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Chapter 3 - Classification of Casting Processes
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- 15 steps of a casting processA cavity is formed in a mold
The metal is reduced to liquid by heating
The molten metal is poured into the mold and allowed to solidify
As solidification occurs, the metal regains its original physical properties during cooling
When solid, the casting is removed from the mold and is ready for secondary operations - 2Production of good quality castings requires (4)Design of a good gating system
A sufficiently sized and correctly located feeder
Control of heat flow out of the casting
Control of the rate of heat extraction during solidification - 3Advantages of metal casting (10)Inherently versatile and flexible
Rapid transition to finished product
Suiting shape and size to function
Permits the use of difficult design techniques
Placement of metal for maximum effectiveness
Complex parts as an integral unit
Optimal appearance
Significant cost savings
Economically viable
Range of material compositions - 4Limitations of metal casting (4)Low recovery of metal alloys
Comparatively poor surface quality
Poor dimensional tolerances
Inferior mechanical properties - 5Inferior mechanical properties of metal casting (4)Chemical heterogeneity, caused by segregation of alloying elements during solidification
Shrinkage and gas-induced porosity
Non-uniform microstructure, due to variations in thickness
Coarse constituent phase particles, caused by slow solidification rate associated with thick sections and non-metallic molds - 6Casting may be used when (6)The engineering material selected is too hard and strong to be mechanically worked or machined
Strength of the as-cast product is adequate
Design is based on factors other than strength
Complex shape makes other manufacturing methods uneconomic or even impossible
Use of casting saves development time
Casting gives substantial cost saving over other methods of manufacture - 7Bases for classification of metal casting processes (8)State of completion of the cast product
Shape of the cast products
Nature of operation
Type and nature of the mold material
Manner in which the molten metal is introduced into the mold cavity
The state of the metal
State of the mold cavity itself
Dimensional tolerance and surface finish of cast product - 8MoldThe form made of sand, metal, or refractory material that contains the cavity into which the molten metal is poured
- 9Mold cavityThe space in the mold that is filled with liquid metal
- 10Flask (molding box)Metal or wood frame used for making and holding a sand mold
- 11CopeTop half of the pattern, flask, mold, or core in a two-part casting
- 12DragBottom half of the pattern, flask, mold, or core in a two-part casting
- 13CoreA specially formed material inserted into a mold to shape the interior or other part of a casting that cannot be easily shaped by a pattern.
- 14Core printA projection added to the pattern, core, or mold to form recesses in the mold at points where cores are to be located and supported.
- 15Riser or feederA reservoir of molten metal connected to a casting to provide additional metal to the casting, required as a result of shrinkage during solidification
- 16GatePortion of the runner in a mold through which the molten metal enters the mold cavity
- 17Gating systemNetwork of channels used to deliver the molten metal from outside the mold into the mold cavity
- 18Pouring cupPortion of the gating system that initially receives the molten metal from the pouring vessel and controls its delivery to the rest of the mold.
- 19Sprue wellFound at the bottom of a sprue
- 20SprueMold channel that connects the pouring basin with the runner or directly into which the molten metal is poured
- 21RunnerHorizontal channel through which the molten metal flows from one receptacle to another.
- 22Parting line of parting surfaceInterface that separates the cope and drag halves of the mold, flask, or pattern, and the halves of a core during some core-making processes
- 23DraftTaper on a pattern or casting that permits it to be withdrawn from the mold
- 24CastingDescribes the process and the product when molten metal is solidified in a mold.
- 25FiltersScreen or filter materials that are used for molten metal filtration, the removal of oxide films and inclusions
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- (EGR 367) Engineering Fichas sobre Chapter 3 - Classification of Casting Processes, creado por Jon Jon Jon Campbell el 20/09/2017.
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- Jon Jon Jon Campbell
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