Casting

Casting

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  Babu Banarasi Das NationalInstitute of Technology & Management Seminar Topic On Casting UNDER THE SUPERVISION –Gaurav Sachan Presented To:- Presented By:- Prof. R.N Yadav Ashish Singh Yadav DEPARTMENT OF MECHANICAL ENGINEERING
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  Content • Introduction • Terminology •Classification • Expendable Casting • Non Expendable Casting • Procedure • Pattern • Pattern types • Application • Advantages • Disadvantages • Future scope • References
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  What is Casting? •Casting is a process in which molten metal flows by gravity or other force into a mold and solidifies in the shape of the mold cavity. The part produced is called casting. • Casting Procedure Introduction Fig(1)
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  Terminology • Pattern: Anapproximate duplicate of the final casting used to form the mold cavity • Flask: The rigid wood or metal frame that holds the molding material • Core: An insert in the mold that produces internal features in the casting, such as holes • Riser: An extra void in the mold that fills with molten material to compensate for shrinkage during solidification • Gating system: The network of connected channels that deliver the molten material to the mold cavities. • Draft: The taper on the casting or pattern that allow it to be withdrawn from the mold
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  Classification Casting Process Expendable NonExpendable Permanent Pattern Expandable Pattern Sand Core Metal Core
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  Expendable Casting Expendable moldcasting is a generic classification that includes sand, plastic, shell, plaster, and investment (lost-wax technique) moldings. Sand casting Plaster mold casting  Shell molding Investment casting Fig(2)
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  Non Expendable Casting Nonexpendablemold casting differs from expendable processes in that the mold need not be reformed after each production cycle. Permanent mold casting Die casting Semi-solid metal casting Continuous casting Fig(3)
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  Procedure  Make thepattern out of Wood , Metal or Plastic.  Prepare the necessary sand mixtures for mould and core making.  Prepare the Mould and necessary Cores.  Melt the metal/alloy to be cast.  Pour the molten metal/alloy into mould and remove the casting from the mould after the metal solidifies.  Clean and finish the casting.  Test and inspect the casting.  Remove the defects, if any.  Relieve the casting stresses by Heat Treatment.  Again inspect the casting.  The casting is ready for shipping Fig(4)
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   A patternprepares a mold cavity for the purpose of making a casting.  A pattern may contain projections known as core prints if the casting requires a core and need to be made hollow.  Runner, gates, and risers used for feeding molten metal in the mold cavity may form a part of the pattern.  Patterns properly made and having finished and smooth surfaces reduce casting defects.  A properly constructed pattern minimizes the overall cost of the castings. Pattern
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  Pattern Types Solid orsingle piece pattern Split pattern Loose piece pattern Match plate pattern Sweep pattern Skeleton pattern Cope and drag pattern Shell pattern Fig(5)
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  Applications of Casting Transportation vehicles  Turbine vanes  Power generators  Railway crossings  Agricultural parts  Aircraft jet engine parts  Sanitary fittings  Communication, Construction and Atomic Energy applications, etc..
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  Advantages  It ispossible to cast any material be it ferrous or non-ferrous.  Tools required for casting moulds are very simple and inexpensive.  It is an ideal method for trail production or production of small lots.  Good directional properties.  Casting of any size and weight, even up to 200 tonnes can be made
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  Disadvantages • Dimensional accuracyand surface finish achieved is some what less. • Traditional casting methods are labour intensive. • Difficult to remove the defects in some materials due to moisture in sand
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  Future Scope •Exhaust captureefficiency is possible by use of various systems, such as draughts, hoods and partial covering of the furnace. •During observation it was also noted that ordinary coal was used by the firms so in that coal there is a less amount of oxygen and high carbon so high quality of coal may be used to have a complete consumption. •Policies must be promoted and proper feasible training programme could be developed to improve and promote the best available technology. •The existing study is done in the area of Gujarat state. The foundry units in India are located in 20 different geographical Hub so there is need to study every hub
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  Reference • https://en.wikipedia.org/wiki/Casting • ManufacturingScience by Amitabh Ghosh. • https://www.iitk.ac.in/me/research/specializati on-areas/manufacturing-science • Class Notes by Prof. R.N.Yadav. • www.spectronmanufacturing.com
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