15/7/2014
Diploma in Mechanical Engineering (Material)
JF 302 MATERIAL TECHNOLOGY 1
[Link]
CLO 2 : Synthesis course knowledge into an effective
course assignment and present technical findings
both orally and in writing.
Week 7
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cold work
Understand cold work
CASTING
PROCESS
Understand hot work
Describe the casting process
Describe the heat treatment of steels
peneraju ilmu sejagat
cold work
CASTING
PROCESS
hot work
casting process
casting process
Heat treatment of steels
Principle of Operation:
Metal or alloy is heated above its melting point and
pouring the molten metal/alloy in cavity
approximately of same shape and size as the
machine part.
After the molten metal/alloy cools and solidifies, it
acquires the shape and size of the cavity and
resembles the finished product required.
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Heat treatment of steels
Purposes of casting process:
A large number of metal components in designs we
use every day are made by casting. The reasons
for this include:
a. Casting can produce very complex geometry
parts with internal cavities and hallow sections
b. It can be used to make small to very large size
of parts
c. It is economical, with vey little wastage. The
extra metal in each casting is re-melted and reused
d. Cast metal is isotropic. It has the same
physical/ mechanical properties along any
direction.
peneraju ilmu sejagat
hot work
cold work
CASTING
PROCESS
hot work
casting process
Heat treatment of steels
Types of casting processes:
a. Sand casting
b. Shell moulding
c. Investment casting, etc.
peneraju ilmu sejagat
15/7/2014
cold work
SAND
CASTING
hot work
casting process
Heat treatment of steels
Principle of Operation:
It is a metal casting process characterized by using
sand as the mould material.
There are six steps in this process:
i. place a pattern in sand to create a mould
ii. incorporate the pattern and sand in a gating
system
iii. remove the pattern
iv. fill the mould cavity with molten metal
v. allow the metal to cool
vi. break away the sand mould and remove the
casting
cold work
SAND
CASTING
hot work
casting process
Heat treatment of steels
Think critically 3.4
cold work
casting process
Advantages:
a. low capital investment
b. use of sand cores allows complex shapes to be cast
c. small to large size of components can be produced
d. Less wastage as the extra metal can be re-used
hot work
casting process
Heat treatment of steels
What are the extra metals to be cut
off from final product of casting ?
peneraju ilmu sejagat
hot work
Heat treatment of steels
peneraju ilmu sejagat
What are the extra metals to be cut
off from final product of casting ?
cold work
casting process
Disadvantages:
a. high labour intensive and time consuming
b. sand mould leaves bad surface finish, due to sand
indentation and oxidizing medium, which often requires
further processing
c. not suitable for mass production, often used to produce
few number of products compared with other casting
processes which produce thousands and millions
d. bad dimensional accuracy
peneraju ilmu sejagat
cold work
hot work
Think critically 3.4
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Heat treatment of steels
SHELL
MOULDING
cold work
hot work
casting process
Heat treatment of steels
SHELL
MOULDING
Principle of Operation:
1. The 2-piece pattern is made of metal (e.g.
aluminium or steel), it is heated to between
175C-370C, and coated with a lubricant, e.g.
silicone spray.
2. Pattern and dump box are rotated.
Principle of Operation:
3. Each heated half-pattern is covered with a
mixture of sand and a thermosetting resin/epoxy
binder. The binder glues a layer of sand to the
pattern, forming a shell.
4. The assembly is baked to cure.
peneraju ilmu sejagat
peneraju ilmu sejagat
15/7/2014
cold work
hot work
casting process
Heat treatment of steels
SHELL
MOULDING
cold work
hot work
SHELL
MOULDING
Disadvantages:
a. more expensive metal pattern
b. difficult to justify for small quantities
peneraju ilmu sejagat
hot work
casting process
peneraju ilmu sejagat
Heat treatment of steels
cold work
hot work
INVESTMENT
CASTING
INVESTMENT
CASTING
Principle of Operation:
Principle of Operation:
peneraju ilmu sejagat
cold work
hot work
casting process
casting process
Heat treatment of steels
peneraju ilmu sejagat
Heat treatment of steels
cold work
hot work
INVESTMENT
CASTING
INVESTMENT
CASTING
Principle of Operation:
Principle of Operation:
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Heat treatment of steels
Advantages:
a. smoother cavity surface permits easier flow of molten
metal and better surface finish
b. good dimensional accuracy
c. mould collapsibility minimizes cracks in casting
d. can be mechanized for mass production
Principle of Operation:
5. The patterns are removed, and the two halfshells joined together to form the mould.
6. Molten metal is poured into the mould. When the
metal solidifies, the shell is broken to get the
part.
cold work
casting process
casting process
Heat treatment of steels
peneraju ilmu sejagat
15/7/2014
cold work
hot work
casting process
Heat treatment of steels
cold work
hot work
casting process
Heat treatment of steels
INVESTMENT
CASTING
Advantages:
a. parts of great complexity and intricacy can be cast
b. close dimensional control and good surface finish
c. wax can usually be recovered for re-use
d. additional machining is not required.
List FIVE (5) tools used in sand casting:
Disadvantages:
a. many processing steps are required
b. relatively expensive process
peneraju ilmu sejagat
cold work
hot work
casting process
peneraju ilmu sejagat
Heat treatment of steels
List FIVE (5) tools used in sand casting:
a.
b.
c.
d.
e.
f.
g.
h.
i.
Moulding flask
Strip bar
Ladle
Gate cutter
Rammer
Vent rod
Sprue
Core
Pattern
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