Lecture 1_Introduction.pdf
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Casting involves melting metal and pouring it into a mold to solidify into the desired shape. It allows for complex shapes that would be difficult to form through other manufacturing methods. The key steps in sand casting are preparing the mold, which involves assembling the flasks, pattern, and cores to form the cavity and channels for pouring in the molten metal. Some advantages are the ability to produce large and complex parts at low cost, though there are also limitations like lower strength, tolerance and surface finish compared to other processes. Common applications include engine blocks and manifolds.
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THIS STUDY MATERIAL IS RELATED WITH ONE OF THE TYPE OF MANUFACTURING PROCESSES CALLED CASTING.THIS IS VERY GOOD MATERIAL . CASTING IS BASIC MANUFACTURING PROCESS.EVERY MECHANICAL ENGINEERING STUDENT MUST KNOW CASTING PROCESS,ITS TYPES ,PATTERN ,PATTERN TYPES,PATTERN MAKING ALLOWANCES,DIE CASTING INVESTMENT CASTING.ALL THESE POINTS ARE COVERED IN THIS PPT.
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This document provides an overview of sand casting, including:
1) Sand casting is a process where molten metal is poured into a sand mold cavity and solidifies. It can be used to manufacture metal or non-metal parts like iron and aluminum.
2) Sand casting has a long history dating back thousands of years and was widely used in ancient China. Modern developments improved molding speed and efficiency.
3) Sand casting has advantages like low costs and ability to produce complex shapes, though it also has disadvantages like poor surface finish and accuracy. Future improvements could enhance casting efficiency and quality control.
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Metal casting involves pouring liquid metal into a mold to produce parts of a desired shape. The key steps are melting metal to create a liquid, pouring it into a mold to achieve a solid shape as it cools and extracts heat, and then removing the solidified part from the mold. The quality of castings depends on factors like the flow of molten metal into the mold, the solidification and cooling process, and the type of mold material used. Common casting methods include sand casting, die casting, and investment casting.
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This document provides information on various casting processes and techniques. It discusses properties of moulding sand and different furnace types for ferrous materials. It also describes pattern types, chilled casting, core ingredients, and functions of risers and cores. Common casting defects from poor pattern design are outlined. The document lists casting defects, factors for selecting pattern materials, and products made via centrifugal casting. It provides steps in the casting process and advantages of casting. Common pattern and moulding materials are identified along with essential moulding sand constituents and why cores are reinforced. Squeeze casting, die casting applications, and moulding tools are also covered.
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1) Sand casting is a process where molten metal is poured into a sand mold cavity and solidifies. It can be used to manufacture metal or non-metal parts like iron and aluminum.
2) Sand casting has a long history dating back thousands of years and was widely used in ancient China. Modern developments improved molding speed and efficiency.
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our proposed approach improves accuracy, precision, recall, and F1 score, achieving a high detection
accuracy rate of 99.50%.
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TIME DIVISION MULTIPLEXING TECHNIQUE FOR COMMUNICATION SYSTEM
Time Division Multiplexing (TDM) is a method of transmitting multiple signals over a single communication channel by dividing the signal into many segments, each having a very short duration of time. These time slots are then allocated to different data streams, allowing multiple signals to share the same transmission medium efficiently. TDM is widely used in telecommunications and data communication systems.
### How TDM Works
1. **Time Slots Allocation**: The core principle of TDM is to assign distinct time slots to each signal. During each time slot, the respective signal is transmitted, and then the process repeats cyclically. For example, if there are four signals to be transmitted, the TDM cycle will divide time into four slots, each assigned to one signal.
2. **Synchronization**: Synchronization is crucial in TDM systems to ensure that the signals are correctly aligned with their respective time slots. Both the transmitter and receiver must be synchronized to avoid any overlap or loss of data. This synchronization is typically maintained by a clock signal that ensures time slots are accurately aligned.
3. **Frame Structure**: TDM data is organized into frames, where each frame consists of a set of time slots. Each frame is repeated at regular intervals, ensuring continuous transmission of data streams. The frame structure helps in managing the data streams and maintaining the synchronization between the transmitter and receiver.
4. **Multiplexer and Demultiplexer**: At the transmitting end, a multiplexer combines multiple input signals into a single composite signal by assigning each signal to a specific time slot. At the receiving end, a demultiplexer separates the composite signal back into individual signals based on their respective time slots.
### Types of TDM
1. **Synchronous TDM**: In synchronous TDM, time slots are pre-assigned to each signal, regardless of whether the signal has data to transmit or not. This can lead to inefficiencies if some time slots remain empty due to the absence of data.
2. **Asynchronous TDM (or Statistical TDM)**: Asynchronous TDM addresses the inefficiencies of synchronous TDM by allocating time slots dynamically based on the presence of data. Time slots are assigned only when there is data to transmit, which optimizes the use of the communication channel.
### Applications of TDM
- **Telecommunications**: TDM is extensively used in telecommunication systems, such as in T1 and E1 lines, where multiple telephone calls are transmitted over a single line by assigning each call to a specific time slot.
- **Digital Audio and Video Broadcasting**: TDM is used in broadcasting systems to transmit multiple audio or video streams over a single channel, ensuring efficient use of bandwidth.
- **Computer Networks**: TDM is used in network protocols and systems to manage the transmission of data from multiple sources over a single network medium.
### Advantages of TDM
- **Efficient Use of Bandwidth**: TDM all
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- 2. INTRODUCTION How do we define casting? Casting can be defined as melting the metal and pouring the molten metal in the mould cavity to get the desired shape after solidification. Why casting is important? In order to get the desired & complicated shape which otherwise is not possible by any other means. Also it is the cheapest way of producing the components.
- 3. SEQUENCE OF STEPS INVOLVED IN SAND CASTING
- 4. Advantages • Can produce very large parts (weighing up to 200 tons) • Can form complex shapes • Many material options • Low tooling and equipment cost • Scrap can be recycled • Short lead time possible ADVANTAGES, LIMITATIONS, APPLICATIONS Limitations • Poor material strength • High porosity possible • Poor surface finish and tolerance • Secondary machining often required • Low production rate • High labor cost Applications Engine blocks and manifolds, machine bases, gears, pulleys
- 5. Turbine Manifold Cast-Iron Machine Housing
- 6. SAND CASTING
- 8. SAND CASTING
- 9. MOLD PREPARATION 1. Flask: A metal or wood frame, without fixed top or bottom, in which the mold is formed. Depending upon the position of the flask in the molding structure, it is referred to by various names such as Drag – lower molding flask, Cope – upper molding flask, Cheek – intermediate molding flask used in three piece molding. 2. Pattern: It is the replica of the final object to be made. The mold cavity is made with the help of pattern.
- 10. 3. Parting line: This is the dividing line between the two molding flasks that makes up the mold. 4. Molding sand: Sand, which binds strongly without losing its permeability to air or gases. It is a mixture of silica sand, clay, and moisture in appropriate proportions. 5. Facing sand: The small amount of carbonaceous material sprinkled on the inner surface of the mold cavity to give a better surface finish to the castings. 6. Core: A separate part of the mold, made of sand and generally baked, which is used to create openings and various shaped cavities in the castings. 7. Pouring basin: A small funnel shaped cavity at the top of the mold into which the molten metal is poured. 8. Sprue: The passage through which the molten metal, from the pouring basin, reaches the mold cavity. In many cases it controls the flow of metal into the mold.
- 11. 9. Runner: The channel through which the molten metal is carried from the sprue to the gate. 10. Gate: A channel through which the molten metal enters the mold cavity. 11. Chaplets: Chaplets are used to support the cores inside the mold cavity to take care of its own weight and overcome the metallostatic force. 12. Riser: A column of molten metal placed in the mold to feed the castings as it shrinks and solidifies. Also known as “feed head”. 13. Vent: Small opening in the mold to facilitate escape of air and gases.