavity surface permits easier flow of
molten metal and better surface finish
▪ Good dimensional accuracy
▪ Mold collapsibility minimizes cracks in casting
▪ Can be mechanized for mass production
▪ Disadvantages:
▪ More expensive metal pattern
▪ Difficult to justify for small quantities
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Advantages
● The gating system must be part of the pattern because the entire
mold is formed from the pattern, which can be expensive.
● The resin for the sand is expensive, although not much is required
because only a shell is being formed.[3]
● High equipment cost.
● Poor material strength.
● High porosity possible.
● Secondary machining often required.
● High labor cost if done manually.
Class activity!
Go to : https://padlet.com/mat_utie/casting3
Vacuum Molding
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Vacuum Molding: Advantages
and Disadvantages
▪ Advantages:
▪ Easy recovery of the sand, since no binders
▪ Sand does not require mechanical
reconditioning done when binders are used
▪ Since no water is mixed with sand,
moisture‑related defects are avoided
▪ Disadvantages:
▪ Slow process
▪ Not readily adaptable to mechanization
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Class Activity
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in
Expanded Polystyrene Process
▪ (1) Polystyrene
foam pattern is
coated with
refractory
compound
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in
Expanded Polystyrene Process
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in
Expanded Polystyrene Process
▪ (3) Molten metal is
poured into the portion
of the pattern that
forms the pouring cup
and sprue
▪ As the metal enters the
mold, the polystyrene
foam is vaporized
ahead of the advancing
liquid, thus filling the
mold cavity
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Expanded Polystyrene Process:
Advantages and Disadvantages
▪ Applications:
▪ Mass production of castings for automobile
engines
▪ Automated and integrated manufacturing systems
are used to
1. Mold the polystyrene foam patterns and then
2. Feed them to the downstream casting operation
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Class Activity!
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in Investment Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in Investment Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in Investment Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
One‑piece compressor stator with 108
separate airfoils made by investment
casting (photo courtesy of Howmet Corp.)
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Investment Casting:
Advantages and Disadvantages
▪ Advantages:
▪ Parts of great complexity and intricacy can be cast
▪ Close dimensional control and good surface finish
▪ Wax can usually be recovered for reuse
▪ This is a net shape process
▪ Additional machining is not normally required
▪ Disadvantages:
▪ Many processing steps are required
▪ Relatively expensive process
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Class Activity!
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Plaster Mold Casting:
Advantages and Disadvantages
▪ Advantages:
▪ Good accuracy and surface finish
▪ Capability to make thin cross sections
▪ Disadvantages:
▪ Mold must be baked to remove moisture
▪ Moisture can cause problems in casting
▪ Mold strength is lost if over-baked
▪ Plaster molds cannot stand high temperatures
▪ Limited to lower melting point alloys
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Plaster mold casting
Ceramic Mold Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Ceramic Mold Casting
Class Activity!
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
The Basic Permanent Mold
Process
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in
Permanent Mold Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in
Permanent Mold Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Steps in
Permanent Mold Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Permanent Mold Casting:
Advantages and Limitations
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Die Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Die Casting Machines
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Hot-Chamber Die Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Hot-Chamber Die Casting
▪ Hot‑chamber die
casting cycle: (1)
with die closed
and plunger
withdrawn, molten
metal flows into
the chamber
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Hot-Chamber Die Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Hot-Chamber Die Casting
▪ (3) Plunger is
withdrawn, die is
opened, and
casting is ejected
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Cold‑Chamber Die Casting
Machine
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Cold‑Chamber Die Casting Cycle
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Cold‑Chamber Die Casting Cycle
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Cold‑Chamber Die Casting Cycle
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Molds for Die Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Die Casting:
Advantages and Limitations
▪ Advantages:
▪ Economical for large production quantities
▪ Good accuracy and surface finish
▪ Thin sections possible
▪ Rapid cooling means small grain size and good
strength in casting
▪ Disadvantages:
▪ Generally limited to metals with low metal points
▪ Part geometry must allow removal from die
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Squeeze Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Semi-Solid Metal Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Semi-Solid Metal Casting:
Advantages
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Centrifugal Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
True Centrifugal Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
True Centrifugal Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Semicentrifugal Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Semicentrifugal Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Centrifuge Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Centrifuge Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Furnaces for Casting Processes
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Cupolas
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
▪ Cupola for
melting cast
iron
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Direct Fuel‑Fired Furnaces
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Crucible Furnaces
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Three Types of
Crucible Furnaces
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Electric‑Arc Furnaces
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Induction Furnaces
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Induction Furnace
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Ladles
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Additional Steps After
Solidification
▪ Trimming
▪ Removing the core
▪ Surface cleaning
▪ Inspection
▪ Repair, if required
▪ Heat treatment
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Trimming
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Removing the Core
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Surface Cleaning and Inspection
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Heat Treatment
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Casting Quality
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
General Defects:
Misrun
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
General Defects:
Cold Shut
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
General Defects:
Cold Shot
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
General Defects:
Shrinkage Cavity
▪ Depression in surface
or internal void caused
by solidification
shrinkage that restricts
amount of molten
metal available in last
region to freeze
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Sand Casting Defects:
Sand Blow
▪ Balloon‑shaped gas
cavity caused by
release of mold gases
during pouring
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Sand Casting Defects:
Pin Holes
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Sand Casting Defects:
Penetration
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Sand Casting Defects:
Mold Shift
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Foundry Inspection Methods
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Metals for Casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Ferrous Casting Alloys:
Cast Iron
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Ferrous Casting Alloys:
Steel
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Nonferrous Casting Alloys:
Copper Alloys
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Nonferrous Casting Alloys:
Zinc Alloys
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Product Design Considerations
▪ Geometric simplicity
▪ Although casting can be used to produce complex
part geometries, simplifying the part design usually
improves castability
▪ Avoiding unnecessary complexities:
▪ Simplifies mold‑making
▪ Reduces the need for cores
▪ Improves the strength of the casting
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Product Design Considerations
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Product Design Considerations
▪ Draft Guidelines
▪ In expendable mold casting, draft facilitates
removal of pattern from mold
▪ Draft = 1° for sand casting
▪ In permanent mold casting, purpose is to aid in
removal of the part from the mold
▪ Draft = 2° to 3° for permanent mold processes
▪ Similar tapers should be allowed for solid cores
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Draft
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Product Design Considerations
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Product Design Considerations
▪ Machining Allowances
▪ Almost all sand castings must be machined to
achieve the required dimensions and part
features
▪ Additional material, called the machining
allowance, is left on the casting in those
surfaces where machining is necessary
▪ Typical machining allowances for sand castings
are around 1.5 and 3 mm (1/16 and 1/4 in)
©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e