This document provides information about the Metal Casting Technology course offered at VIT University. It includes details about the course faculty, textbooks, evaluation methods, and modules. The first module introduces metal casting processes, foundry industry basics, casting principles, and moulding practices. It also defines important casting terminology and properties of moulding sand like permeability and refractory properties. Common moulding equipment, patterns, and gating systems are also summarized.
This document provides information on the manufacturing process of metal casting. It discusses the key steps in metal casting which include mould preparation, pouring molten metal, solidification, and inspection for defects. Moulds are prepared using sand and patterns to form cavities. Molten metal is poured into the mould and allowed to solidify to form the final casting. Proper mould design and avoiding defects are important for successful casting. Metal casting allows for intricate shapes but has limitations in dimensional accuracy and surface finish compared to other processes.
Metal casting processes involve making a mold cavity using a pattern, melting and pouring metal into the mold, and allowing the metal to solidify. Key steps include preparing molds, melting and pouring metal, solidification, and inspection. Casting allows intricate shapes and wide material selection. Advantages are dimensional accuracy and surface finish can be limitations but new processes address these. Patterns are models of the final casting and come in various types depending on shape, size, and molding method. Careful pattern preparation helps minimize defects in the final casting.
1. The document discusses various metal casting processes and sand casting in particular. It describes the basic steps in sand casting including mould making, pouring, cooling, and removal.
2. Sand is commonly used as the mould material due to its low cost. It requires binders like clay to give it strength and hold its shape. The properties of ideal moulding sand and types of sands for different applications are explained.
3. Key aspects of sand casting like advantages, disadvantages, and factors affecting the properties of moulding sand are summarized. Common tests to evaluate moulding sand quality are also mentioned.
Casting is a process where molten metal is poured into a mold and solidifies to form the desired shape. There are two main types of casting processes - those using expendable molds like sand, and those using permanent metal molds. The mold contains the cavity that defines the external shape of the part as well as any internal cores. Direction solidification is important to prevent shrinkage defects and is controlled using features like risers and chills. Properties of the final part are dependent on factors like alloy composition and solidification rate.
Metal Casting - Manufacturing Technology 1Ramesh Kumar A
The document discusses manufacturing technology and focuses on sand casting. It defines key terms like manufacturing, technology, and manufacturing technology. It then discusses the history and process of metal casting. The main focus is on sand casting, including its definition, the 6 step process, and types like green sand and dry sand. Pattern materials and allowances are explained. Finally, it touches on moulding sand constituents, properties, core making, and sand testing methods.
The document discusses the casting process. It begins by describing how a liquid material is poured into a mold cavity to take its shape, then solidifies. This allows for complex geometries and net-shape production. Casting can be done with any material that melts and is suited for mass production. Common casting defects and their causes are also outlined.
This document provides an overview of casting processes and patterns used in manufacturing. It discusses various types of foundries based on production levels. Patterns are models used to form mold cavities and can be made from various materials like wood, metal, and plastic. Allowances must be provided in patterns to account for shrinkage, draft, machining needs, and potential distortions during solidification. Different types of patterns are used depending on the part geometry, including single-piece, split, gated, sweep, and skeleton patterns.
casting introduction, steps involved in casting,gating system,gates,pattern, patterns allowances, advantages and disadvantages of casting process and applications of casting process
This document provides information on the manufacturing process of metal casting. It discusses the key steps in metal casting which include mould preparation, pouring molten metal, solidification, and inspection for defects. Moulds are prepared using sand and patterns to form cavities. Molten metal is poured into the mould and allowed to solidify to form the final casting. Proper mould design and avoiding defects are important for successful casting. Metal casting allows for intricate shapes but has limitations in dimensional accuracy and surface finish compared to other processes.
Metal casting processes involve making a mold cavity using a pattern, melting and pouring metal into the mold, and allowing the metal to solidify. Key steps include preparing molds, melting and pouring metal, solidification, and inspection. Casting allows intricate shapes and wide material selection. Advantages are dimensional accuracy and surface finish can be limitations but new processes address these. Patterns are models of the final casting and come in various types depending on shape, size, and molding method. Careful pattern preparation helps minimize defects in the final casting.
1. The document discusses various metal casting processes and sand casting in particular. It describes the basic steps in sand casting including mould making, pouring, cooling, and removal.
2. Sand is commonly used as the mould material due to its low cost. It requires binders like clay to give it strength and hold its shape. The properties of ideal moulding sand and types of sands for different applications are explained.
3. Key aspects of sand casting like advantages, disadvantages, and factors affecting the properties of moulding sand are summarized. Common tests to evaluate moulding sand quality are also mentioned.
Casting is a process where molten metal is poured into a mold and solidifies to form the desired shape. There are two main types of casting processes - those using expendable molds like sand, and those using permanent metal molds. The mold contains the cavity that defines the external shape of the part as well as any internal cores. Direction solidification is important to prevent shrinkage defects and is controlled using features like risers and chills. Properties of the final part are dependent on factors like alloy composition and solidification rate.
Metal Casting - Manufacturing Technology 1Ramesh Kumar A
The document discusses manufacturing technology and focuses on sand casting. It defines key terms like manufacturing, technology, and manufacturing technology. It then discusses the history and process of metal casting. The main focus is on sand casting, including its definition, the 6 step process, and types like green sand and dry sand. Pattern materials and allowances are explained. Finally, it touches on moulding sand constituents, properties, core making, and sand testing methods.
The document discusses the casting process. It begins by describing how a liquid material is poured into a mold cavity to take its shape, then solidifies. This allows for complex geometries and net-shape production. Casting can be done with any material that melts and is suited for mass production. Common casting defects and their causes are also outlined.
This document provides an overview of casting processes and patterns used in manufacturing. It discusses various types of foundries based on production levels. Patterns are models used to form mold cavities and can be made from various materials like wood, metal, and plastic. Allowances must be provided in patterns to account for shrinkage, draft, machining needs, and potential distortions during solidification. Different types of patterns are used depending on the part geometry, including single-piece, split, gated, sweep, and skeleton patterns.
casting introduction, steps involved in casting,gating system,gates,pattern, patterns allowances, advantages and disadvantages of casting process and applications of casting process
This document provides an overview of sand casting processes. It discusses the key steps which include pattern making, molding sand properties and testing, core making, melting furnaces, casting defects and inspection methods. The main molding processes covered are green sand molding and dry sand molding. Common casting defects like blowholes and surface cracks are addressed. Non-destructive testing methods for inspecting castings such as magnetic particle, dye penetrant, radiography and ultrasonic testing are also summarized.
This document provides information on the casting process, including definitions, components, steps, and considerations. Some key points:
1. The casting process involves pouring molten metal into a mold patterned after the part, allowing it to solidify, and removing the part from the mold. Important considerations are metal flow, solidification, and mold material.
2. Components include patterns, molds, cores, and gating systems. Steps are pattern making, molding, melting, pouring, solidification, cleaning, and inspection.
3. Patterns are modified replicas of the object and include allowances for shrinkage, draft, and machining. Common pattern materials are wood, metal, and plastic
The document discusses manufacturing processes and sand casting. It defines manufacturing as making goods by hand or machinery. Manufacturing processes are classified into casting, joining, forming, sheet metal work, plastics processing, machining, powder metallurgy, heat treatment, and assembly. Sand casting is described as producing metal parts by pouring molten metal into sand molds. Molds are made using patterns, cores, and molding machines in a foundry. Sand casting can make complex shapes and is used to produce parts in large quantities.
Metal casting involves pouring molten metal into a mold cavity to solidify into the desired shape, with common mold materials including sand. The main steps are making patterns and molds, melting metal, pouring into the mold, solidification, and finishing. Key casting methods include green sand molding, shell molding, and die casting which offer advantages like complexity of parts and better dimensional accuracy and surface finish compared to sand casting.
The document describes the casting process and its key terms. It discusses the main steps: pattern making, mould preparation including gating and risering, core making, melting and pouring, and cleaning and inspection. It provides details on each step and describes how a mould is made by packing sand around a pattern. Common components produced by casting are also listed, such as automobile and aircraft parts. Advantages include the ability to make complex shapes easily and economically, while limitations include potential defects and inferior properties compared to other processes.
This document summarizes various metal casting processes and techniques. It discusses sand casting and the key components of sand molds like the flask, pouring basin, sprue, runners, and risers. It also covers cores, moulding sands, patterns, moulding machines, melting furnaces, and common defects in sand casting. Testing methods for moulding sands like moisture content, clay content, and permeability are also summarized.
The document provides an overview of the sand casting process in 13 steps:
1. Mix sand and create molds using patterns.
2. Place pattern in bottom mold and compact sand.
3. Add top mold and fill with compacted sand.
4. Remove pattern to leave a cavity in the sand.
5. Pour molten metal into the mold.
6. Allow metal to cool and harden.
7. Break apart mold and remove the new cast part.
The document discusses various aspects of casting processes and patterns used in casting. It describes the casting process where molten metal is poured into a mold and solidifies. It then discusses different types of patterns used including single piece, split piece, loose piece, and sweep patterns. The key considerations for pattern materials are also summarized such as wood, metal, plastic and their advantages. Pattern allowances including shrinkage, draft, machining and distortion allowances are explained.
This document provides information on conducting a sand casting demonstration or lab. Sand casting is an inexpensive way to make metal parts and is commonly used in industries like automotive and aerospace. In sand casting, molten metal is poured into a mold cavity formed in sand. While inexpensive, sand casting often results in flaws that can affect material properties. The demonstration aims to introduce students to sand casting and show how processing can influence defect formation and properties. It outlines objectives, procedures, equipment needed and safety considerations for an instructor to replicate the sand casting process in the classroom.
The document discusses the key steps in the sand casting process:
1. Creating a mechanical drawing and pattern of the part to be cast
2. Preparing molds by setting cores and positioning patterns
3. Pouring molten metal and allowing it to solidify in the mold
4. Removing the casting and performing trimming and finishing operations
The document provides an overview of the sand casting process from pattern making to final inspection and packaging for shipment.
Manufacturing Technology 1 full unit notesGopinath Guru
The document provides information on various metal casting processes and their working principles. It discusses sand casting process which uses expandable sand molds and involves steps of making the mold, pouring molten metal, solidification and breaking the mold. Other casting processes mentioned are permanent mold casting, die casting and investment casting. It also describes mold properties, types of patterns and allowances in patterns. Testing of molds and cores is outlined.
The document discusses various casting processes including shell molding, expanded polystyrene casting, investment casting, plaster mold casting, ceramic mold casting, permanent mold casting, die casting, and centrifugal casting. It provides details on the key steps for each process as well as their advantages and limitations. Various furnace types for melting metals are also outlined, such as cupolas, direct fuel-fired furnaces, crucible furnaces, and electric-arc furnaces.
This document provides an overview of the sand casting process. It discusses the key steps which include pattern making, making the sand mold, melting and pouring, and post-solidification operations. It also describes important elements like cores, gating systems, and common casting defects. The sand casting process is widely used due to its ability to cast a variety of alloys in both small and large quantities.
Sand casting is an economical method for producing near net shape components with intricate shapes and complex contours. While it allows for alterations to improve strength, sand casting parts may have irregular surfaces and size variations requiring additional machining. The process has disadvantages including a relatively high defect rate, limitations on dimensional accuracy, safety and environmental controls increasing costs, and potential quality issues from overseas suppliers. However, for many applications the advantages of low tooling costs and design flexibility outweigh the drawbacks of sand casting.
1) Casting is a manufacturing process that involves pouring molten material into a mold and allowing it to solidify. The mold can be either permanent or temporary.
2) There are two main types of casting based on the mold: expendable mold casting, which uses sand casting; and non-expendable mold casting, which includes die casting and centrifugal casting.
3) Sand casting uses various types of sand as the mold material and is performed using either the green sand or air set method. Over 70% of metal castings are produced via sand casting.
This document provides information on foundry processes and sand casting. It defines important casting terminology like flasks, drags, copes, patterns, and parting lines. It describes the tools used in sand mold making like molds, hammers, and trowels. It explains the procedure for making a sand mold in steps from preparing the bottom board and drag to applying facing sand in the mold cavity. It also defines different types of molds like green sand molds, dry sand molds, and skin dried molds. The document outlines properties of molding sand and types of patterns used in casting.
This document discusses metal casting processes and patterns used in sand mold casting. It provides information on the basic steps of the casting process, including melting metal, pouring it into a mold, allowing it to solidify, and removing the casting. It classifies casting processes and describes sand mold casting in detail. This includes the use of patterns to form cavities in molds, common pattern materials like wood and metal, and different types of patterns such as single-piece, two-piece, loose-piece, and multi-piece patterns. Gating systems and cores are also discussed.
This document provides an overview of metal casting fundamentals and processes. It defines metal casting as a process where molten metal is poured into a mold and solidifies. The main types of casting processes discussed are sand casting, permanent mold casting, and die casting. Sand casting uses expendable molds made of sand while permanent mold and die casting use reusable metal molds. The document explains the key steps in casting like heating, pouring, solidification and explains concepts like gating, risers and shrinkage. It also discusses advantages and limitations of different casting processes.
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.
This document provides an overview of sand casting processes. It discusses the key steps which include pattern making, molding sand properties and testing, core making, melting furnaces, casting defects and inspection methods. The main molding processes covered are green sand molding and dry sand molding. Common casting defects like blowholes and surface cracks are addressed. Non-destructive testing methods for inspecting castings such as magnetic particle, dye penetrant, radiography and ultrasonic testing are also summarized.
This document provides information on the casting process, including definitions, components, steps, and considerations. Some key points:
1. The casting process involves pouring molten metal into a mold patterned after the part, allowing it to solidify, and removing the part from the mold. Important considerations are metal flow, solidification, and mold material.
2. Components include patterns, molds, cores, and gating systems. Steps are pattern making, molding, melting, pouring, solidification, cleaning, and inspection.
3. Patterns are modified replicas of the object and include allowances for shrinkage, draft, and machining. Common pattern materials are wood, metal, and plastic
The document discusses manufacturing processes and sand casting. It defines manufacturing as making goods by hand or machinery. Manufacturing processes are classified into casting, joining, forming, sheet metal work, plastics processing, machining, powder metallurgy, heat treatment, and assembly. Sand casting is described as producing metal parts by pouring molten metal into sand molds. Molds are made using patterns, cores, and molding machines in a foundry. Sand casting can make complex shapes and is used to produce parts in large quantities.
Metal casting involves pouring molten metal into a mold cavity to solidify into the desired shape, with common mold materials including sand. The main steps are making patterns and molds, melting metal, pouring into the mold, solidification, and finishing. Key casting methods include green sand molding, shell molding, and die casting which offer advantages like complexity of parts and better dimensional accuracy and surface finish compared to sand casting.
The document describes the casting process and its key terms. It discusses the main steps: pattern making, mould preparation including gating and risering, core making, melting and pouring, and cleaning and inspection. It provides details on each step and describes how a mould is made by packing sand around a pattern. Common components produced by casting are also listed, such as automobile and aircraft parts. Advantages include the ability to make complex shapes easily and economically, while limitations include potential defects and inferior properties compared to other processes.
This document summarizes various metal casting processes and techniques. It discusses sand casting and the key components of sand molds like the flask, pouring basin, sprue, runners, and risers. It also covers cores, moulding sands, patterns, moulding machines, melting furnaces, and common defects in sand casting. Testing methods for moulding sands like moisture content, clay content, and permeability are also summarized.
The document provides an overview of the sand casting process in 13 steps:
1. Mix sand and create molds using patterns.
2. Place pattern in bottom mold and compact sand.
3. Add top mold and fill with compacted sand.
4. Remove pattern to leave a cavity in the sand.
5. Pour molten metal into the mold.
6. Allow metal to cool and harden.
7. Break apart mold and remove the new cast part.
The document discusses various aspects of casting processes and patterns used in casting. It describes the casting process where molten metal is poured into a mold and solidifies. It then discusses different types of patterns used including single piece, split piece, loose piece, and sweep patterns. The key considerations for pattern materials are also summarized such as wood, metal, plastic and their advantages. Pattern allowances including shrinkage, draft, machining and distortion allowances are explained.
This document provides information on conducting a sand casting demonstration or lab. Sand casting is an inexpensive way to make metal parts and is commonly used in industries like automotive and aerospace. In sand casting, molten metal is poured into a mold cavity formed in sand. While inexpensive, sand casting often results in flaws that can affect material properties. The demonstration aims to introduce students to sand casting and show how processing can influence defect formation and properties. It outlines objectives, procedures, equipment needed and safety considerations for an instructor to replicate the sand casting process in the classroom.
The document discusses the key steps in the sand casting process:
1. Creating a mechanical drawing and pattern of the part to be cast
2. Preparing molds by setting cores and positioning patterns
3. Pouring molten metal and allowing it to solidify in the mold
4. Removing the casting and performing trimming and finishing operations
The document provides an overview of the sand casting process from pattern making to final inspection and packaging for shipment.
Manufacturing Technology 1 full unit notesGopinath Guru
The document provides information on various metal casting processes and their working principles. It discusses sand casting process which uses expandable sand molds and involves steps of making the mold, pouring molten metal, solidification and breaking the mold. Other casting processes mentioned are permanent mold casting, die casting and investment casting. It also describes mold properties, types of patterns and allowances in patterns. Testing of molds and cores is outlined.
The document discusses various casting processes including shell molding, expanded polystyrene casting, investment casting, plaster mold casting, ceramic mold casting, permanent mold casting, die casting, and centrifugal casting. It provides details on the key steps for each process as well as their advantages and limitations. Various furnace types for melting metals are also outlined, such as cupolas, direct fuel-fired furnaces, crucible furnaces, and electric-arc furnaces.
This document provides an overview of the sand casting process. It discusses the key steps which include pattern making, making the sand mold, melting and pouring, and post-solidification operations. It also describes important elements like cores, gating systems, and common casting defects. The sand casting process is widely used due to its ability to cast a variety of alloys in both small and large quantities.
Sand casting is an economical method for producing near net shape components with intricate shapes and complex contours. While it allows for alterations to improve strength, sand casting parts may have irregular surfaces and size variations requiring additional machining. The process has disadvantages including a relatively high defect rate, limitations on dimensional accuracy, safety and environmental controls increasing costs, and potential quality issues from overseas suppliers. However, for many applications the advantages of low tooling costs and design flexibility outweigh the drawbacks of sand casting.
1) Casting is a manufacturing process that involves pouring molten material into a mold and allowing it to solidify. The mold can be either permanent or temporary.
2) There are two main types of casting based on the mold: expendable mold casting, which uses sand casting; and non-expendable mold casting, which includes die casting and centrifugal casting.
3) Sand casting uses various types of sand as the mold material and is performed using either the green sand or air set method. Over 70% of metal castings are produced via sand casting.
This document provides information on foundry processes and sand casting. It defines important casting terminology like flasks, drags, copes, patterns, and parting lines. It describes the tools used in sand mold making like molds, hammers, and trowels. It explains the procedure for making a sand mold in steps from preparing the bottom board and drag to applying facing sand in the mold cavity. It also defines different types of molds like green sand molds, dry sand molds, and skin dried molds. The document outlines properties of molding sand and types of patterns used in casting.
This document discusses metal casting processes and patterns used in sand mold casting. It provides information on the basic steps of the casting process, including melting metal, pouring it into a mold, allowing it to solidify, and removing the casting. It classifies casting processes and describes sand mold casting in detail. This includes the use of patterns to form cavities in molds, common pattern materials like wood and metal, and different types of patterns such as single-piece, two-piece, loose-piece, and multi-piece patterns. Gating systems and cores are also discussed.
This document provides an overview of metal casting fundamentals and processes. It defines metal casting as a process where molten metal is poured into a mold and solidifies. The main types of casting processes discussed are sand casting, permanent mold casting, and die casting. Sand casting uses expendable molds made of sand while permanent mold and die casting use reusable metal molds. The document explains the key steps in casting like heating, pouring, solidification and explains concepts like gating, risers and shrinkage. It also discusses advantages and limitations of different casting processes.
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.
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.
Metal casting is a manufacturing process where liquid metal is poured into a mold and solidifies. Sand casting is a common type of metal casting that uses sand as the mold material. Key steps in sand casting include pattern making, molding, melting and pouring the metal, solidification, and cleaning. Sand provides advantages as a mold material such as low cost, high temperature stability, and permeability. Shell molding is an alternative casting method that uses a resin-bonded sand mixture to form the mold around a pattern.
Presentation study of manufacturing process in hmt machine tools limited.docxAbu Sufyan Malik
Manufacturing is the production of products for use or sale using labour and machines, tools, chemical and biological processing, or formulation, and is the essence of secondary industry. The term may refer to a range of human activity, from handicraft to high-tech, but is most commonly applied to industrial design, in which raw materials from primary industry are transformed into finished goods on a large scale. Such finished goods may be sold to other manufacturers for the production of other more complex products or distributed via the tertiary industry to end users and consumers (usually through wholesalers, who in turn sell to retailers, who then sell them to individual customers).
Manufacturing engineering or manufacturing process are the steps through which raw materials are transformed into a final product. The manufacturing process begins with the product design, and materials specification from which the product is made. These materials are then modified through manufacturing processes to become the required part.
The manufacturing sector is closely connected with engineering and industrial design. Examples of major manufacturers in North America include General Motors Corporation, General Cast Parts. Examples in Europe include Volkswagen Group, Siemens, FCA and Michelin. Examples in Asia include Toyota, Yamaha, Panasonic, LG, Samsung and Tata Motors.
The document discusses casting and the casting process. Casting involves pouring liquid material into a mold to create objects. Common casting materials include metals, epoxy, concrete, and plaster. A foundry produces metal castings by melting metals and pouring them into molds. After solidification, the casting is removed from the mold. The casting process involves designing molds and patterns, melting and pouring metals, solidification and cooling, then finishing and inspecting the final casting for defects. Key aspects of casting include mold composition, gating system design, pouring parameters, and solidification properties to minimize defects during production.
This document provides information on metal casting processes and patterns. It discusses the different types of patterns used such as single piece patterns, shell patterns, and wax patterns. It also covers the various pattern allowances including shrinkage allowance, machining allowance, draft allowance, and others. The document discusses the properties and types of molding sands used including green sand, dry sand, facing sand, loam sand, backing sand, parting sand and core sand. It provides details on the requirements for molding materials including refractoriness, permeability, green strength and others.
This document provides information on casting processes and terms. It defines casting as pouring molten metal into a mold cavity. Key terms discussed include patterns, cores, gates, risers, and molds. Sand casting is described as the most common casting method, using sand mixtures to form temporary molds. The document outlines the sand casting process and discusses mold properties. It also covers heating metal, pouring, solidification, and using risers to compensate for shrinkage. Overall, the document provides an overview of casting techniques and terminology.
This document provides information about the Manufacturing Technology-I course taught at Mepco Schlenk Engineering College. It discusses the objective of imparting knowledge of basic manufacturing processes, forming processes, and deformation processes. The course outcomes are listed as gaining understanding of casting, welding, metal forming principles, sheet metal forming applications, and metal/material forming processes. The document outlines the topics to be covered in each of the 5 units - metal casting processes, metal joining processes, metal forming processes, sheet metal processes, and plastic component processing. Key casting processes like sand casting and types of patterns and their materials are defined.
This document provides an overview of course material on fundamentals of manufacturing processes. It discusses various casting processes like sand casting, shell mold casting, investment casting, die casting, and centrifugal casting. Key steps and terminology related to sand casting like preparation of drag box and cope box are explained. Important properties of molding sand like permeability, refractory, and hot strength are also defined.
sand casting and other expendable castingAli Hameed
Sand casting involves pouring molten metal into a sand mold. Patterns are used to define the shape and are made of materials like wood, metal, or plastic. There are different types of patterns including solid, split, match-plate, and cope-and-drag patterns. Shell molding uses a thermosetting resin to bind sand into a thin shell mold with better dimensional accuracy than sand casting. Lost-wax casting involves making a wax pattern, coating it with refractory material to form a mold, then heating to melt out the wax leaving a cavity to pour molten metal into. Continuous casting is used for steel and involves pouring molten metal directly into a water cooled mold to slowly solidify into sheets or plates
very useful for 1st year engineering student who studying the workshop manufacturing practices. in this ppt pdf all about casting viz. pattern, mould, different type of sand, riser design, different casting process and defects in casting is given in short.
Investment casting, also known as lost-wax casting, involves making a wax pattern of the desired part, coating it with refractory material to create a ceramic mold, melting away the wax, and pouring molten metal into the mold cavity. This allows for the production of parts with complex geometries and close tolerances with minimal finishing required. Suitable for casting metals that are difficult to machine like aluminum, copper, and alloys. While allowing for intricate designs, investment casting has limitations on part size, thickness, and material selection due to the high costs involved.
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.
This seminar report discusses shell molding, also known as shell mold casting. Some key points:
1) Shell molding uses a resin-covered sand to form molds for casting small to medium metal parts, providing better dimensional accuracy and productivity than sand casting.
2) The process involves creating a pattern, applying a heated sand-resin mixture to form a shell around the pattern, curing the shell, assembling two shell halves, and pouring molten metal to form the casting.
3) Shell molding allows casting of both ferrous and non-ferrous metals for parts requiring precision, such as gear housings and cylinder heads.
4) The sand used is finer
The document discusses various metal casting processes including sand casting, permanent mold casting, shell molding, vacuum molding, expanded polystyrene casting, investment casting, and plaster mold casting. It describes the key steps, advantages, and disadvantages of each process. Sand casting is the most widely used process due to ability to cast nearly all alloys and produce castings in a wide range of sizes.
1. The document discusses the ingredients and components used in the moulding process for casting metals. It describes the key materials like sand, clay, moisture and their properties.
2. The moulding process involves making a cavity in sand using a pattern, incorporating the pattern in a gating system, removing the pattern, pouring molten metal, allowing it to cool, and removing the casting.
3. The advantages of the moulding process are its reusability, good dimensional accuracy, and high production rates compared to other casting methods. Typical tolerances and surface finishes are provided.
ACEP Magazine edition 4th launched on 05.06.2024Rahul
This document provides information about the third edition of the magazine "Sthapatya" published by the Association of Civil Engineers (Practicing) Aurangabad. It includes messages from current and past presidents of ACEP, memories and photos from past ACEP events, information on life time achievement awards given by ACEP, and a technical article on concrete maintenance, repairs and strengthening. The document highlights activities of ACEP and provides a technical educational article for members.
Comparative analysis between traditional aquaponics and reconstructed aquapon...bijceesjournal
The aquaponic system of planting is a method that does not require soil usage. It is a method that only needs water, fish, lava rocks (a substitute for soil), and plants. Aquaponic systems are sustainable and environmentally friendly. Its use not only helps to plant in small spaces but also helps reduce artificial chemical use and minimizes excess water use, as aquaponics consumes 90% less water than soil-based gardening. The study applied a descriptive and experimental design to assess and compare conventional and reconstructed aquaponic methods for reproducing tomatoes. The researchers created an observation checklist to determine the significant factors of the study. The study aims to determine the significant difference between traditional aquaponics and reconstructed aquaponics systems propagating tomatoes in terms of height, weight, girth, and number of fruits. The reconstructed aquaponics system’s higher growth yield results in a much more nourished crop than the traditional aquaponics system. It is superior in its number of fruits, height, weight, and girth measurement. Moreover, the reconstructed aquaponics system is proven to eliminate all the hindrances present in the traditional aquaponics system, which are overcrowding of fish, algae growth, pest problems, contaminated water, and dead fish.
DEEP LEARNING FOR SMART GRID INTRUSION DETECTION: A HYBRID CNN-LSTM-BASED MODELgerogepatton
As digital technology becomes more deeply embedded in power systems, protecting the communication
networks of Smart Grids (SG) has emerged as a critical concern. Distributed Network Protocol 3 (DNP3)
represents a multi-tiered application layer protocol extensively utilized in Supervisory Control and Data
Acquisition (SCADA)-based smart grids to facilitate real-time data gathering and control functionalities.
Robust Intrusion Detection Systems (IDS) are necessary for early threat detection and mitigation because
of the interconnection of these networks, which makes them vulnerable to a variety of cyberattacks. To
solve this issue, this paper develops a hybrid Deep Learning (DL) model specifically designed for intrusion
detection in smart grids. The proposed approach is a combination of the Convolutional Neural Network
(CNN) and the Long-Short-Term Memory algorithms (LSTM). We employed a recent intrusion detection
dataset (DNP3), which focuses on unauthorized commands and Denial of Service (DoS) cyberattacks, to
train and test our model. The results of our experiments show that our CNN-LSTM method is much better
at finding smart grid intrusions than other deep learning algorithms used for classification. In addition,
our proposed approach improves accuracy, precision, recall, and F1 score, achieving a high detection
accuracy rate of 99.50%.
Understanding Inductive Bias in Machine LearningSUTEJAS
This presentation explores the concept of inductive bias in machine learning. It explains how algorithms come with built-in assumptions and preferences that guide the learning process. You'll learn about the different types of inductive bias and how they can impact the performance and generalizability of machine learning models.
The presentation also covers the positive and negative aspects of inductive bias, along with strategies for mitigating potential drawbacks. We'll explore examples of how bias manifests in algorithms like neural networks and decision trees.
By understanding inductive bias, you can gain valuable insights into how machine learning models work and make informed decisions when building and deploying them.
Literature Review Basics and Understanding Reference Management.pptxDr Ramhari Poudyal
Three-day training on academic research focuses on analytical tools at United Technical College, supported by the University Grant Commission, Nepal. 24-26 May 2024
Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
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3. Text Book
1. Heine, et. al (2003), Principles of Metal Casting, Tata-
McGraw-HiII Publication.
Reference Books
1. Campbell, J., Castings (2003), Butter Worth,
Heinemann Publishers.
2. Beeley P.R. (2001), Foundry Technology, Buttersworth.
3. Srinath Viswanathan (2008), Metal Casting ASME
Handbook.
4. Mode of Evaluation :
Digital Assignments /Surprise Test/
Seminars/CAT/FAT
5.
6.
7. Introduction to casting and foundry industry-Basic
principles of casting processes-Sequence in foundry
operations-Moulding sand and its properties-
Carbon dioxide moulding-Moulding Equipment,
Moulding technique, Patterns and Cores.
Module 1
Moulding practices-Production of Moulds and Cores
16. Sprinkle dry facing Sand after placing the pattern so that the
pattern does not stick to the moulding sand during withdrawal
of pattern
17.
18.
19.
20.
21.
22.
23. Step2: Preparation of
Cope Box
Sprinkle dry parting sand on the top of the drag box and
then keep the cope part of pattern on the drag and then
align them with dowel pins
36. Venting: The basic purpose of
vent creating vent holes in cope
is to permit the escape of gases
generated during pouring and
solidification of the casting.
Remove conical pins
by rapping
71. Refractory: Resistance to heat
Ex: Silica is a very good refractory material (1,713 °C)
It is the ability of the moulding material to resist the
temperature of the liquid metal to be poured so that
it does not get fused with the metal. The
refractoriness of the Silica sand is highest.
72. Permeability tells us how well
the generated gases can pass
through the moulding sand
The moulding sand must be sufficiently porous to allow the
dissolved gases, which are evolved when the metal freezes or
moisture present or generated within the moulds to be
removed freely when the moulds are poured. This property of
sand is called porosity or permeability.
73. It is an important property of the moulding sand
as the sand particles must be capable of
adhering to another body, then only the sand
should be easily attached itself with the sides of
the moulding box and give easy of lifting and
turning the box when filled with the sand.
74.
75. Green strength is the strength of sand in the
wet state and is required for making possible to
prepare and handle the mould.
76. • If the metal is poured into a green mould the
sand adjacent to the metal dries and in the
dry state it should have strength to resist
erosion and the pressure of metal.
• The strength of the sand that has been dried
is called dry strength
78. At the time of pouring molten metal, mould must
be able to withstand flow and pressure of the
molten metal at high temperature otherwise the
mould may enlarge, crack, get washed or break
Hot Strength
79. The sand adjacent to the metal is suddenly
heated and undergoes expansion. If the
mould wall is not dimensionally stable under
rapid heating, cracks, buckling and flacking
off sand may occur.
Thermal stability
83. Carbon dioxide moulding (Co2) Moulding
Mould Material : Sand + Liquid form Sodium Silicate Binder (Na2Sio3)
((3-5% based on sand weight) )
The carbon dioxide gas is passed through
the vent holes for a few seconds.
84. Mould Material : Sand + Sodium Silicate Binder (Na2Sio3)
Sodium silicate reacts with carbon dioxide gas to form silica gel that binds the
sand particles together.
The chemical reaction is given by: Na 2 Si03 + C0 2 -> Na 2 C0 3 + Si02 (Sodium
Carbonate) (silica gel)
85. Advantages:
• Instantaneous strength development and moulds are strong
• Provides great dimensional accuracy in production
Disadvantages:
• Poor collapsibility of moulds
• Over gassing and under gassing adversely affects the properties of cured
sand
Applications:
• Can be where speed and flexibility is the prime requirement
• molds of a varied sizes and shapes can be moulded by this process.
96. The Pattern
A full-sized model of the part, slightly enlarged
to account for shrinkage and machining
allowances in the casting
• Pattern materials:
– Wood - common material because it is easy to work, but it
warps
– Metal - more expensive to make, but lasts much longer
– Plastic - compromise between wood and metal
97. Types of Patterns
Figure: Types of patterns used in sand casting:
(a) solid pattern
(b) split pattern
(c) match-plate pattern
(d) cope and drag pattern
99. Characteristics of Match Plate Pattern
• It is a split pattern
• Cop and Drags on the opposite site of the metallic (generally) plate.
• The gates are runners are on the match plate.
• Can be used for large number of casting with very little hand work.
• A match plate can be single pattern or a combination of many small
patterns
• Example : IC engine piston rings can be produced by match plate
pattern
100. Cope and Drag Pattern
https://www.youtube.com/watch?v=m4qBETv7bX0
143. Moulding Sand Composition
Ingredients of Moulding Sand:
• Silica grains (SiO2)
• Clay (as binder)
• Moisture (to activate clay and
provide plasticity)
144.
145.
146. Refractory: Resistance to heat
Ex: Silica is a very good refractory material (1,713 °C)
It is the ability of the moulding material to resist the
temperature of the liquid metal to be poured so that
it does not get fused with the metal. The
refractoriness of the Silica sand is highest.
147. Permeability tells us how well
the generated gases can pass
through the moulding sand
The moulding sand must be sufficiently porous to allow the
dissolved gases, which are evolved when the metal freezes or
moisture present or generated within the moulds to be
removed freely when the moulds are poured. This property of
sand is called porosity or permeability.
148. It is the important property of the moulding
sand and it is defined as the sand particles must
be capable of adhering to another body, then
only the sand should be easily attach itself with
the sides of the moulding box and give easy of
lifting and turning the box when filled with the
sand.
149.
150. Green strength is the strength of sand in the
wet state and is required for making possible to
prepare and handle the mould.
151. • If the metal is poured into a green mould the
sand adjacent to the metal dries and in the dry
state it should have strength to resist erosion
and the pressure of metal.
• The strength of the sand that has been dried
is called dry strength
152.
153. At the time of pouring the molten metal the
mould must be able to withstand flow and
pressure of the metal at high temperature
otherwise the mould may enlarge, crack, get
washed or break
Hot Strength
154. The sand adjacent to the metal is suddenly
heated and undergoes expansion. If the
mould wall is not dimensionally stable under
rapid heating, cracks, buckling and flacking
off sand may occur.
Thermal stability
186. Advantages :
-High precision and accurate castings with smooth surface finish can be
produced economically.
-complex parts having intricate shapes, and cleaning of casting is reduced or
completely eliminated.
-size of casting is 10 - 13.5 kg and minimum wall thickness 2 - 2.5mm is
possible.
Examples: Brake drum, bushing, cam/cam shaft, piston, piston rings, pinions,
pipe bends, air compressor crank cases, etc.,
261. • Core may or may not be used
• Mostly used for making hollow objects
like pipes, tubes and bushes
262. The forces generated by the rotation of the mould ensure the distribution of
molten material to all the regions of the casting
263. Semi centrifugal casting technique is a variation of
true centrifugal casting and uses vertical axis with
less rotational speeds.
The main difference is that in semi
centrifugal casting the mold is filled completely
with molten metal, which is supplied to
the casting through a central sprue.
Castings manufactured by this process will
possess rotational symmetry.
If a central bore is required in the casting, a dry
sand core is best suited.
264.
265.
266.
267.
268.
269.
270.
271.
272. Gating system and its purpose
Gating system: Refers to all the passageways through
which the molten metal travels to enter the mould cavity
Typical Gating System
273. Components of A Gating System
• Pouring Basin
• Sprue
• Sprue base well
• Runner
• Runner extension
• Ingate
• Riser
Elements of a typical gating system:
274. Functions of Gating System Elements
Pouring Basin
Molten metal is not directly poured in to the mould cavity
275. Functions of Gating System Elements
Sprue
To avoid air aspiration problem the sprue is gradually tapered to reduce the cross section
276. Functions of Gating System Elements
Sprue base well
Acts as reservoir of molten metal at bottom of sprue to reduce momentum
and thereby mould erosion is reduced
277. Functions of Gating System Elements
Sprue base well
Acts as reservoir of molten metal at bottom of sprue to reduce momentum
and thereby mould erosion is reduced
278. Functions of Gating System Elements
Runner
Partially filled runner causes slag to enter the mould cavity
279. Functions of Gating System Elements
Runner Extension
Runner is extended a little further to trap the slag in the molten metal
281. Functions of Gating System Elements
Bottom gate
Mould erosion would not cause
282. (a) Top pouring system, (b) Bottom pouring system, (c)Side pouring system
Top pouring vs. Bottom pouring systems
283. Gating System Design
Molten metal obeys Bernouli’s theorem which states that the total energy head
remains constant at any section
284. Gating System Design
Law of Continuity
Law of continuity is also useful in understanding the gating system behaviour which
states that the volume of the molten metal flowing at any section in the mould is
constant
The same in the equation form can be written as
Q= A1V1= A2V2
Where Q= rate of flow.m3/s
A= area of cross section, m2
V= velocity of metal flow, m/s
285. Gating Ratio
Gating ratio refers to the proportion of the cross
sectional areas between the sprue, runner and
ingates and it is generally denoted as
sprue area: runner area: ingate area
Editor's Notes
A pattern-removal allowance is also subtracted from the dimensions of the pattern. The removal process enlarges the cavity a little bit
Solid Pattern: Problem in locating the parting line. Locating is skill dependent. Suitable for low production
Split pattern: Relatively easy to locate parting line. Used for low-medium size production
Match-plate pattern -> The cope and drag portions of the pattern are mounted on opposite sides of a wood or metal plate conforming to the parting line. Match plates are also integrally cast in which cast pattern and plate are cast as one piece in sand or plaster molds. It is used with some type of molding machine, in order to obtain maximum speed of molding. Advantages of the match-plate patterns are:(a) Costly but good production rate(b) Increase the dimensional accuracy Cope and Drag pattern ->
Similar to match-plate pattern but split pattern halves are attached to separate plates.
The pattern contains built-in gating system thus save time for making separate gating system in each mold.