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.
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.
casting introduction, steps involved in casting,gating system,gates,pattern, patterns allowances, advantages and disadvantages of casting process and applications of casting process
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.
casting introduction, steps involved in casting,gating system,gates,pattern, patterns allowances, advantages and disadvantages of casting process and applications of casting process
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.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
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About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
5. Advantages:
Inexpensive
Easily available in large quantities
Easy to fabricate
Light in weight
Thay can be repaired easily
Easy to obtain good surface finish
Limitations:
Susceptible to shrinkage and swelling
Possess poor wear resistance
Abraded easily by sand action
Obsorb moisture, consequently get wraped
Cannot withstand rough handling
These are used where the no. of castings to
be produced is small and pattern size is large.
6. Advantages:
Do not absorb moisture
More stronger
Possess much longer life
Do not wrap, retain their shape
Greater resistance to abrasion
Accurate and smooth surface finish
Good machinability
Limitations:
Expensive
Not easily repaired
Ferrous patterns get rusted
Heavy weight
These are employed where large no. of
castings have to be produced from same patterns.
7. Advantages:
Durable
Provides a smooth surface
Moisture resistant
Does not involve any appreciable change in size or shape
Light weight
Good strength
Wear and corrosion resistance
Easy to make
Abrasion resistance
Good resistance to chemical attack
Limitations:
Plastic patterns are Fragile
These are may not work well when subject to conditions of
severe shock as in machine molding (jolting).
8. Advantages:
It can be easily worked by using wood working tools.
Intricate shapes can be cast without any difficulty.
It has high compressive strength.
Plastermaybe madeout of Plasterof parisor
Gypsumcement.
Plastermixtureis pouredintoa mould
madebya sweeppatternor a woodenmaster
pattern,in orderto obtaina Plasterpattern.
9. Advantages:
Provide very good surface finish.
Impatr high accuracy to castings.
After being molded, the wax pattern is not taken out of the mould
like other patterns; rather the mould is inverted and heated; the
molten wax comes out and/or is evaporated. Thus there is no
chance of the mould cavity getting damaged while removing the
pattern.
Wax patterns find
applications in Investment casting
process.
20. 11. Shell pattern:
• A pattern which has Hollow hole in it. only the outer
shape is used for making the mould
• The core is prepared inner surface of the pattern itself
Hole
21.
22. A pattern is larger in size as compared to the final
casting, because it carries certain allowances due to
metallurgical and mechanical reasons for example,
shrinkage allowance is the result of metallurgical
phenomenon where as machining, draft, distortion, shake
and other allowances are provided on the patterns
because of mechanical reasons.
23. The various pattern allowances are:
1. shrinkage or contraction
allowance.
2. Machining or finish allowance.
3. Draft of tapper allowances.
4. Distortion or chamber allowance.
5. Shake or rapping allowance.
24. All most all cast metals shrink or contract
volumetrically on cooling.
The metal shrinkage is of two types:
1. Liquid Shrinkage:
it refers to the reduction in volume when the metal
changes from liquid state to solid state at the solidus
temperature. To account for this shrinkage; riser, which
feed the liquid metal to the casting, are provided in the
mold.
2. Solid Shrinkage:
it refers to the reduction in volume caused when metal
loses temperature in solid state. To account for this,
shrinkage allowance is provided on the patterns.
28. Almost all cast metals shrink or contract volumetrically
after solidification and therefore the pattern to obtain a
particular sized casting is made oversize by an amount
equal to that of shrinkage or contraction.
Different metals shrink at different rates because
shrinkage is the property of the cast metal/alloy.
The metal shrinkage depends upon:
1. The cast metal or alloy.
2. Pouring temp. of the metal/alloy.
3. Casted dimensions(size).
4. Casting design aspects.
5. Molding conditions(i.e., mould
materials and molding methods
29. A Casting is given an allowance for machining, because:
i. Castings get oxidized in the mold and during heat treatment;
scales etc., thus formed need to be removed.
ii. It is the intended to remove surface roughness and other
imperfections from the castings.
iii. It is required to achieve exact casting dimensions.
iv. Surface finish is required on the casting.
How much extra metal or how much machining allowance
should be provided, depends on the factors listed below:
i. Nature of metals.
ii. Size and shape of casting.
iii. The type of machining operations to be employed for cleaning the
casting.
iv. Casting conditions.
v. Molding process employed
30. It is given to all surfaces perpendicular to parting line.
Draft allowance is given so that the pattern can be
easily removed from the molding material tightly
packed around it with out damaging the mould cavity.
The amount of taper depends upon:
i. Shape and size of pattern in the depth
direction in contact with the mould
cavity.
ii. Moulding methods.
iii. Mould materials.
iv. Draft allowance is imparted on internal
as well as external surfaces; of course
31.
32.
33. A casting will distort or wrap if :
i. It is of irregular shape,
ii. All it parts do not shrink uniformly i.e., some
parts shrinks while others are restricted from
during so,
iii. It is u or v-shape,
iv. The arms possess unequal thickness,
v. It has long, rangy arms as those of propeller
strut for the ship,
vi. It is a long flat casting,
vii. One portion of the casting cools at a faster
34. A patter is shaken or rapped by striking the same with a
wooden piece from side to side. This is done so that the
pattern a little is loosened in the mold cavity and can be
easily removed.
In turn, therefore, rapping enlarges the mould cavity
which results in a bigger sized casting.
Hence, a –ve allowance is provided on the pattern i.e.,
the pattern dimensions are kept smaller in order to
compensate the enlargement of mould cavity due to
rapping.
The magnitude of shake allowance can be reduced by
increasing the tapper.
35. Moulding sands are classified according to their use.
These are classified and described below :
Green Sand
It is a mixture of silica sand with 18 to 30 percent clay,
having quantity of water 6 to 8 percent. Green sand in its
natural state contains enough moisture to give it
sufficient bonding property. It is soft, light, porous and
retains the shape easily when squeezed in the hand.
Moulds prepared by this sand are known as green sand
moulds which are used for small and medium castings
only.
36. Dry Sand
When moisture from green sand mould is
removed, it is known as dry sand mould and is used
for large size of casting. By drying the mould in
moulding box it becomes stronger and compact.
Facing Sand
It is used directly next to the surface of pattern.
When the mould is poured with the molten metal it
comes directly in contact with the molten metal.
As it is subjected to most severe conditions, it must
possess high strength and refractoriness. It is made
of silica sand and clay in fine powder form.
37. Loam Sand
It is a mixture of clay (about 50%), sand and water
(about 18-20%) to obtain a thin plastic paste which is
used to plaster on moulds with soft bricks and
hardens on drying. This is particularly employed for
loam moulding usually for rough and large castings.
Backing Sand
It is the sand obtained from mould and is used again
and again. Due to its black colour which is due to
burning and addition of coal dust, it is also known as
black sand.
It reduce the cost of moulding.
38.
39. Parting Sand
It is fine sharp dry sand used to keep the green
sand from sticking to the pattern and also to keep
the moulding boxes (drag and cope) separated.
Core Sand
This is silica sand mixed with core oil which is
composed of linseed oil, light mineral oil, resin and
other binding materials. For the sake of economy,
pitch or flours and water may also be used in case
of large cores.
40.
41. A large variety of molding materials is used in foundries for
manufacturing molds and cores. They include molding
sand, system sand or backing sand, facing sand, parting
sand, and core sand. The choice of molding materials is
based on their processing properties. The properties that
are generally required in molding materials are:
42. It is the ability of the molding material to with stand
high temperatures (experienced during pouring)
with out
1. Fusion,
2. Cracking, buckling or scabbing,
3. Experiencing any major physical
change.
Silica sand have high
refractoriness.
43. During pouring and subsequent solidification of a
casting, a large amount of gases and steam is
generated.
These gases are those that have been absorbed by the
metal during melting, air absorbed from the atmosphere
and the steam generated by the molding and core sand.
If these gases are not allowed to escape from the mold,
they would be entrapped inside the casting and cause
casting defects.
To overcome this problem the molding material must be
porous.
Proper venting of the mold also helps in escaping the
gases that are generated inside the mold cavity.
44. • The molding sand that contains moisture is termed as
green sand.
• The green sand particles must have the ability to cling to
each other to impart sufficient strength to the mold.
• The green sand must have enough strength so that the
constructed mold retains its shape.
• Green strength helps in making and handling the
moulds.
45. A mould may either intentionally be dried, or a green
sand mould may lose its moisture and get dried while
waiting for getting poured or when it comes in contact
with molten metal being poured.
The sand thus dried must have dry strength to
1. Withstand erosive forces due to
molten metal,
2. Withstand pressure of molten
metal,
3. Retain its exact shape,and
4. Withstand the metallostatic
pressure of the liquid material.
46. As soon as the moisture is eliminated, the sand would
reach at a high temperature when the metal in the mold is
still in liquid state.
The strength of the sand that is required to hold the shape of
the cavity is called hot strength.
In the absence of adequate hot strength, the mold may
1. enlarge
2. break, erode or
3. get cracked.
47. Collapsibility determines the readiness with which the
molding sand,
1. Automatically gets collapsed after
the casting solidifies, and
2. Breaks down in knock out and
cleaning operations.
If the mould or core does not collapse, it may restrict
free contraction of solidifying metal and cause the
same to tear or crack.
48. • It is the ability of the molding sand to get compacted
to a uniform density.
• Flowability assists molding sand to flow and pack
all-around the pattern and take up the required
shape.
• Flowability increases as clay and water contents
increase.
49. It is the property of molding sand owing to which, it
1. Sticks with the walls of molding boxes,
2. Sticks with gaggers, and
3. Thus makes it possible to mold cope
and drag.
50. • Finer sand mould resist metal penetration and
produce smooth casting surfaces.
• Fineness and permeability are in conflict with
each other and hence they must be balanced for
optimum results.
51. The main ingredients of any molding sand are:
• Base sand,
• Binder, and
• Moisture
52. • Silica sand is most commonly used base sand.
• Other base sands that are also used for making mold are
zircon sand, Chromite sand, and olivine sand.
• Silica sand is cheapest among all types of base sand and
it is easily available.
53. Binders are of many types such as:
1. Clay binders,
2. Organic binders and
3. Inorganic binders
Clay binders are most commonly used binding agents mixed
with the molding sands to provide the strength.
The most popular clay types are:
◦ Kaolinite or fire clay (Al2O3 2 SiO2 2 H2O)
and Bentonite (Al2O3 4 SiO2 nH2O)
◦ Of the two the Bentonite can absorb more
water which increases its bonding power.
54.
55. Clay acquires its bonding action only in the presence of the
required amount of moisture.
When water is added to clay, it penetrates the mixture and
forms a microfilm, which coats the surface of each flake of
the clay.
The amount of water used should be properly controlled.
This is because a part of the water, which coats the
surface of the clay flakes, helps in bonding, while the
remainder helps in improving the plasticity.
57. Moisture content Test
Clay content Test
Chemical composition of sand
Grain shape and surface texture of sand.
Grain size distribution of sand
Refractoriness of sand
Strength Test
Permeability Test
Flowability Test
Shatter index Test
Mould hardness Test.
58. Moisture content Test
CaC2 + 2H2O--->C2H2 + Ca(OH)2
Amount of acetylene released is directly
proportional to moisture content.
speedy moisture teller
59. Dried 50 g sample + 475ml water + 1% NaOH
Floating clay removed
Till clear sand
Dried
Weight
60. • AFS = sum of products / total sum of the percentage of
sand retained on pan and each sieve
Sum of product =
Sum of (
precentage of
sand retained in
each sieve *
factor)
61.
62.
63.
64.
65. • P = VH /ATp
• Where, P = permeability
• V = volume of air passing through the specimen in c.c.
• H = height of specimen in cm
• p = pressure of air in gm/cm2
• A = cross-sectional area of the specimen in cm2
• T = time in minutes.
66. • Sand specimen heated to very high temperatures ranges
depending upon the type of sand.
• The heated sand test pieces are cooled to room temperature
and examined under a microscope for surface characteristics
or by scratching it with a steel needle.
• Sharply silica sand grains easily give way to the needle.
• Thus we evaluating surface characteristics or by scratching it
with a steel needle.