Scribd Logo
Upload

Welcome to Scribd!

  • 73 views

    Lecture04 - Casting Processes

    Uploaded by

    berhane
    The document summarizes various metal casting processes. It discusses how casting involves pouring molten metal into a mold where it solidifies. The main steps are preparing the mold, melting the metal, pouring it in, letting it solidify, and finishing. Casting allows producing parts with complex shapes and internal features economically. The document classifies casting by mold type and filling condition and describes processes like sand casting, investment casting, permanent mold casting, centrifugal casting, and die casting. It discusses the science behind melting metals, fluid flow of molten metal, solidification of alloys, and calculating solidification time.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    Lecture04 - Casting Processes

    Uploaded by

    berhane
    73 views33 pages
    The document summarizes various metal casting processes. It discusses how casting involves pouring molten metal into a mold where it solidifies. The main steps are preparing the mold, melting the metal, pouring it in, letting it solidify, and finishing. Casting allows producing parts with complex shapes and internal features economically. The document classifies casting by mold type and filling condition and describes processes like sand casting, investment casting, permanent mold casting, centrifugal casting, and die casting. It discusses the science behind melting metals, fluid flow of molten metal, solidification of alloys, and calculating solidification time.

    Original Title

    lecture04 - Casting processes

    Copyright

    © © All Rights Reserved

    Available Formats

    PPT, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document summarizes various metal casting processes. It discusses how casting involves pouring molten metal into a mold where it solidifies. The main steps are preparing the mold, melting the metal, pouring it in, letting it solidify, and finishing. Casting allows producing parts with complex shapes and internal features economically. The document classifies casting by mold type and filling condition and describes processes like sand casting, investment casting, permanent mold casting, centrifugal casting, and die casting. It discusses the science behind melting metals, fluid flow of molten metal, solidification of alloys, and calculating solidification time.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    73 views33 pages

    Lecture04 - Casting Processes

    Uploaded by

    berhane
    The document summarizes various metal casting processes. It discusses how casting involves pouring molten metal into a mold where it solidifies. The main steps are preparing the mold, melting the metal, pouring it in, letting it solidify, and finishing. Casting allows producing parts with complex shapes and internal features economically. The document classifies casting by mold type and filling condition and describes processes like sand casting, investment casting, permanent mold casting, centrifugal casting, and die casting. It discusses the science behind melting metals, fluid flow of molten metal, solidification of alloys, and calculating solidification time.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 33

    Metal casting processes

    Introduction
    • Casting – Verb (process) ‫ ׀‬Noun (product)
    • Casting is a process in which molten metal is
    poured into a suitably shaped mold where it
    solidifies in the shape of the mold cavity.
    Introduction (cont.)
    • Steps in casting - Prepare mould/die; Melt the metal;
    Pouring melt into a mould/die; Let it solidify; Finishing
    processes

    as-cast after machining.


    Introduction (cont.)
    • Advantages: Economical production of
    parts with:
    – Complex shapes (e.g. Engine block, statues etc.)
    – Intricate holes and internal features
    – No limit to size - wide variety of Size or weight (e.g.
    dental crowns, jewelry)
    – Any metal
    – Difficult to machine metals
    – Net shape or near net shape
    Classification of casting process
    • By type of mold
    – Expendable (ex. Sand) – for high melting point
    metals
    • Sand casting, investment casting, etc
    • Expendable sand mold is created by packing sand around a
    pattern
    – Permanent (ex. steel) – for low melting point metals
    • Permanent mold casting, die casting, centrifugal casting
    • Created by machining from a metal block
    Classification of casting process (cont.)

    • Filling condition
    – Mold filling under
    • Gravity
    • Pressure: low ‫ ׀‬high
    – Mold temperature
    • Ambient
    • Warm
    • hot
    Sand casting
    Sand casting (cont.)
    Investment casting
    Permanent mold casting
    Centrifugal casting
    Die casting
    Continuous casting
    Analysis
    • Similarities between metal casting
    – Metal alloy is melted
    – Poured or forced into a mold
    – Cools and solidifies
    – Takes the shape of the mold
    – Some require finishing (appearance, tolerance,
    surface finish)
    – Wide choice of alloys available BUT
    • not all alloys can be cast by all processes
    Analysis
    • Melt metals
    • Pouring/ molten metal flow into mold
    cavity
    • Cool / Solidify
    • Remove
    • Finish
    Melting
    • Raw material (charge)
    – scrap, alloying materials
    • •Atmosphere
    – Air (oxygen), vacuum, inert gas
    (argon)
    • Heating
    – External - electric, gas, oil
    – Internal - induction, mix fuel
    with charge
    • Furnace material
    – refractory ceramics
    Heat

    – H = heat [J]
    –  density
    – V = volume
    – c = specific heat (s = solid, l = liquid)
    – Hf = heat of fusion
    Melting time
    • Estimate by (take into account oven efficiency):

    • Given Density = 2700 kg/m3, melting point = 660oC, heat


    of fusion = 396 kJ/kg, specific heat of liquid = 1.05 kJ/kg-
    K, specific heat of solid = 0.9 kJ/kg-K of aluminum,
    calculate the time required to raise the temperature of a
    120 kg aluminum billet from 20oC to 50oC above its
    melting point using a 20 kW furnace that is 75% efficient.
    Melting time (cont.)
    H = 120 * [0.9 * (660-20) + 396 + 1.05 * (710 – 660)] = 123 MJ
    = 1.17 x 105 BTU

    time = 123 MJ / (20 kW * 75%) = 2.3 hours

    •Should probably buy a bigger furnace


    Pouring temperature
    Pouring - Fluid Flow
    • Bernoulli’s equation
    • Reynold’s number
    • Continuity
    Bernoulli’s equation - Molten
    Metal Flow
    • Bernoulli’s Theorem – the sum of energies (head,
    pressure, kinetic, and friction) at any two points in a
    flowing liquid are equal
    • Used to calculate flow velocities
    • Assumptions: steady state, incompressible, inviscid flow
    p1 v12 p2 v22
    h1    h2   F
     2g  2g
    where, h = head (cm); p = pressure (N/cm2);
    ρ = density(g/cm3); v = velocity (cm/s);
    g = gravity (981 cm/s2); F = head loss due to friction (cm)
    Reynolds number
    • Reynold’s number, Re = fluid inertial forces/fluid viscous
    forces
    • A 4 variable function
    – Velocity
    – Geometry of flow
    – Dynamic viscosity (resistance to flow)
    – Density
    2rV
    Re 

    Renold’s number (cont.)
    • Critical Reynold’s number
    – Re < 2,000
    • viscosity dominated, laminar flow
    – Re > 20,000
    • inertia dominated, turbulent flow
    • Controlled through gate and runner design
    Continuity
    • Continuity of Flow Law – volume rate of flow is
    constant:
    Q  v1 A1  v2 A2
    where Q = volumetric flow rate (cm3/s)

    • Time to fill a mold cavity:


    V Vvolumeofmold
    TMF  
    Q Agate v gate
    Pouring example
    • The height of a downsprue is 10cm, cross-sectional area at
    the bottom is 2cm2 (dia.= 1.6cm), at the top 4cm2 (dia.=
    2.25cm), and the area of pouring cup is 38.5cm2 (dia.=
    7cm)
    – What is the velocity at the bottom of the downsprue?
    V  2 gh  2(981cm / s 2 )(10cm)  140cm / s

    – What is the volume flow rate?


    Q  V2 A2  140cm / s * 2cm 2  280cm3 / s

    – What is the velocity at the top of the downsprue?


    Q  V1 A1  V1  Q
    3
     280cm / s  70cm / s
    A1 4cm 2
    Pouring example
    Given
    – height of sprue (ht) = 20 cm
    – area of sprue (A3) = 2.5 cm2
    – volume of mold cavity (V) = 1560 cm3
    Find
    – vsprue
    – Flow rate (Q)
    – Mold filling time
    Solidification of Metals

    • Transformation of molten metal back into solid


    state. Solidification differs depending on whether
    the metal is:
    – A pure element or
    – An alloy
    Cooling Curve for a Pure Metal
    Solidification of Alloys
    • Most alloys freeze over a temperature range rather than at a single
    temperature

    Phase diagram and cooling curve for 50%Ni‑50%Cu


    Solidification Time
    • TTS depends on size and shape of casting by
    relationship known as Chvorinov's Rule
    n
    V 
    TTS  Cm  
     A
    where TTS = total solidification time;
    V = volume of the casting;
    A = surface area of casting;
    n = exponent with typical value = 2;
    Cm = mold constant (determined experimentally)
    Exercise - Solidification time
    • Given: Disk diameter D = 500 mm thickness t = 20 mm.
    • Material: Al, Cm = 2.0 sec/mm2 in Chvorinov's Rule,
    • Find: solidification time

    n
    V 
    TTS  Cm  
     A
    Thank you for your attention

    You might also like