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Introduction To Casting
Processes by Stead Fast
Engineers Pvt Ltd – part 2
one of the leading Induction
heating system manufactures
Design, Materials and Economics
Design Considerations in Casting
• Design of the part
• Casting process and
material
• Locate parting line
• Locate design gates
• Locate mold features
such as sprue, screens
and risers
Design Consideration of Cast Parts
• Corners, angles,
section thickness
– Avoid sharp corners
angles and fillets
– Stress raisers,
cracking, and tearing
– Sections should be
blended smoothly
Design Consideration of Cast Parts
Design Consideration of Cast Parts
• Flat Areas
– Large flat areas may
warp during cooling
– Poor surface finish from
uneven flow in pouring
– Resolve with ribs, and
serrations
• Circles and Rounds
– Lower cooling rate in
circles induces hot spots
– Shrinkage cavities and
porosity
Design Consideration of Cast Parts
• Shrinkage
– to avoid cracking during
the cooling process
there should be
shrinkage allowance
– Staggered ribs, change
the intersection
geometry
• Patternmaker’s Shrinkage
Allowance
– 10-20 mm/m
Design Consideration of Cast Parts
• Draft
– Used to enable easy
removal of pattern
without damage to mold
– Range from 5 to
15mm/m
– Angles of 0.5° to 2°
• Dimensional Tolerances
– As wide as possible
within limits of good
performance
– Letters and markings
Locating the Part Line
• Part line
– separates upper and
lower mold
– Flat plane, along
corners or edges
– This will avoid flash
at the parting lines
Locating and Designing Gates
• Gates
– Connections between
runners and the part
– Multiple gates preferred
– Feed into thick sections
of the castings
• Runners
– Distribution channel for
molten metal from the
sprue into the gates
Casting Alloys
• Nonferrous Alloys
– Aluminum, magnesium,
copper, zinc, tin, lead
– Good electrical
conductivity and
resistant to corrosion
– Most of these alloys
share characteristics of
good machinability and
can all be welded
Casting Alloys
• Ferrous alloys
– Cast irons
• Largest quantity of all
metals cast
• Good wear resistance,
hardness and
machinability
– Cast Steels
• Material used under
extreme heat conditions
• Railroad, mining and
construction
Casting Economics
• Cost
– Depends on materials,
equipment, and labor
– Preparations require raw
materials, time and effort
– Melting, pouring, heating,
cleaning, inspections
– Equipment cost lowers
with large # of castings
– Solutions to alleviate
unneeded cost are being
looked into
• Rapid prototyping
Molten Metal Pour
Solidification
Solidification Temperatures
Dimensional Change
Pinholes
Blowhole
Scab
Pinholes
Rough Surface
Thank you…

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Introduction to casting processes by stead fast engineers pvt ltd – part 2

  • 1. Introduction To Casting Processes by Stead Fast Engineers Pvt Ltd – part 2 one of the leading Induction heating system manufactures
  • 3. Design Considerations in Casting • Design of the part • Casting process and material • Locate parting line • Locate design gates • Locate mold features such as sprue, screens and risers
  • 4. Design Consideration of Cast Parts • Corners, angles, section thickness – Avoid sharp corners angles and fillets – Stress raisers, cracking, and tearing – Sections should be blended smoothly
  • 6. Design Consideration of Cast Parts • Flat Areas – Large flat areas may warp during cooling – Poor surface finish from uneven flow in pouring – Resolve with ribs, and serrations • Circles and Rounds – Lower cooling rate in circles induces hot spots – Shrinkage cavities and porosity
  • 7. Design Consideration of Cast Parts • Shrinkage – to avoid cracking during the cooling process there should be shrinkage allowance – Staggered ribs, change the intersection geometry • Patternmaker’s Shrinkage Allowance – 10-20 mm/m
  • 8. Design Consideration of Cast Parts • Draft – Used to enable easy removal of pattern without damage to mold – Range from 5 to 15mm/m – Angles of 0.5° to 2° • Dimensional Tolerances – As wide as possible within limits of good performance – Letters and markings
  • 9. Locating the Part Line • Part line – separates upper and lower mold – Flat plane, along corners or edges – This will avoid flash at the parting lines
  • 10. Locating and Designing Gates • Gates – Connections between runners and the part – Multiple gates preferred – Feed into thick sections of the castings • Runners – Distribution channel for molten metal from the sprue into the gates
  • 11. Casting Alloys • Nonferrous Alloys – Aluminum, magnesium, copper, zinc, tin, lead – Good electrical conductivity and resistant to corrosion – Most of these alloys share characteristics of good machinability and can all be welded
  • 12. Casting Alloys • Ferrous alloys – Cast irons • Largest quantity of all metals cast • Good wear resistance, hardness and machinability – Cast Steels • Material used under extreme heat conditions • Railroad, mining and construction
  • 13. Casting Economics • Cost – Depends on materials, equipment, and labor – Preparations require raw materials, time and effort – Melting, pouring, heating, cleaning, inspections – Equipment cost lowers with large # of castings – Solutions to alleviate unneeded cost are being looked into • Rapid prototyping
  • 20. Scab