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Introduction to casting processes by stead fast engineers pvt ltd – part 2
- 1. Introduction To Casting Processes by Stead Fast Engineers Pvt Ltd – part 2 one of the leading Induction heating system manufactures
- 2. Design, Materials and Economics
- 3. Design Considerations in Casting • Design of the part • Casting process and material • Locate parting line • Locate design gates • Locate mold features such as sprue, screens and risers
- 4. Design Consideration of Cast Parts • Corners, angles, section thickness – Avoid sharp corners angles and fillets – Stress raisers, cracking, and tearing – Sections should be blended smoothly
- 5. Design Consideration of Cast Parts
- 6. Design Consideration of Cast Parts • Flat Areas – Large flat areas may warp during cooling – Poor surface finish from uneven flow in pouring – Resolve with ribs, and serrations • Circles and Rounds – Lower cooling rate in circles induces hot spots – Shrinkage cavities and porosity
- 7. Design Consideration of Cast Parts • Shrinkage – to avoid cracking during the cooling process there should be shrinkage allowance – Staggered ribs, change the intersection geometry • Patternmaker’s Shrinkage Allowance – 10-20 mm/m
- 8. Design Consideration of Cast Parts • Draft – Used to enable easy removal of pattern without damage to mold – Range from 5 to 15mm/m – Angles of 0.5° to 2° • Dimensional Tolerances – As wide as possible within limits of good performance – Letters and markings
- 9. Locating the Part Line • Part line – separates upper and lower mold – Flat plane, along corners or edges – This will avoid flash at the parting lines
- 10. Locating and Designing Gates • Gates – Connections between runners and the part – Multiple gates preferred – Feed into thick sections of the castings • Runners – Distribution channel for molten metal from the sprue into the gates
- 11. Casting Alloys • Nonferrous Alloys – Aluminum, magnesium, copper, zinc, tin, lead – Good electrical conductivity and resistant to corrosion – Most of these alloys share characteristics of good machinability and can all be welded
- 12. Casting Alloys • Ferrous alloys – Cast irons • Largest quantity of all metals cast • Good wear resistance, hardness and machinability – Cast Steels • Material used under extreme heat conditions • Railroad, mining and construction
- 13. Casting Economics • Cost – Depends on materials, equipment, and labor – Preparations require raw materials, time and effort – Melting, pouring, heating, cleaning, inspections – Equipment cost lowers with large # of castings – Solutions to alleviate unneeded cost are being looked into • Rapid prototyping
- 15. Solidification
- 18. Pinholes
- 19. Blowhole
- 20. Scab
- 21. Pinholes
- 22. Rough Surface
- 23. Thank you…