METAL CASTING DESIGN
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The document discusses the design and simulation process for casting the rear cover of a gear pump. It includes drafting and parting line analysis of the casting drawing, design of the gating system and sand mold, import of the 3D geometry into casting simulation software, setup and running of flow and solidification simulations, and results including shrinkage predictions. It also mentions the design of drag and cope patterns and core box for the casting pattern.
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ORBITAL FORGING
Orbital forging, also known as rotary forging, is a forging process where one die rotates relative to the other, gradually deforming the workpiece into the final shape. The tilt angle between the dies determines the amount of forging force applied. While orbital forging requires less force than conventional forging, the process is limited to symmetrical parts due to complex die motions required for asymmetrical shapes. Common applications include gears, hubs, and thin disks. Advantages include lower forces, accuracy, and tooling costs compared to conventional forging.
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Semi Solid Metal Casting
Semi-solid metal casting (SSM) involves processing metals between their liquidus and solidus temperatures, when they are partially solidified. This allows for modifying the dendritic microstructure and improving mechanical properties compared to fully liquid casting. SSM techniques include thixocasting, which uses pre-cast semi-solid billets that are reheated and injected into dies, and rheocasting, where the liquid metal is sheared as it cools through the semi-solid range. SSM offers advantages over traditional casting like reduced porosity and finer microstructures, making it suitable for high-strength automotive and machine components.
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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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This document discusses the design of gating and risering systems for ductile iron castings. It begins with introductions to computer-aided design of gating and risering as well as the objectives of optimal design. The main body of the document then covers the following topics: risering system design principles and methods, including pressure control risering; gating system design principles and calculations for choke size and pouring time; and the algorithm used in the software for inputting data and calculating risering and gating dimensions based on casting properties. Design is checked to ensure adequate liquid feed is provided by the riser.
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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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It is Referred by many names such as “squeeze casting” , “pressure infiltration”, “liquid metal forging”, “extrusion casting”, “liquid pressing'', “pressure crystallization”.
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Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and increase the length. There are two main types:
1) Hot rolling is performed above the metal's recrystallization temperature for lower pressure and improved ductility. It produces coarse grains and no residual stresses.
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- The main moulding sands used are green sand, dry sand, loam sand, and core sand, which differ in their mixture proportions and required drying. Green sand moulding is most common and adaptable but provides lower strength.
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Bulk deformation processes are metal forming operations that cause significant shape change through plastic deformation of initially bulk metal parts like bars, billets, and slabs. The main bulk deformation processes are rolling, forging, extrusion, and drawing.
Rolling reduces the thickness of metal by passing it through opposing rolls. Forging shapes metal by compressing it between dies under impact or gradual pressure. Extrusion forces metal through a die opening to take on its cross-sectional shape. Drawing reduces the diameter of wires or bars by pulling them through a die. These processes are commonly done hot to facilitate greater plastic deformation.
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Welding is the most important joining technique in the industry, and its evaluation plays a prominent role in determining the final properties of the joints. Therefore, in the current work, the microstructure and mechanical properties of a weld metal joints deposited with Trefisoud cellulosic electrodes was investigated. Different microstructures of various sites were observed and identified using optical and electron microscopy. Mechanical properties of the weldments were investigated through tensile, Charpy V as well as hardness testing. XRF spectrometry was used to determine the chemical compositions of the weld. SEM fractography was conducted to determine the fracture modes and mechanisms.
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The document discusses various casting processes and defects. It describes the functions of gating systems which include providing uniform feed of molten metal to the mould cavity. It also explains the components of gating systems such as pouring basins, sprues, runners and gates. Risering systems are discussed as are common casting defects like shifts, warpage, swell and blowholes along with their causes and remedies. Shell moulding, die casting, and centrifugal casting processes are also summarized.
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This document discusses various manufacturing technologies related to forging. It describes forging as a metalworking process involving plastic deformation between dies to achieve a desired shape. Forging can be classified based on the process (open die or closed die) or equipment (drop, power hammer/press, hand, or machine forging). The document outlines the key characteristics and applications of these different forging methods. It also describes various forging tools and common forging operations like upsetting, drawing down, setting down, bending, punching, welding, and cutting.
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METAL CASTING DESIGN
- 1. METAL CASTING DESIGN Rear Cover GP63 (Part for Gear Pump) Rear Cover GP63 (Casting Part for Gear Pump) Drafting and Parting Line Analysis for Casting Drawing of Casting
- 2. Gating System for Casting Sand Casting: Parts of a Sand Mold METAL CASTING SIMULATION (NovaFlow & Solid) Geometry 3D-Import (from CAD to CAE-system) Initial Settings (Parameters of Control Volume CV-Mesh, Box Dimensions, Boundary Conditions)
- 3. Initial Settings (Alloy and Materials Settings) Initial Settings (Set Gating Points) Flow & Solid Simulation Process
- 4. Results of Simulation (3D-Shrinkage) Results of Simulation (2D-Shrinkage in X-Ray View)
- 5. CASTING PATTERN DESIGN Drag & Cope Patterns on Plate Core Box