Casting process / Die casting process
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This presentation summarizes the die casting process. It discusses that die casting involves forcing molten metal under high pressure into a mold cavity created by hardened steel dies. It describes the main steps of the die casting process as well as the two primary types - gravity die casting and pressure die casting (cold chamber and hot chamber processes). The presentation outlines the key advantages of die casting as high production rates, dimensional accuracy, and ability to cast intricate parts. It also notes some disadvantages such as limitations on hollow shapes, size of parts, and alloy selection.
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METAL FORMING PROCESS
Introduction Hot Working and Cold Working of Metals Forging Processes- Open, impression die forging, Closed die forging-forging operation Rolling of metals-types of rolling- Flat strip rolling-shape rolling operation -Defects in rolled parts- Principle of rod and wire drawing-tube drawing -Principle of extrusion Types-hot and cold extrusion.
Metal casting ppt3
The document discusses various aspects of solidification processes for pure metals and alloys. It covers topics such as solidification curves, grain structure formation, mushy zone formation in alloys, segregation of elements, shrinkage during solidification, and directional solidification techniques. It also discusses the functions and design of gating systems, including elements like pouring basins, sprues, runners, gates, and risers.
Casting
The document discusses the process of sand casting. It begins by defining foundry and casting as the process of producing metal parts by pouring molten metal into a prepared mold. It then provides terminology used in casting such as flask, pattern, parting line, pouring basin, sprue, runner, riser, gate, core, and chaplets. The steps of sand casting are outlined as making the pattern, preparing sand mixtures, making the mold and cores, melting metal, pouring, cleaning, inspecting, and heat treating. Common casting materials and applications are also listed.
Rod, wire and tube drawing
Rod, wire and tube drawing is a metalworking process where a rod, wire or tube is pulled through a die to reduce its cross-sectional area and increase its length. It involves applying both tensile and compressive forces. Products include wire, rods, and tubes used in applications like electrical wiring, springs and hydraulic tubing. The process offers close dimensional control, lower costs than rolling or extrusion, and can produce very small cross-sections. Lubrication and annealing are important to control work hardening during multiple drawing passes. Dies are commonly made of alloy steels, carbides or diamond to withstand wear from the process.
Continuous casting
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
Thixocasting or semi solid metal casting
Thixocasting is a near-net shape forming process that uses partially molten alloys. It involves three steps: 1) Producing a pre-cast billet with a globular microstructure through electromagnetic stirring, 2) Reheating the billet to the semi-solid temperature, and 3) Casting the component by pressing the billet into a die cavity. Thixocasting provides benefits like energy efficiency, dimensional accuracy, and fine microstructures. However, it requires strict control of parameters like temperature and stirring. Common applications include automotive components like engine mounts and housings.
Pressure die casting
Pressure die casting is a manufacturing process where molten metal is injected under high pressure into a steel mold cavity. This allows for the rapid solidification of net-shaped metal components with tight tolerances. There are two main types - high pressure die casting for parts requiring close tolerances, and low pressure die casting for larger, less critical parts. Pressure die casting allows for high-volume production of complex parts and good dimensional accuracy.
4.patterns
Patterns are models used to form cavities in molds for metal casting. There are different types of patterns based on their construction:
- Solid or one-piece patterns are made from a single piece for simple castings.
- Split patterns are made in two pieces for more complex shapes, with dowel pins to align the pieces.
- Loose-piece patterns have removable pieces to allow pattern withdrawal, connected by dowel pins.
- Match-plate patterns mount multiple split patterns on a plate, which is positioned between cope and drag molds.
Patterns are made larger than the intended casting to allow for material shrinkage and machining during production. Allowances are also made for draft,
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Introduction Hot Working and Cold Working of Metals Forging Processes- Open, impression die forging, Closed die forging-forging operation Rolling of metals-types of rolling- Flat strip rolling-shape rolling operation -Defects in rolled parts- Principle of rod and wire drawing-tube drawing -Principle of extrusion Types-hot and cold extrusion.
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Casting
The document discusses the process of sand casting. It begins by defining foundry and casting as the process of producing metal parts by pouring molten metal into a prepared mold. It then provides terminology used in casting such as flask, pattern, parting line, pouring basin, sprue, runner, riser, gate, core, and chaplets. The steps of sand casting are outlined as making the pattern, preparing sand mixtures, making the mold and cores, melting metal, pouring, cleaning, inspecting, and heat treating. Common casting materials and applications are also listed.
Rod, wire and tube drawing
Rod, wire and tube drawing is a metalworking process where a rod, wire or tube is pulled through a die to reduce its cross-sectional area and increase its length. It involves applying both tensile and compressive forces. Products include wire, rods, and tubes used in applications like electrical wiring, springs and hydraulic tubing. The process offers close dimensional control, lower costs than rolling or extrusion, and can produce very small cross-sections. Lubrication and annealing are important to control work hardening during multiple drawing passes. Dies are commonly made of alloy steels, carbides or diamond to withstand wear from the process.
Continuous casting
Continuous casting is a process used to cast metal into a continuous length. Molten metal is poured into a mold and solidifies into a casting as it travels downward. New molten metal is continuously supplied to the mold to keep the process going and produce a casting of indefinite length. The process requires precise control of parameters like molten metal flow to ensure smooth, continuous casting.
Thixocasting or semi solid metal casting
Thixocasting is a near-net shape forming process that uses partially molten alloys. It involves three steps: 1) Producing a pre-cast billet with a globular microstructure through electromagnetic stirring, 2) Reheating the billet to the semi-solid temperature, and 3) Casting the component by pressing the billet into a die cavity. Thixocasting provides benefits like energy efficiency, dimensional accuracy, and fine microstructures. However, it requires strict control of parameters like temperature and stirring. Common applications include automotive components like engine mounts and housings.
Pressure die casting
Pressure die casting is a manufacturing process where molten metal is injected under high pressure into a steel mold cavity. This allows for the rapid solidification of net-shaped metal components with tight tolerances. There are two main types - high pressure die casting for parts requiring close tolerances, and low pressure die casting for larger, less critical parts. Pressure die casting allows for high-volume production of complex parts and good dimensional accuracy.
4.patterns
Patterns are models used to form cavities in molds for metal casting. There are different types of patterns based on their construction:
- Solid or one-piece patterns are made from a single piece for simple castings.
- Split patterns are made in two pieces for more complex shapes, with dowel pins to align the pieces.
- Loose-piece patterns have removable pieces to allow pattern withdrawal, connected by dowel pins.
- Match-plate patterns mount multiple split patterns on a plate, which is positioned between cope and drag molds.
Patterns are made larger than the intended casting to allow for material shrinkage and machining during production. Allowances are also made for draft,
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Bulk metal forming processes change the shape of metal parts through plastic deformation. Hot working above the metal's recrystallization temperature allows for significant shape changes with less force. Cold working below this temperature increases strength but requires more force. Common bulk metal forming processes include forging, rolling, and extrusion, which can produce parts near their final net shape with little waste.
Die casting 1
There are two main types of die casting: hot-chamber and cold-chamber. In hot-chamber die casting, molten metal is kept inside the die casting machine, while in cold-chamber die casting the molten metal is poured into the machine from outside. Both processes use pressure to force molten metal into a die cavity to create parts. Cold-chamber die casting is more economical for large production quantities, provides good accuracy and surface finish, and requires less floor space than hot-chamber die casting.
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pattern allownaces
This document discusses various pattern allowances that must be accounted for when designing casting patterns. It describes shrinkage allowance, which accounts for the contraction of metals as they cool from liquid to solid. It also mentions machining allowance to allow for removal of surface imperfections during machining. Draft allowance tapers the pattern for easy removal from the mold. Distortion allowance accounts for uneven shrinking that can warp irregularly shaped castings. Finally, shake allowance enlarges the pattern to compensate for the mold cavity expanding slightly when the pattern is rapped to help removal.
9.special casting processes
- Shell moulding is an efficient and economical casting method that uses a resin-sand mixture to form a thin "shell" around a heated pattern. This shell is then used as the mold cavity.
- Investment casting, also called lost-wax casting, is an ancient casting process used to produce complex shapes. It involves creating a wax pattern, coating it with refractory materials to form a ceramic "shell" mold, heating to remove the wax, and pouring molten metal into the shell. This allows for net-shape casting of intricate parts.
- Pressure die casting is a high-pressure casting process where molten metal is injected into steel dies to form castings. It is well-su
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Die casting
Die casting is a process where molten metal is injected into a steel die under high pressure to form complex shapes. Common metals used include aluminum, magnesium, and copper alloys. The die is made of steel and consists of two halves, with one half fixed and the other movable. During die casting, molten metal is injected into the die cavity using pressures up to 9,800 psi and solidifies into the final part. Die casting allows for high production rates and close dimensional tolerances of the parts produced.
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PPT on fully study about DIE CASTING by M.M.RAFIK.
In this presentation following parameters like Introduction,
History of casting,
Types of Die casting,
Types of Dies are used in Die casting.
Possible Defects in Die casting.
Minimum recommended wall thickness.
Design Rules in Die casting.
Advantages & Disadvantages of die casting.
covered by M.M.RAFIK.
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Die casting is a metal casting process where molten metal is forced under high pressure into a mold cavity created by hardened steel dies. Most die castings are made from non-ferrous metals like zinc, aluminum, magnesium, and copper. There are two main types of die casting machines: hot-chamber machines that keep molten metal in the machine, and cold-chamber machines that melt metal separately before injection. Common die casting defects include misruns, cold shuts, gas porosity, and shrinkage caused by issues like cold dies, low metal temperature, or lack of venting during solidification.
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This document discusses various metal forming processes including forging, rolling, drawing, extrusion, and sheet metal forming operations. It provides details on the mechanics and applications of these processes. Key forming processes covered are forging, which uses compressive forces to shape metal; drawing, which reduces the diameter of wires or tubes by pulling them through a die; and extrusion, which forces metal to flow through a die to produce a desired cross-sectional shape. The document also addresses design considerations, lubrication techniques, and common defects in metal forming.
Design Consideration For Casting
The document discusses design considerations for castings. It notes that casting involves pouring molten material into a mold to create complex shapes. Successful casting requires controlling variables like the material, casting method, cooling rate, and gases. The document outlines design considerations like designing parts for easy casting, selecting suitable materials and processes, locating parting lines and gates, and including features like sprues and risers. It also discusses designing parts to avoid defects from things like shrinkage, stress concentrations, and uneven cooling. The document concludes by mentioning some common casting defects and factors in the economics of casting like costs of molds, materials, and production rates.
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This PPT will let you know about metal casting and more specifically about the type of casting that is, Die casting, types of die casting, Cleaning of castings and inspection of casting
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Die casting is a process where molten metal is injected into a metal mold under high pressure. Common metals used include aluminum, magnesium, and copper alloys. The mold is made of die steel and has two halves, one fixed and one movable. In the process, molten metal is injected into the mold cavity at high pressure, then allowed to solidify before the mold opens and the casting is ejected. Die casting can be done by gravity or pressure and is used to manufacture parts that require high production volumes due to the high costs of the metal molds.
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Casting is a manufacturing process where liquid material is poured into a mold and allowed to solidify. The solidified part is known as a casting. Investment casting, also known as lost-wax casting, involves creating a wax pattern, coating it with refractory material to create a ceramic mold, melting away the wax to leave a cavity, and pouring molten metal into the mold cavity. This allows for very intricate parts to be cast with close tolerances and smooth finishes. Investment casting is commonly used for parts that are difficult to machine from difficult to machine alloys like aluminum, copper, and steels.
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Metal forming process
Bulk metal forming processes change the shape of metal parts through plastic deformation. Hot working above the metal's recrystallization temperature allows for significant shape changes with less force. Cold working below this temperature increases strength but requires more force. Common bulk metal forming processes include forging, rolling, and extrusion, which can produce parts near their final net shape with little waste.
Die casting 1
There are two main types of die casting: hot-chamber and cold-chamber. In hot-chamber die casting, molten metal is kept inside the die casting machine, while in cold-chamber die casting the molten metal is poured into the machine from outside. Both processes use pressure to force molten metal into a die cavity to create parts. Cold-chamber die casting is more economical for large production quantities, provides good accuracy and surface finish, and requires less floor space than hot-chamber die casting.
Casting Process.ppt
The document provides an overview of the metal casting process. It discusses the history and basic features of casting, including the types of molds used. The main casting processes are classified as either expandable mold casting (such as sand casting) or permanent mold casting (such as die casting and centrifugal casting). Sand casting uses expendable sand molds, while die casting uses reusable steel dies and forces molten metal into the mold under high pressure. Selection of the appropriate casting process depends on factors like alloy, size, shape, tolerance, and economics of machining versus production costs.
pattern allownaces
This document discusses various pattern allowances that must be accounted for when designing casting patterns. It describes shrinkage allowance, which accounts for the contraction of metals as they cool from liquid to solid. It also mentions machining allowance to allow for removal of surface imperfections during machining. Draft allowance tapers the pattern for easy removal from the mold. Distortion allowance accounts for uneven shrinking that can warp irregularly shaped castings. Finally, shake allowance enlarges the pattern to compensate for the mold cavity expanding slightly when the pattern is rapped to help removal.
9.special casting processes
- Shell moulding is an efficient and economical casting method that uses a resin-sand mixture to form a thin "shell" around a heated pattern. This shell is then used as the mold cavity.
- Investment casting, also called lost-wax casting, is an ancient casting process used to produce complex shapes. It involves creating a wax pattern, coating it with refractory materials to form a ceramic "shell" mold, heating to remove the wax, and pouring molten metal into the shell. This allows for net-shape casting of intricate parts.
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Die casting is a process where molten metal is injected into a steel die under high pressure to form complex shapes. Common metals used include aluminum, magnesium, and copper alloys. The die is made of steel and consists of two halves, with one half fixed and the other movable. During die casting, molten metal is injected into the die cavity using pressures up to 9,800 psi and solidifies into the final part. Die casting allows for high production rates and close dimensional tolerances of the parts produced.
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This document provides information on various sheet metal forming processes. It discusses the characteristics of sheet metal and tests used to determine formability. The main sheet metal forming processes covered are tube bending and forming as well as bending of sheet and plate. Tube bending can be done via press bending, rotary drawing, heat induction, roll bending, and sand packing. Sheet and plate bending includes techniques like roll bending, air bending, bottoming, coining, folding, wiping, and rotary bending. Common applications of sheet metal forming in industries like automotive, aircraft, appliances, and furniture are also mentioned.
PPT on fully study about DIE CASTING by M.M.RAFIK.
In this presentation following parameters like Introduction,
History of casting,
Types of Die casting,
Types of Dies are used in Die casting.
Possible Defects in Die casting.
Minimum recommended wall thickness.
Design Rules in Die casting.
Advantages & Disadvantages of die casting.
covered by M.M.RAFIK.
Casting and types
This document discusses various casting processes including investment casting, plaster mold casting, ceramic mold casting, permanent mold casting, and die casting. It describes the key steps in each process and notes advantages and limitations. Defects that can occur in castings such as misruns, cold shuts, and shrinkage cavities are also outlined.
U4 p1 metal forming processes
This document provides an overview of various metal forming processes taught in a Manufacturing Technology II course. It discusses processes like rolling, forging, extrusion, drawing, bending, and high-energy rate forming. For each process, it describes the basic mechanics, advantages, disadvantages, applications, and defects. It also defines key terms like hot working, cold working, and gives examples of specific processes like wire drawing, tube drawing, and thread rolling. Overall, the document serves as teaching material covering essential information on different metal forming techniques.
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Die casting is a metal casting process where molten metal is forced under high pressure into a mold cavity created by hardened steel dies. Most die castings are made from non-ferrous metals like zinc, aluminum, magnesium, and copper. There are two main types of die casting machines: hot-chamber machines that keep molten metal in the machine, and cold-chamber machines that melt metal separately before injection. Common die casting defects include misruns, cold shuts, gas porosity, and shrinkage caused by issues like cold dies, low metal temperature, or lack of venting during solidification.
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This document discusses various metal forming processes including forging, rolling, drawing, extrusion, and sheet metal forming operations. It provides details on the mechanics and applications of these processes. Key forming processes covered are forging, which uses compressive forces to shape metal; drawing, which reduces the diameter of wires or tubes by pulling them through a die; and extrusion, which forces metal to flow through a die to produce a desired cross-sectional shape. The document also addresses design considerations, lubrication techniques, and common defects in metal forming.
Design Consideration For Casting
The document discusses design considerations for castings. It notes that casting involves pouring molten material into a mold to create complex shapes. Successful casting requires controlling variables like the material, casting method, cooling rate, and gases. The document outlines design considerations like designing parts for easy casting, selecting suitable materials and processes, locating parting lines and gates, and including features like sprues and risers. It also discusses designing parts to avoid defects from things like shrinkage, stress concentrations, and uneven cooling. The document concludes by mentioning some common casting defects and factors in the economics of casting like costs of molds, materials, and production rates.
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PPT on fully study about DIE CASTING by M.M.RAFIK.
PPT on fully study about DIE CASTING by M.M.RAFIK.
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This document discusses various special casting processes including centrifugal casting, die casting, and investment casting. It provides details on the centrifugal casting process, including true centrifugal casting used to make hollow pipes and tubes, semi-centrifugal casting for more complex shapes, and centrifuging for precision castings. It also describes die casting processes like gravity die casting and pressure die casting methods. Investment casting involves making a wax pattern, coating it, and then melting out the wax to form the hollow mold. Common casting defects such as blowholes, shrinkage, cracks, and inclusions are also summarized along with their causes and remedies.
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3. Die casting uses high pressure to force molten metal into molds, allowing precise replication of complex shapes. It is well-suited for producing parts from non-ferrous alloys in high volumes.
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The document discusses various permanent mold casting processes including basic permanent mold casting, squeeze casting, die casting, centrifugal casting, slush casting, pressure casting, and semi-solid metal forming (thixocasting). Permanent mold casting involves reusing the same mold for multiple castings. The mold material depends on the alloy being cast. Die casting injects molten metal into a mold under high pressure using either a hot or cold chamber machine. Centrifugal casting involves pouring molten metal into a rotating mold to produce hollow tubular parts.
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Casting process / Die casting process
- 1. PRESENTATION ON DIE CASTING PROCESS BY NAME :- LAXMAN KR. JHA S. NO :- 417325 G.SEC :- G2E
- 2. CONTENTS 1. WHAT IS DIE CASTING 2. DIE CASTING PROCESS 3. TYPES OF DIE CASTING 4. ADVANTAGES 5. DISADVANTAGES
- 3. WHAT IS DIE CASTING • Die casting is assentialy parmament mold Casting in Which pressure force the molten into the mould cavity.
- 4. DIE CASTING PROCESS • Die casting is a metal casting process that is characterized by forcing Molten metal under the high pressure into a mold cavity. • The mold cavity is created using two handened tool steel dies which have been machined into shape and work similarly to an injectian mold during the process.
- 5. DIE CASTING PROCESS FLOW CHART
- 6. TYPES OF DIE CASTING 1. Gravity die casting 2. Pressure die casting
- 7. GRAVITY DIE CASTING • Gravity die casting is also know as parmanent mold casting. • Both ferrous or non- ferrous metals Can be casted.
- 8. PRESSURE DIE CASTING 1. COLD CHAMBER PROCESS • The metal is forced into the die casting at pressures usally ranging form 20- 70 mpa, althought it may be as high as 150 mpa. • The machince may be horizental as verticle. • High melting paint alloys as alluminium, megnesium and copper are normally cast by this mathod.
- 10. PRESSURE DIE CASTING 2. HOT CHEMBER PROCESS • In which the matal is held under perssure until it solidifies in the die. • The present ranges upto 35 mpa, with as everage as about 15 mpa. • Low melting paint alloys such zinc, tin and lead are commonly cast by this process.
- 12. ADVANTAGES 1. High producatin rate. 2. High accuracy in part dimensions. 3. Smooth surface finish for minimum mechanical finishing. 4. Ability to make many intricate part such as hole opening slat trademark number etc. 5. Ability to cast inserts such as pins studs shafts, fasteners etc.
- 13. DISADVANTAGES 1. Hollow shapes are not readily casted because of high metal pressure. 2. Limited sizes of the products can be produced based on the availability of the equipment. 3. High melting temp alloys are practically not die casted. 4. Flash is present except for very small zinc die casted. 5. Undercut can not be found in simple two piece dies.
- 14. THANK YOU