BMM 3643 Page 2

Lesson Objectives:
Todays lesson objectives:
Fundamentals of casting process
Applications, advantages and limitations
of casting
Patterns in casting
Cores and core prints in casting
1. SOLIDIFICATION
BMM 2643
P
a
g
e
3
Schematic illustration of various casting processes
BMM 3643 Page 4
Sand Mould Features
Schematic illustration of a sand mould, showing various
features.
BMM 3643 Page 5
Sand Mould
Schematic illustration of a sand mold, showing various features.
BMM 3643 Page 6
Sand Casting
Cope & drag (top and bottom halves of a sand
mold), with cores in place on the drag
BMM 3643 Page 7
Sand Casting
Two sets of castings (bronze and aluminium)
from the above sand mold
BMM 3643 Page 8
A process means pouring molten
metal into refractory mould with a
cavity of the shape to be made, and
allowing it to solidify.
The mould cavity is often created via a
pattern around which the mould is
formed.
The pattern is removed before the
molten metal is introduced to the
mould.
Casting (also called Foundry)
BMM 3643 Page 9
Once poured, the mould material extracts
heat from the liquid and the metal
solidifies in the shape of the mould cavity.
The solidified metal shape is then
removed from the mold and the now
superfluous metal (gates, runners, risers,
etc.) are removed.
The resultant solidified metal discrete
component is also called the Casting.
FOUNDRY (CONT.)
BMM 3643 Page 10
ADVANTAGES
Intricate shapes internal or
external can be made
Any material can be cast
Inexpensive and simple tools
used
Ideal method for trial production
or production of a small lot
Weight reduction in design can
be achieved
ADVANTAGES AND DISADVANTAGES
BMM 3643 Page 11
ADVANTAGES
Casting are generally cooled
uniformly from all sides and
therefore they are expected to
have no directional properties
Any sizes of product can be cast
ADVANTAGES AND DISADVANTAGES
BMM 3643 Page 12
LIMITATIONS
Dimensional accuracy and
surface finished would not be
adequate for final application in
many cases
Labour intensive
Difficult to remove defects
arising out of the moisture
present in sand castings.

ADVANTAGES AND
DISADVANTAGES (CONT.)
BMM 3643 Page 13
FOUNDRY PROCESES
MOULDING
MOULD SAND
POURING
INTO MOULD
MELTING
OF METAL
PATTERN MAKING
CORE MAKING
GATING SYSTEM
CASTING
HEAT
TREATMENT
CLEANING
AND
FINISHING
INSPECTION
Solidification Shakeout
Removal of risers
and gates
Additional
heat
treatment

Defects
Pressure tightness
Dimensions
BMM 3643 Page 14
Basic Requirements of Foundry
Processes
1. A mould cavity
2. A melting process
3. A pouring technique
4. The solidification process
5. Mould removal
6. Finishing (cleaning, inspection etc.)

BMM 3643 Page 15
PATTERNS
WHAT ARE PATTERNS?
- Pattern is the exact replica of the part
you want to make.
- It is the tool to make the cavity having
same size and dimensions.
BMM 3643 Page 16
PATTERN ALLOWANCES
The modifications that are incorporated into a
pattern are called allowances.
The allowances are made mainly due to:
1) Shrinkage allowance (most
important)
Patterns are made larger than the
casting to compensate contraction of the
liquid while freezing.
2) Machining Allowance
Allowance required to remove the rough
cast surface. 2 to 25 mm (0.1 to 1)
BMM 3643 Page 17
Solidification Contraction for
Various Cast Metals
TABLE 10.1
Metal or alloy
Volumetric
solidification
contraction (%) Metal or alloy
Volumetric
solidification
contraction (%)
Aluminum 6.6 70%Cu30%Zn 4.5
Al4.5%Cu 6.3 90%Cu10%Al 4
Al12%Si 3.8 Gray iron Expansion to 2.5
Carbon steel 2.53 Magnesium 4.2
1% carbon steel 4 White iron 45.5
Copper 4.9 Zinc 6.5
Source: After R. A. Flinn.
BMM 3643 Page 18
PATTERN ALLOWANCES
(cont.)
3) Draft Allowance (slight taper)
To facilitate ease of removal, usually
to 2
BMM 3643 Page 19
Patterns for Sand
Casting
Taper on patterns for ease of
removal from the sand mold.
BMM 3643 Page 20
Wood Pine, Teak, Mahagony
Metal- Cast iron, Brass, Broze, Al alloys
Plastic and Rubber Quick setting
compound, polystyrene, silicone rubber
Plaster Gypsum plaster, plaster of
Paris
Other wax and Mercury
PATTERN MATERIALS
BMM 3643 Page 21
Lightweight for handling and working
Strong hard and durable
Easy to work, shape and join
Resistance to wear, abrasion, corrosion
and chemical attack
Easily available at low cost
Easy to repair
Ability to give good surface finish
CHARACTERISTICS OF
PATTERNS
BMM 3643 Page 22
Pattern Material Characteristics
TABLE 11.3
Rating
a
Characteristic Wood Aluminum Steel Plastic Cast iron
Machinability E G F G G
Wear resistance P G E F E
Strength F G E G G
Weightb E G P G P
Repairability E P G F G
Resistance to:
Corrosionc E E P E P
Swellingc P E E E E
aE, Excellent; G, good; F, fair; P, poor.
bAs a factor in operator fatigue.
cBy water.
Source : D.C. Ekey and W.R. Winter, Introduction to Foundry Technology. New York.
McGraw-Hill, 1958.
BMM 3643 Page 23
1. Single piece or solid pattern
2. Two piece or split pattern
3. Multiple piece or loose pattern
4. Match plate pattern
5. Gated pattern
6. Skeleton pattern
7. Cope and drag pattern
TYPES OF PATTERN
BMM 3643 Page 24
CORES
WHAT ARE CORES?
Cores are materials used for making the
cavities and hollow projections which cannot
normally be produced by pattern alone
Any complicated contour or cavity can be made
by means of cores so that really intricate
shapes can be easily obtained
Generally made of sand
Subjected to much more severe thermal and
mechanical condition and should be of higher
strength than moulding sand
BMM 3643 Page 25
Cores and Core Prints
Cores are made separately by pressing
sand in boxes (core boxes)
To support core in the mould an
impression is made in the mould with
the help of a projection suitably placed
on the pattern.
The projection is known as core prints.
BMM 3643 Page 26
BMM 3643 Page 27
Examples of Sand Cores and
Chaplets
Examples of sand cores showing core prints and chaplets to support cores.
BMM 3643 Page 28
CHARACTERISTIC OF A CORE
Green strength
Dry strength
Refractoriness
Permeability
Collapsibility
Friability
Smoothness
Low gas emission
BMM 3643 Page 29
TYPE OF CORES
CORE
GREEN SAND CORES
Obtained by pattern itself during
moulding
DRY SAND CORES
Made by means by special core sands
in a separate core box, baked and
placed in the mould before pouring
Thats all for now..
Any questions??
IQ + EQ + SQ = TQ

Thank You for coming and
see you again..