Casting ppt pdf

Permanent Mold Casting Permanent mold casting is a metal casting process that shares similarities to both sand casting and die casting.


As in sand casting, molten metal is poured into a mold which is clamped shut until the material cools and solidifies into the desired part shape. However, sand casting uses an expendable mold which is destroyed after each cycle. Permanent mold casting, like die casting, uses a metal mold die that is typically made from steel or cast iron and can be reused for several thousand cycles. Because the molten metal is poured into the die and not forcibly injected, permanent mold casting is often referred to as gravity die casting.

Permanent mold casting is typically used for high- volume production, production of small, simple metal parts with uniform wall thickness. Non-ferrous metals are typically used in this process, such as aluminum alloys, magnesium alloys, and copper alloys.

However, irons and steels can also be cast using graphite molds. Common permanent mold parts include gears and gear housings, pipe fittings, and other automotive and aircraft components such as pistons, impellers, and wheels Permanent Mold Casting Slush Casting Slush casting is a variant of permanent molding casting to create a hollow casting or hollow cast.

It is a technique wherein you rely on the adhesive properties of a casting substance to create a hollow shell replica from a negative mold.

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A small amount of the casting substance is poured into the mold. The mold is then rotated or "slushed" around so the casting medium clings to the walls of the mold.

Depending on the viscosity of the medium, care must be taken not to create air bubbles. The substance then cures or dries and the process may either be repeated for added thickness, or the prosthetic may be pulled as appropriate for the desired effect. Uses The process is usually used to cast ornamental products, such as candlesticks, lamp bases, and statuary from low-melting- point materials. A similar technique is used to make hollow chocolate figures.

Slush casting is also used to skin a mold. It also allows the skin to have a different makeup than the underlying "flesh" of a prosthetic, which thereby mimics real life.

When producing a cast part using the slush casting method, a permanent mold is employed and set up. The mold is clamped together and prepared for pouring. After pouring the mold will set, as solidification begins to take place. Slush Casting Steps The main principle of this casting process relies on the fact that when a metal Casting hardens in a mold, it will solidify from the mold wall towards the inside of the casting. In other word a metal skin forms first, This skin thickens as more of the metal casting's material converts to a solid state.

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In slush mold casting, during the solidification of the material, when the solid-liquid boundary has reached a certain point, the mold is turned over and the remaining liquid metal from the casting is poured out. This will leave only the solidified skin with the exterior geometry of the metal cast part and a hollow interior. The longer the metal casting was allowed to solidify before pouring out the excess metal, the greater the casting's wall thickness will be.

The cast part is then removed from the die and allowed to cool. Properties And Considerations Of Manufacturing By Slush Casting Slush casting is a type of permanent mold casting, therefore many of the basic principles of a permanent mold process will apply. Slush casting is mainly suited to lower melting point materials, zinc, tin, or aluminum alloys are commonly slush cast in manufacturing industry.

With this process you need to have a mechanical means of turning over the mold in order to pour out the molten metal from the cast part.

When manufacturing by slush casting it is difficult to accurately control the metal casting's strength and other mechanical properties. The casting's internal geometry cannot be effectively controlled with this process. Advantages Reusable mold, good surface finish, and good dimensional accuracy are the main advantages. Ease of inducing directional solidification by changing the mold wall thickness or by heating or cooling portions of the mold.

The hollow metal castings manufactured by this process are lighter than solid parts, and save on material esults in a finer grain structure than sand casting Disadvantages High tooling cost, limited to low-melting- point metals, and short mold life.


The high tooling costs make this process uneconomical for small production runs. When the process is used to cast steel or iron the mold life is extremely short.Add Files Email when done? Convert To. Convert Now And agree to our Terms Email when done? Drop your files to convert them We'll get right on it. Files to Convert.

casting ppt pdf

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Skip to main content. Log In Sign Up. Dental casting defects. Pallavi Madanshetty. In almost all instances, defects in castings can be avoided by strict observance of procedures governed by certain fundamental rules and principles.

NOTE: The surface roughness of the casting is invariably greater than that of the wax pattern from which it is made. The difference is related to particle size of the investment and its ability to reproduce the wax pattern in 8 microscopic detail. As a result, walls of the mold are roughened. REMEDY : When thermal expansion technique is employed, the mold should be heated to casting temperature — never higher and the casting should be made immediately.

Generalized casting roughness may indicate a breakdown of During the casting, the bubble is filled with the casting material alloy and is manifested as a nodule small These nodules if present on the margins or on internal surface might alter the fit of the casting, if removal of these irregularities is attempted.

But if they are present in some non-critical area they can be removed easily. A binocular microscope is extremely helpful in detecting and removing them. This type of irregularity appears as minute ridges or veins on the surface. Molten alloy flows into the cracks forming thin fins on the casting. Significance : Finning increases the time required for to finish the casting and if the defects occur in critical areas e.

Positioning of several patterns too close and in the same plane in the mold lead to formation of fins. Reason : The expansion of the wax is much greater than that of the investment, causing breakdown or cracking of the investment if the spacing between patterns is less than 3mm.

Patterns placed too near the edge of the investment causes fins. Reason If too little investment covers the wax patterns, the alloy is more likely to break through the mold. Outside layer tends to expand more than the inner parts.By using this website you accept the use of cookies and the privacy policy. By continuing, you accept cookies and the privacy policy. One PDF tool. Endless features.

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casting ppt pdf

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Automatic orientation Standard Portrait Landscape. Images per page:. Image size:. Left Middle Right mm cm inch.What is Manufacturing? Materials in Manufacturing 3.

Manufacturing Processes 4. Production Systems. Technology - the application of science to society and its members live better They are all manufactured. What do these products have in common? M P Groover.

CASTING - PowerPoint PPT Presentation

Agriculture, minerals, etc. Manufacturing adds value to the material by changing its shape or properties, or by combining it with other materials Manufacturing as an economic process.

casting ppt pdf

Manufacturing Industries Industry consists of enterprises and organizations that produce or supply goods and services. Industries can be classified as: 1. Primary industries - those that cultivate and exploit natural resources, e.

Secondary industries - take the outputs of primary industries and convert them into consumer and capital goods manufacturing is the principal activity. Manufacturing Industries - continued manufacturing, construction, and electric power generation.

Manufacturing includes several industries whose products are not covered in this book; e. Nuts and bolts, forgings, cars, airplanes, digital computers, plastic parts, and ceramic products. Two basic types: 1. Processing operations - transform a work material from one state of completion to a more advanced state. Processing Operations Alters a materials shape, physical properties, or appearance in order to add value Three categories of processing operations:.

Property-enhancing operations - improve physical properties without changing shape. Surface processing operations - to clean, treat, coat, or deposit material on exterior surface of the work. Starting material is heated sufficiently to transform it into a liquid or highly plastic state.

Figure Shell Molding Casting process in which the mold is a thin shell of sand held together by thermosetting resin binder. Starting workpart is shaped by application of forces that exceed the yield strength of the material. Figure Left Inclinable gap-frame press with sliding bolster to accommodate two die sets for rapid change of tooling.

Figure Right A ton kN straight-sided press. Usually involves pressing and sintering, in which powders are first compressed and then heated to bond the individual particles. Excess material removed from the starting piece so what remains is the desired geometry.

Examples: machining such as turning, drilling, and milling; also grinding and nontraditional processes. Arc Welding A pool of molten metal is formed near electrode tip, and as electrode is moved along joint, molten weld pool solidifies in its wake. Resistance Spot Welding Resistance welding, showing the components in spot welding, the main process in the RW group. Sequence: 1 before, and 2 after. Joining Process: Adhesive Bonding Figure Learn more about Scribd Membership Home.

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casting ppt pdf

Importance of Casting Process: Importance of Casting Process This process is widely used to manufacture complex parts. All major parts like milling machine bed, the bed of lathe machine, IC engine components, etc. It produces the best quality sand casting products at the lowest possible cost compared to machining Process. High Production rate. Short lead time: Short lead time compared to others and hence, ideal for short production runs.

Low-cost tooling: Tooling and equipment costs are low compared to some other metal manufacturing processes. Wider material choice: all types of engineering alloys can be cast.

So, the designers must take care of providing the allowance to the product Pattern before pouring the molten metal. Low strength: Due to high porosity compared to a machined part. Slide7: Post processing: It requires Secondary machining operations in order to improve the surface finish. Lower Melting Point: Generally limited to metals of the lower melting point. Not suitable for low-volume production. Mould or Mold: Mould or Mold It is described as a void or cavity created in a compact sand mass with the help of pattern which moldwhen filled with molten metal produce a casting.

The mold is made by using the molding sand consists of basic elements such as Slide9: Silica Sand Particles: They are used for producing the required strength of the molding sand. Clay: It is used for producing the bond between the sand particles. Thus, the mold making material can be metallic or non-metallic sand. For Metallic Mouldsthe common materials are Cast iron, mild steel, and alloy steels.

Slide Note : Out of all materials, the molding sand is the most commonly utilized non-metallic molding material because of its certain inherent properties namely refractoriness, high permeability, and workability along with good strength.After you enable Flash, refresh this page and the presentation should play. Get the plugin now.

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Toggle navigation. Help Preferences Sign up Log in. To view this presentation, you'll need to allow Flash. Click to allow Flash After you enable Flash, refresh this page and the presentation should play. View by Category Toggle navigation. Products Sold on our sister site CrystalGraphics. Title: Casting Processes. Description: two half shells are made and are clamped together in preparation for pouring Tags: casting clamping processes. Latest Highest Rated.

Two piece molds consist of a cope on top and a drag on the bottom. The seam between them is the parting line. A pouring basin or cup, into which the molten metal is poured.

A sprue, through which the molten metal flows downward. A gate, which is located at the base of the sprue. Molds typically contain a system of gates constructed to minimized turbulence in the molten metal and control flow so that metal is supplies at a rate to adequately supply the critical section thickness of the casting.

Gating systems often include passageways called runners. Risers, which supply additional metal to the casting as it shrinks during solidification. Cores, which are inserts made from sand. They are placed in the mold to form hollow regions. Vents, which are placed in molds to carry off gases produced when the molten metal comes into contact with the sand in the molds.

The flask is filled with loose fine fine sand. The molten metal is poured into the mold. A mixture of the fine sand and urethane is molded over metal dies and cured with amine vapor. Then the mold is held with a robot arm and partially immersed into molten metal held in an induction furnace. The metal may be melted in air or in a vacuum.

The vacuum reduces the air pressure inside the mold to about two thirds of atmospheric pressure, drawing the molten metal into the mold cavities through a gate in the bottom of the mold. The molten metal in the furnace is at a temperature usually 55C above the liquidus temperature consequently it begins to solidify within a fraction of a second. After the mold is filled, it is withdrawn from the molten metal.

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