This document provides information about the MECH 423 - Casting, Welding, Heat Treating and NDT course offered in the Fall 2011 term at Concordia University. The course covers casting processes, welding and brazing techniques, heat treatments, and non-destructive testing. It is aimed at mechanical engineering students to understand how components are shaped and joined, and the effects on material properties. The course involves lectures, labs, assignments, presentations and exams. The instructor is Dr. S. Narayanswamy and it meets on Tuesdays from 5:45-8:15pm in room EV-11.119.
This document presents a thesis submitted to Worcester Polytechnic Institute in partial fulfillment of the requirements for a Master of Science degree in Manufacturing Engineering. The thesis focuses on optimizing gating/riser systems for castings based on CAD and simulation technology to improve casting quality by reducing porosity and incomplete filling. The author develops an optimization framework involving castability analysis, parametric modeling of gating systems, simulation analysis, and optimization of gating/riser designs. The framework is demonstrated on an engine block casting, showing improvements such as an 18% reduction in porosity and a 16% increase in yield.
The document discusses two gating system designs - Design A and Design B - for filling an oil panel. It describes the filling process for each design and provides contact information for the authorized distributor, Auto-Design-Online, including their email, Skype, and website.
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.
This document discusses various molding and casting processes, including:
1. Carbon dioxide molding process, investment casting process, shell molding process, die casting process, full molding process, and vacuum-sealed casting process.
2. It provides details on the steps and advantages/disadvantages of processes like shell molding, investment casting, plaster mold casting, and permanent mold casting.
3. References are made to keywords and websites for additional information on topics like sand casting and carbon dioxide molding.
The document discusses various properties required for molding materials used in foundries, including refractoriness, permeability, green strength, dry strength, and hot strength. It also describes common molding materials like molding sand and core sand. Several standard tests are outlined to measure properties like moisture content, clay content, grain size, permeability, and strength. Key tests include those for moisture content, clay content, grain size distribution via sieve analysis, permeability, and compression/shear/tensile strengths at different temperatures and moisture levels. The document provides details on how to prepare standardized samples and testing procedures.
This document provides an overview of manufacturing processes and riser design concepts. It discusses solidification of castings, functions of risers, types of risers, and methods for riser design including the Chvorinov rule, modulus method, and NRL method. Examples are provided to demonstrate how to calculate riser dimensions using these methods based on properties of the casting such as volume, surface area, and solidification time.
This document provides information about the MECH 423 - Casting, Welding, Heat Treating and NDT course offered in the Fall 2011 term at Concordia University. The course covers casting processes, welding and brazing techniques, heat treatments, and non-destructive testing. It is aimed at mechanical engineering students to understand how components are shaped and joined, and the effects on material properties. The course involves lectures, labs, assignments, presentations and exams. The instructor is Dr. S. Narayanswamy and it meets on Tuesdays from 5:45-8:15pm in room EV-11.119.
This document presents a thesis submitted to Worcester Polytechnic Institute in partial fulfillment of the requirements for a Master of Science degree in Manufacturing Engineering. The thesis focuses on optimizing gating/riser systems for castings based on CAD and simulation technology to improve casting quality by reducing porosity and incomplete filling. The author develops an optimization framework involving castability analysis, parametric modeling of gating systems, simulation analysis, and optimization of gating/riser designs. The framework is demonstrated on an engine block casting, showing improvements such as an 18% reduction in porosity and a 16% increase in yield.
The document discusses two gating system designs - Design A and Design B - for filling an oil panel. It describes the filling process for each design and provides contact information for the authorized distributor, Auto-Design-Online, including their email, Skype, and website.
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.
This document discusses various molding and casting processes, including:
1. Carbon dioxide molding process, investment casting process, shell molding process, die casting process, full molding process, and vacuum-sealed casting process.
2. It provides details on the steps and advantages/disadvantages of processes like shell molding, investment casting, plaster mold casting, and permanent mold casting.
3. References are made to keywords and websites for additional information on topics like sand casting and carbon dioxide molding.
The document discusses various properties required for molding materials used in foundries, including refractoriness, permeability, green strength, dry strength, and hot strength. It also describes common molding materials like molding sand and core sand. Several standard tests are outlined to measure properties like moisture content, clay content, grain size, permeability, and strength. Key tests include those for moisture content, clay content, grain size distribution via sieve analysis, permeability, and compression/shear/tensile strengths at different temperatures and moisture levels. The document provides details on how to prepare standardized samples and testing procedures.
This document provides an overview of manufacturing processes and riser design concepts. It discusses solidification of castings, functions of risers, types of risers, and methods for riser design including the Chvorinov rule, modulus method, and NRL method. Examples are provided to demonstrate how to calculate riser dimensions using these methods based on properties of the casting such as volume, surface area, and solidification time.
Pattern allowances are extra material added to patterns to account for shrinkage and other factors during the casting process. Patterns are larger than the final casting size. Allowances include shrinkage allowance for metal contraction, machining allowance for finishing, and draft allowance so patterns can be easily removed from molds. Proper allowances and pattern design can reduce defects and costs in metal casting.
This document provides information on various casting processes including expendable mold casting processes like sand casting, shell molding, investment casting, vacuum casting, plaster mold casting and ceramic mold casting. It also discusses permanent mold casting processes such as pressure die casting, squeeze casting, centrifugal casting and continuous casting. Finally, it outlines common defects in casting like shrinkage, porosity, hot tears, blows and warping, and methods to prevent or minimize these defects.
Casting is a process where liquid material is poured into a mold and allowed to solidify. The solidified part that is formed is known as a casting. Casting dates back thousands of years, with early humans casting materials like gold, silver, and copper. The basic casting process of melting material, using patterns to form molds, and allowing the material to solidify has remained the same, though furnace technology, mold materials, and allowed alloys have advanced over time.
Casting is a process where liquid material is poured into a mold and allowed to solidify. It has been used since ancient times to shape metals like gold, silver, and copper according to a desired form. Over time, casting processes evolved with advances in furnace technology, mold materials, and an increased understanding of metallurgy and solidification. Key aspects of casting include the mold design, gating and riser systems to compensate for shrinkage, and allowances for factors like contraction and machining.
Casting involves pouring molten metal into a mold cavity. It solidifies and takes the shape of the cavity. Casting can produce complex shapes easily and is often the most economical manufacturing process. Key factors that influence the casting process include solidification and shrinkage of the metal, flow of molten metal, heat transfer during cooling, and the mold material.
This 4-day course from the Cast Metals Institute provides instruction on gating and riser design for ferrous alloys. Students will learn about fluid flow principles, designing gating systems, heat transfer considerations, solidification of metals, and calculating riser sizes. The course covers functions of risers and gating components, placement and sizing of risers, and gating and riser design experiments. Students will design their own gating and riser systems and observe mold preparation, pouring, and evaluation. Upon completion, students will receive 2.3 continuing education credits.
Pattern allowances are extra material added to patterns to account for shrinkage and other factors during the casting process. Patterns are larger than the final casting size. Allowances include shrinkage allowance for metal contraction, machining allowance for finishing, and draft allowance so patterns can be easily removed from molds. Proper allowances and pattern design can reduce defects and costs in metal casting.
This document provides information on various casting processes including expendable mold casting processes like sand casting, shell molding, investment casting, vacuum casting, plaster mold casting and ceramic mold casting. It also discusses permanent mold casting processes such as pressure die casting, squeeze casting, centrifugal casting and continuous casting. Finally, it outlines common defects in casting like shrinkage, porosity, hot tears, blows and warping, and methods to prevent or minimize these defects.
Casting is a process where liquid material is poured into a mold and allowed to solidify. The solidified part that is formed is known as a casting. Casting dates back thousands of years, with early humans casting materials like gold, silver, and copper. The basic casting process of melting material, using patterns to form molds, and allowing the material to solidify has remained the same, though furnace technology, mold materials, and allowed alloys have advanced over time.
Casting is a process where liquid material is poured into a mold and allowed to solidify. It has been used since ancient times to shape metals like gold, silver, and copper according to a desired form. Over time, casting processes evolved with advances in furnace technology, mold materials, and an increased understanding of metallurgy and solidification. Key aspects of casting include the mold design, gating and riser systems to compensate for shrinkage, and allowances for factors like contraction and machining.
Casting involves pouring molten metal into a mold cavity. It solidifies and takes the shape of the cavity. Casting can produce complex shapes easily and is often the most economical manufacturing process. Key factors that influence the casting process include solidification and shrinkage of the metal, flow of molten metal, heat transfer during cooling, and the mold material.
This 4-day course from the Cast Metals Institute provides instruction on gating and riser design for ferrous alloys. Students will learn about fluid flow principles, designing gating systems, heat transfer considerations, solidification of metals, and calculating riser sizes. The course covers functions of risers and gating components, placement and sizing of risers, and gating and riser design experiments. Students will design their own gating and riser systems and observe mold preparation, pouring, and evaluation. Upon completion, students will receive 2.3 continuing education credits.