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Lesson Outcomes
By the end of this lessons, students should be able to
explain:
1. The generic metal casting process
2. The sand casting process and example products
3. The investment casting process and example
products
4. The die casting process and example products
Why Casting?
Casting process are most often selected over other
manufacturing method because:
1. Casting can produce complex shape
2. Can incorporate internal cavities
3. Can produce large parts in one piece
4. Can utilize material difficult or uneconomic to
process by other means
Types of molds
Casting processes can be classified by the type of mold
used:
Expendable molds
After the casting has solidified, mold is broken to remove the
casting
Typically made of sand, plaster, ceramics
Permanent molds
Used repeatedly (not broken after solidification)
Made of metals
Composite molds
Consists of permanent and expendable portions
Made of two or more different materials (eg: sand, graphite,
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metal)
Sand Casting
Most common type of casting
The mold is made of sand
There are two types of sand used:
Naturally bonding
Synthetic
Flask
2.
Pouring basin
3.
Sprue
4.
Runner System
5.
Channels that allow metal to flow from the sprue to mold cavity
Risers
6.
Cores
7.
Vents
Investment casting
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Permanent-Mold Casting
Permanent-Mold Casting
Permanent-Mold Casting
Permanent-Mold Casting
Various types:
Die Casting
Vacuum Casting
Centrifugal Casting
Squeeze Casting
Composite Mold Casting
Die Casting
The two halves of a mold are made from materials that
resist erosion and thermal fatigue such as cast iron, steel
and graphite.
The die casting process:
A piston traps a volume of molten metal
Piston then forces molten metal into the die cavity through a
nozzle at pressures ranging from 0.7 to 700 MPa.
Metal is held under pressure (up to 35 MPa) until it solidifies.
The part is then ejected by an ejector mechanism
The die is normally cooled using circulating water or oil
Example products:
Engine blocks, hand tools, motor housings, engine blocks,
business-machine and appliance components, hand tools, and toys.
Example products:
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Examples
(a)
(b)
Hot-chamber die-casting
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Heated chamber
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Die Casting
Process capabilities
Die casting has the capability for rapid production of
strong, high-quality parts with complex shapes, especially
with aluminum, brass, magnesium, and zinc.
It also produces good dimensional accuracy and surface
details, so that parts require little or no subsequent
machining or finishing operations (net-shape forming).
Die Casting
Vacuum Casting
Centrifugal Casting
Squeeze casting
Summary
Metal casting involves pouring molten metal into a
mold, allowing the metal to solidify and removing
the part from the mold
Casting processes can be classified as permanent
mold and expendable mold processes
Each process is suitable for manufacturing a
particular class of products.
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