Casting
Metal Casting History (India)
3000 BC Earliest castings include the 11 cm high bronze
dancing girl found at Mohen-jo-daro.
2000 BC Iron pillars, arrows, hooks, nails, bowls and daggers or
earlier have been found in Delhi, Ropar, Nashik and other
places.
500 BC Large scale state-owned mints and jewelry units, and
processes of metal extraction and alloying have been mentioned
in Kautilya's Arthashastra
500 A.D. Cast crucible steel is first produced in India, but the
process is lost until 1750, when Benjamin Huntsman reinvents it
in England
Metal casting is a shape obtained by pouring liquid metal into a
mould or cavity, allowing it to freeze and thus take the form of the
mould.
Course objective: The objective of this course is to
introduce metal processing techniques i.e. Casting,
Welding and Forming
Learning objectives
The student will be able to;
Apply knowledge of solidification to casting process
Design of different parts of casting
Emphasis of the course will be on fundamentals and principles
i.e. On Why? instead of How?
Syllabus
1. Application and advantages of metal
casting processes
2. Mould and Core Making: Ingredients: sand,
clay, binders, and moisture,
3. Gating and Risering: Various component of gating system,
types of gates, principle and practice of gating and risering for
various metals and alloys, methods for directional solidification,
plane front vs denderitic solidification, and concept of
constitutional supercooling .
4. Casting Defects Causes and Remedies: Defects arise due to
pattern, molding sand, and due to improper designing of the
gating system viz lap, scab, rattail, pipe, and porosity.
Textbook:
Fundamentals of Metal Casting, Richard A. Flinn, Addison-Wesley
Publishing Company, Inc. 1963
“Fundamentals of Welding” Welding Handbook, 7th Edition, Vol. 1,
American Welding Society, 1981
Manufacturing Science II edition, Amitabh Ghosh and Asok Kumar Mallik,
EWP, New Delhi, 2010.
Manufacturing Technology Vol-1 III Edition, P. N. Rao, Tata McGraw Hill,
New Delhi, 2010.
References:
Heine, R.W., Loper C.R. and Rosenthal, P.C. "Principles of Metal
Casting ", Tata McGraw-Hill; 2002
Mukhrjee, P.C., "Fundamentals of Metal Casting technology", Oxford and
IBH Publishinh Company; 1996
"Welding and Brazing ", Metals Handbook, Vol. 6, ASM; 1996
Parmar, R.S., "Welding Engineering and Technology", Khanna
Publishers; 2002
Websites:
Casting
[Link]
[Link]
[Link]
[Link]
[Link]
FACTURING-PROCESSES/[Link]
(for welding also)
Good sites for lot of stuff –
[Link]
[Link]
Database on websites is not exhaustive, you are encouraged to explore
more and bring it to notice of the class.
Sand casting
Advantages
Any intricate shape can be casted in one step
Any material – ferrous or nonferrous can be casted
Disadvantages
Dimensional accuracy and surface finish is inadequate
Applications
Cylinder blocks
Liners
Machine tool beds
Pistons
Piston rings
Mill rolls
Wheels
Bells
Casting terms
Flask: A moulding flask holds
the sand mould intact
Cope: Upper moulding flask
Drag: Lower moulding flask
Cheek: Intermediate moulding
flask
Pattern: Pattern is replica of the final object
Parting line: This is the dividng line between the two moulding flask
In split pattern it is dividing line between the two halves of the pattern
Bottom board: Wooden board to support the mould
Casting terms
Facing sand: Fine carbonaceous material sprinkled on the inner
surface of the mould cavity for a better surface finish
Moulding sand: Freshly prepared refractory material used for making
mould cavity. A mixture of silica, clay, and moisture.
Core: is used for making hollow cavities in the castings
Casting terms
Pouring basin: A small funnel shaped cavity at the top of the mould
into which molten metal is poured.
Sprue: The passage through which the molten metal from the pouring
basin reaches the mould cavity.
Runner: The passageway in the parting plane through which molten
metal flow
Casting terms
Gate: The actual entry point through which molten metal enters the
mould cavity.
Chaplet: used to support core.
Chill: Chills are metallic objects, placed in the mould to increase
cooling rate
Riser: a reservoir of molten metal to take care of shrinkage of the
casting during cooling.