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Introduction To Casting
Processes by Stead Fast
Engineers Pvt Ltd – part 1
one of the leading Induction heating system
manufactures
History of Casting
Advantages
• Complex forms, low cost
• Certain shapes cannot be
machined
• One piece parts vs. multiple
piece parts
• Design changes are easily
incorporated
• High volume, low skilled labor
• Large, heavy parts can be made
easily
Disadvantages
• Problems with internal
porosity
• Dimensional variations due
to shrinkage
• Trapped impurities, solids
and gasses
• High-tolerance, smooth
surfaces not possible
• More costly than stamping
or extruding in some cases
Expendable Molds
• Green Sand
• Dry Sand
• Shell
• Investment
• Plaster
Expendable Molds
• Pattern must be produced
• New mold for every cycle
Permanent Molds
• Die
• Centrifugal
• Pressure
• Injection
Permanent Molds
• Made of durable material
• Multiple use
• Built-in Alignment
Cupola Furnaces
Five Zones
• Stack
• Charging Zone
• Melting Zone
• Tuyers (Air Intake)
• Crucible or Hearth
Induction Furnaces
• Magnetic field
• Rapid melting rate
• Low pollution
Foundries
• Pattern and Mold Making
– Computer Aided
Design
– Manufacturing
– Rapid Prototyping
• The Casting Process
– Metal Melting
– Metal Compositions
– Impurities
– Pouring into molds
Foundries
Foundry Automation
• Pouring into Molds
• Cleaning
• Heat Treatment
• Inspection
• Automated Guided
Vehicles
– Automatic Storage
– Moving Cores and
patterns
– Etc.
Reasons For Automation
• Increased Manufacturing
Efficiency
• Reducing Costs
• Reliability in Harsh
Environments
• Release of Skilled Man
Power
• Maximize Space
• Improved Quality
Why Fluid Flow?
• When Heated Metal
Becomes Liquid
• Important in Cast Design
- Sprue
- Well
- Runner
- Gate
Fluidity of Metals
• Viscosity
• Surface Tension
• Inclusions
• Mold Design
• Degree of Super Heat
• Mold Material
- Thermal Conductivity
- Surface Roughness
• Heat Transfer
Tests for Fluidity
• There are several
different fluidity tests
• All use the same principle
• Useful in simulating how
metal will react
• See how far the metal will
travel before solidification
Heat Transfer
• Heat transfer is important
in many aspects of
casting
- Pouring
- Solidification
- Cooling rate
- Rate is a function
of Volume and
surface area

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Introduction to casting processes by stead fast engineers pvt ltd – part 1

  • 1. Introduction To Casting Processes by Stead Fast Engineers Pvt Ltd – part 1 one of the leading Induction heating system manufactures
  • 3. Advantages • Complex forms, low cost • Certain shapes cannot be machined • One piece parts vs. multiple piece parts • Design changes are easily incorporated • High volume, low skilled labor • Large, heavy parts can be made easily
  • 4. Disadvantages • Problems with internal porosity • Dimensional variations due to shrinkage • Trapped impurities, solids and gasses • High-tolerance, smooth surfaces not possible • More costly than stamping or extruding in some cases
  • 5. Expendable Molds • Green Sand • Dry Sand • Shell • Investment • Plaster
  • 6. Expendable Molds • Pattern must be produced • New mold for every cycle
  • 7. Permanent Molds • Die • Centrifugal • Pressure • Injection
  • 8. Permanent Molds • Made of durable material • Multiple use • Built-in Alignment
  • 9. Cupola Furnaces Five Zones • Stack • Charging Zone • Melting Zone • Tuyers (Air Intake) • Crucible or Hearth
  • 10. Induction Furnaces • Magnetic field • Rapid melting rate • Low pollution
  • 11. Foundries • Pattern and Mold Making – Computer Aided Design – Manufacturing – Rapid Prototyping • The Casting Process – Metal Melting – Metal Compositions – Impurities – Pouring into molds
  • 13. Foundry Automation • Pouring into Molds • Cleaning • Heat Treatment • Inspection • Automated Guided Vehicles – Automatic Storage – Moving Cores and patterns – Etc.
  • 14. Reasons For Automation • Increased Manufacturing Efficiency • Reducing Costs • Reliability in Harsh Environments • Release of Skilled Man Power • Maximize Space • Improved Quality
  • 15. Why Fluid Flow? • When Heated Metal Becomes Liquid • Important in Cast Design - Sprue - Well - Runner - Gate
  • 16. Fluidity of Metals • Viscosity • Surface Tension • Inclusions • Mold Design • Degree of Super Heat • Mold Material - Thermal Conductivity - Surface Roughness • Heat Transfer
  • 17. Tests for Fluidity • There are several different fluidity tests • All use the same principle • Useful in simulating how metal will react • See how far the metal will travel before solidification
  • 18. Heat Transfer • Heat transfer is important in many aspects of casting - Pouring - Solidification - Cooling rate - Rate is a function of Volume and surface area