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    Solidification Process (Metal Casting: Expendable Mold Casting: Sand Casting)

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    The Noob
    The document discusses the solidification process and sand mold casting. It describes the steps in sand mold casting including mold making. The mold is made of sand and consists of cope, drag, parting line, core, riser, runner, downsprue, and vent holes. Patterns are used to form the mold cavity and come in different types like solid, split, match plate, and cope-and-drag patterns depending on the part geometry and production quantity.

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    Solidification Process (Metal Casting: Expendable Mold Casting: Sand Casting)

    Uploaded by

    The Noob
    53 views29 pages
    The document discusses the solidification process and sand mold casting. It describes the steps in sand mold casting including mold making. The mold is made of sand and consists of cope, drag, parting line, core, riser, runner, downsprue, and vent holes. Patterns are used to form the mold cavity and come in different types like solid, split, match plate, and cope-and-drag patterns depending on the part geometry and production quantity.

    Original Title

    Lecture 02 Solidifictaion Process

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    The document discusses the solidification process and sand mold casting. It describes the steps in sand mold casting including mold making. The mold is made of sand and consists of cope, drag, parting line, core, riser, runner, downsprue, and vent holes. Patterns are used to form the mold cavity and come in different types like solid, split, match plate, and cope-and-drag patterns depending on the part geometry and production quantity.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    53 views29 pages

    Solidification Process (Metal Casting: Expendable Mold Casting: Sand Casting)

    Uploaded by

    The Noob
    The document discusses the solidification process and sand mold casting. It describes the steps in sand mold casting including mold making. The mold is made of sand and consists of cope, drag, parting line, core, riser, runner, downsprue, and vent holes. Patterns are used to form the mold cavity and come in different types like solid, split, match plate, and cope-and-drag patterns depending on the part geometry and production quantity.

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    Solidification Process (Metal Casting:

    Expendable Mold Casting: Sand


    Casting)
    Lecture 02
    Manufacturing Processes
    ME-3401
    Lecture Outline
    • Solidification Process
    and its types
    • Metal Casting and its
    types
    – Permanent Mold
    Casting
    – Expendable Mold
    Casting
    • Sand Mold Casting
    – The Mold
    – Mold Making
    • Mold Material
    • Pattern
    Solidification processes

    Particulate processing
    Shaping processes
    Deformation processes

    Material removal
    Processes
    operations Property enhancing
    Heat treatment
    processes
    Cleaning & surface treatment
    Surface enhancement &
    protection Processes
    Manufacturing Coating and deposition processes
    processes
    Welding
    Permanent joining
    Brazing and soldering
    processes
    Assembly Adhesive bonding
    operations
    Threaded fasteners
    Mechanical fastening
    Permanent fastening methods
    Shaping Processes
    • Most shape processing operations apply heat, mechanical
    force, or a combination of these to effect a change in
    geometry of the work material. There are various ways to
    classify the shaping processes.
    Solidification Process
    Solidification processes exploit the properties of a liquid as it
    flows into and assumes the shape of a prepared hollow
    container with a cavity of required shape; and then solidified
    into the cavity shape upon cooling.
    Solidification Processes
    Melting Process

    Pouring Cleaning

    Hollow
    Container Solidification Removal Part
    Making

    1) Metals 2) Ceramic 3) Plastics


    Glasses
    Classification of Solidification Processes
    Sand Casting
    Expendable
    Mold Casting
    Other Casting
    Metal Casting
    Processes
    Permanent
    Mold Casting
    Solidification Glass working Extrusion and
    Processes Related
    Molding Casting /
    Processing of Injection Molding
    Polymers Molding ???
    Other Molding
    Processes
    Metal Casting
    • Metal is melted, heated to a proper temperature.
    • Molten Metal is then poured, either by gravity or other forces,
    into a hollow container having a cavity of the required shape.
    • The container then holds it in the cavity shape during cool-
    down and solidification.
    Metal Casting Mold
    Mold:
    A hollow container having a cavity of the
    required shape used to give shape to molten
    or hot liquid material.
    Types of Mold based on Cavity
    1.Open Mold: Mold having a open cavity
    2.Closed Mold: Mold having the closed cavity
    Types of Molds (Based on Mold Reusability)

    Permanent Mold Expendable Mold

    “Mold can be used over and “Mold must be destroyed


    over to produce many when the molten metal
    castings” solidifies to remove the casted
    part.”
    Permanent Mold Casting
    In Permanent Mold Casting Operations, the mold is
    made up of a durable material and thus can be used
    many times to make many castings.

    • Can manufacture many metal castings


    • Mold has sections that can open or close, permitting
    removal of the casting
    Expendable Mold Casting
    In Expendable Mold Casting Operations, the mold must
    be sacrificed in order to remove the casted part.

    • Can produce one metal casting only


    • Mold that metal solidifies in, must be destroyed to
    remove casting
    • More intricate geometries are possible for casting
    Expendable Mold Casting Processes
    1.Sand Mold Casting
    2.Shell Molding
    3.Vacuum Molding
    4.Plaster-Mold and Ceramic-Mold Casting.
    5.Expended polystyrene Process
    6.Investment Casting
    Sand Mold Casting
    • Consists of pouring molten metal into a sand mold
    • Allowing the metal to solidify, and then breaking up
    the mold to remove the casting.
    • The cavity in the sand mold is formed by packing
    sand around a pattern (an approximate duplicate of
    the part to be cast)
    • Removing the pattern by separating the mold into two
    halves.
    Steps in the production sequence in sand casting. The
    steps include not only the casting operation but also
    pattern making and mold making.
    Sand Mold Casting
    (The Mold)
    Sand Mold Casting
    (The Mold)
    Cope:
    The upper half of the mold is called cope
    Drag:
    The bottom half of the mold is called drag
    Flask:
    The box or container which hold cope and drag. Flask is also
    divided into cope-flask and the drag-flask
    Parting Line:
    The two halves of the mold separate at the parting line
    Sand Mold Casting
    (The Mold)
    Core The core is placed inside the mold cavity to define the
    interior geometry of the cast part.

    Riser The riser is a reservoir in the mold that serves as a


    source of liquid metal for the casting to compensate for
    shrinkage during solidification
    Sand Mold Casting
    (The Mold)
    Runner Runner is the channel or network of channels through
    which the molten metal flows inside the mold to reach the
    cavity.

    Downsprew The entrance for the molten metal to flow inside.

    Pouring Cup Pouring cup minimize splash and turbulence as


    the metal flows into the downsprew
    Sand Mold Casting
    (The Mold)
    Gating System The gating system consist of pouring cup,
    downsprew, runner and riser.

    Vent Holes: Provide escape route for the trapped air or hot
    gases from inside the mold.
    Sand Mold Casting Video
    Sand Mold Casting
    (Mold Making)
    Patterns
    • Pattern is a full sized model of the part, enlarged to account for
    shrinkage and machining allowances in the final casting.
    • In Sand Mold Casting (and other expendable mold processes),
    the mold cavity is formed by means of a pattern.
    • The cavity is formed by packing sand around the pattern, about
    half way each in the cope and drag, so that when the pattern is
    removed, the remaining void has the desired shape of the cast
    part.
    • Made from wood, metal, plastic or any other such material.
    Types of Patterns
    • Solid Patterns
    • Split Patterns
    • match-plate
    • Cope and drag Patterns
    Solid Patterns
    • This is the simplest type of pattern,
    exactly like the desired casting.
    • For making a mould, the pattern is
    accommodated either in cope or drag.
    • Used for producing a few
    large castings, for example, stuffing
    box of steam engine.
    • solid patterns are generally limited to
    very low production quantities.
    Split Patterns
    • These patterns are split along the parting plane
    (which may be flat or irregular surface).
    • The parting line of the mold is predetermined
    by the two pattern halves, rather than by
    operator judgment.
    • Split patterns are appropriate for complex part
    geometries and moderate production
    quantities.
    • For a more complex casting, the pattern may
    be split in more than two parts.
    Match Plate Patterns
    • A match plate pattern is a split pattern
    having the cope and drags
    portions mounted on opposite sides of a
    plate (usually metallic), called the "match
    plate" that conforms to the contour of the
    parting surface.
    • The gates and runners are also mounted on
    the match plate, so that very little hand work
    is required.
    • This results in higher productivity. This type
    of pattern is used for a large number
    of castings.
    Cope-and-drag Patterns
    • A cope and drag pattern is a
    split pattern having the cope
    and drag portions each mounted
    on separate match plates.
    • These patterns are used when
    in the production of
    large castings;
    • The complete moulds are too
    heavy and unwieldy to
    be handled by a single worker.
    Sand Mold Casting
    (Mold Making)
    Types of Patterns

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