Design for manufacturing Casting

1. DESIGN CONSIDERATION FOR CASTING
By
Pradeep N B
Assistant Professor
Department of Mechanical
Engineering
JNNCE, Shivamogga
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2. INTRODUCTION
• Successful casting practice requires the proper
control of a large number of variables:
characteristics of the metals (or alloys) casts,
method of casting, and various process parameters.
• The flow of the molten metal in the mold cavities,
the gating systems, the rate of cooling, and the
gases evolved all influence the quality of a
casting.
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3. CASTING
• Casting is a manufacturing process in which a liquid material is
usually poured into a mold, which contains a hollow cavity of
the desired shape, and then allowed to solidify.
• The solidified part is also known as a casting, which is ejected
or broken out of the mold to complete the process.
• Casting materials are usually metals or various cold setting
materials that cure after mixing two or more components
together.
• Example - epoxy, concrete, plaster and clay.
• Casting is most often used for making complex shapes that
would be otherwise difficult or uneconomical to make by other
methods.
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Flow chart of conventional sand casting process

6. Design Considerations in Casting
1. Design the part so that the shape is cast easily.
2. Select a casting process and material suitable for the
part, size, mechanical properties, etc.
3. Locate the parting line of the mold in the part.
4. Locate and design the gates to allow uniform feeding of
the mold cavity with molten metal.
5. Select an appropriate runner geometry for the system.
6. Locate mold features such as sprue, screens and risers, as
appropriate.
7. Make sure proper controls and good practices are in place.
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7. Pattern
Construction of pattern must take account of
a) The mould parting line
b) Machined surfaces
c) Shrinkage of the material
d) Draft or “draw” (to facilitate extraction from the mould)
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Pulley The pattern/casting/component relationship

8. THE PARTING LINE, CAST HOLES AND CORED HOLES
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9. IDENTIFIYING THE POSSIBLE AND PROBABLE
PARTING LINES
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10. CONTD..
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11. CASTINGS REQUIRING SPECIAL SAND CORES
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12. DESIGNING TO OBVIATE SAND CORES
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13. Contd..
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14. Contd...
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15. Design Considerations in
Casting - Design of cast parts
 Corners, angles and section thickness: avoid using
sharp corners and angles (act as stress raisers) and
may cause cracking and tearing during solidification.
Use fillets with radii ranging from 3 to 25 mm
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16. Design Considerations in Casting -
Design of cast parts
Figure Suggested design modifications to avoid defects in castings. Note
that sharp corners are avoided to reduce stress concentrations.
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17. Design Considerations in Casting -
Design of cast parts
• Sections changes in castings should be blended smoothly into each
other. Location of the largest circle that can be inscribed in a
particular region is critical so far as shrinkage cavities are
concerned (a & b). Because the cooling rate in regions with large
circles is lower, they are called hot spots. These regions can
develop shrinkage cavities and porosity (c & d).
• Cavities at hot spots can be eliminated by using small cores (e). It is
important to maintain (as much as possible) uniform cross sections
and wall thicknesses throughout the casting to avoid or minimize
shrinkage cavities. Metal chills in the mold can eliminate or
minimize hot spots.
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18. Design Considerations in Casting -
Design of cast parts
Figure: Examples of designs showing the importance of maintaining uniform
cross-sections in castings to avoid hot spots and shrinkage cavities.
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19. Design Considerations in Casting -
Design of cast parts
Figure - Examples of design
modifications to avoid shrinkage
cavities in castings.
Figure - The use of metal padding (chills)
to increase the rate of cooling in thick
regions in a casting to avoid shrinkage
cavities
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20. Design Considerations in Casting -
Design of cast parts
1.Flat areas: large flat areas (plain surfaces) should be avoided,
since they may warp during cooling because of temperature
gradients, or they develop poor surface finish because of
uneven flow of metal during pouring. To resolve this one can
break up flat surfaces with staggered ribs.
2.Shrinkage: pattern dimensions also should allow for
shrinkage of the metal during solidification and cooling.
3. Allowances: for shrinkage, known as patternmaker’s
shrinkage allowances, usually range from about 10 to 20
mm/m.
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21. Design Considerations in Casting -
Design of cast parts
4.Draft: a small draft (taper) typically is provided in sand mold pattern
to enable removal of the pattern without damaging the mold. Drafts
generally range from 5 to 15 mm/m. Depending on the quality of the
pattern, draft angles usually range from 0.5o to 2o.
5.Dimensional tolerances: tolerances should be as wide as possible,
within the limits of good part performance; otherwise, the cost of the
casting increases. In commercial practices, tolerances are usually in
the range of ± 0.8 mm for small castings. For large castings,
tolerances may be as much as ± 6 mm.
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22. Design Considerations in Casting -
Design of cast parts
6.Lettering and markings: it is common practice to
include some form of part identification (such lettering or
corporate logos) in castings. These features can be sunk
into the casting or protrude from the surface.
7.Machining and finishing operations: should be taken
into account. For example, a hole to be drilled should be
on a flat surface not a curved one. Better yet, should
incorporate a small dimple as a starting point. Features to
be used for clamping when machining.
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23. CASTING DEFECTS
Some defects are common to any and all process. These defects
are illustrated in figure 13.22 and briefly described in the
following:
a)Misruns: A Misruns is a casting that has solidified before
completely filling the mold cavity. Typical causes include
1) Fluidity of the molten metal is insufficient,
2) Pouring Temperature is too low,
3) Pouring is done too slowly and
4) Cross section of the mold cavity is too thin.
b) Cold Shut: A cold shut occurs when two portion of the metal
flow together , but there is lack of fusion between them due to
premature freezing, Its causes are similar to those of a Misruns.
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24. c) Cold Shots: When splattering occurs during pouring, solid
globules of the metal are formed that become entrapped in the
casting. Pouring procedures and gating system designs that avoid
splattering can prevent these defects.
d) Shrinkage Cavity: This defects is a depression in the surface
or an internal void in the casting caused by solidification
shrinkage that restricts the amount of the molten metal available
in the last region to freeze. It often occurs near the top of the
casting in which case it is referred to as a pipe. The problem can
often be solved by proper riser design.
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25. e) Microporosity: This refers to a network of a small voids
distributed throughout the casting caused by localized
solidification shrinkage of the final molten metal in the dendritic
structure. The defect is usually associated with alloys, because of
the protracted manner in which freezing occurs in these metals.
f) Hot Tearing: This defect, also called hot cracking, occurs
when the casting is restrained or early stages of cooling after
solidification. The defect is manifested as a separation of the
metal (hence the terms tearing or cracking) at a point of high
tensile stress caused by metal’s inability to shrink naturally. In
sand casting and other expandable mold processes,
compounding the mold to be collapsible prevents it. In
permanent mold processes, removing the part from the mold
immediately after freezing reduces hot tearing.
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26. Economics of Casting
• There are also major costs involved in making patterns for casting.
• The cost of the cast part (unit cost) depends on several factors:
including materials, tooling, equipment, and labor.
• Costs also are involved in melting and pouring the molten metal into
molds and in heat treating, cleaning, and inspecting the casting.
• Heat treatment in an important part of the production of many alloys
groups (especially ferrous castings) and may be necessary to produce
improved mechanical properties.
• The equipment cost per casting will decrease as the number of parts
cast increase. Sustained high-production rates, therefore, can justify the
high cost of dies and machinery.
• However, if the demand is relatively small, the cost-per-casting
increases rapidly.
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