MANUFACTURING
PROCESSES
MODUE MODULE
5 6
SHEET METAL POWDER
CASTING FORMING WORKING ASSEMBLY METALLURGY MACHINING
Shearing
Moulding Forging
operations
Soldering Lathe
Sand Forming
Casting
Rolling
operations
Brazing Milling
Die
Casting
Extrusion Welding Drilling
Grinding
Shaper
Planer
Slotter
Casting
Sand casting (closed-mold)
Pouring basin
Cope
Riser
Core
Flask Sprue
Parting Runner
line
Drag Gate
Flask: it is the box that contains the mould cavity
o Drag: lower part of the flask
o Cope: upper part of the flask
Pattern: is a replica of the object to be cast, used to prepare the cavity into
which molten material will be poured during the casting process. Patterns
used in sand casting may be made of wood, metal, plastics or other
materials
Core: made of core sand, used for making holes inside the casing
Pouring basin: reservoir at the top of the sprue that receives molten metal
from the ladle
Sprue: it is a vertical channel that connects the pouring basin with runner.
Runner: runner is generally a horizontal channel, it connects sprue to the
gate, thus allowing molten metal to enter the mould cavity
Gate: it is the opening through which molten metal enters the mould cavity.
Risers: these are reservoirs of molten metal that feed molten metal to the
casting as it solidifies, to prevent shrinkage cavities in the casting.
1. Pick the right flasks for intended pattern.
2. Identify which side of pattern should be on the cope or drag side.
Flasks are always tapered upward and cope is usually taller than drag.
3. Assemble the flasks and pattern. Make sure that the flasks are firmly
locked.
4. Fill sand over the pattern and Ram sand down firmly and
systematically.
5. Add more sand and ram it down until the top surface has been
reached.
6. Scrape the top surface using scraper.
7. In case of venting is needed, use the vent wire to poke the cope few
times.
8. Locate and cut the sprue with appropriate size of sprue cutter.
9. Separate the cope and drag, pull out the pattern and sprue cutter,
blow any loose sand out of the mold cavity. Reassemble the cope and
drag.
10. Take the assembly to the pouring area, release the flasks and put on
the pouring jacket.
1.2 Sand Casting
More than 70% of all casing is by sand casting method.
Sand casting uses natural or synthetic sand which is
mostly a refractory material called silica (SiO2).
The sand grains must be small enough so that it can be
packed densely; however, the grains must be large enough
to allow gasses formed during the metal pouring to escape
through the pores.
Larger sized molds use green sand (mixture of sand, clay
and some water). Sand can be re-used.
The casting procedure:
(a) Preparation of a pattern,
(b) Preparation of a mould with the help of the pattern, by
packing sand around it, inside a flask
(c) Melting of metal or alloy in a furnace,
(d) Pouring of molten metal into mould cavity,
(e) Breaking the mould to get the casting,
(f) Cleaning the casting and cutting off risers, runners etc.,
(this operation is called fettling),
(g) Inspection of casting.
Advantages of Sand Casting:
1) Casting can be used to create external arid internal shapes.
2. Large casting dimensions may be obtained
3. Wide variety of metals and alloys can be casted
Disadvantages of Sand Casting
1) Limitation on mechanical properties
2) Porosity (empty spaces within the metal - reduces the strength of metal)
3) Poor dimensional accuracy and surface finish
4) Safety hazards to humans and environmental problems
Casting Defects:
1) Misruns (due to rapid solidification in the runner)
2) Cold shuts (due to rapid solidification before complete filling of the mold) 3) Cold
shots (due to splattered globules of metal during pouring)
4) Shrinkage cavity (due to lack of riser system)
5) Microporosity (due to localized solidification shrinkage)
6) Hot tearing (due to the die's prevention of contraction)
Die casting
Cold chamber die casting
Cold chamber die casting
Stationary Moving
die die
Molten
metal
Plunger Ejector pins
Sprue
Parting line