Finishedproduct.ppt

2.008 Metal Casting Reading: Kalpakjian pp. 239-316 Outline Introduction Process Constraints Green Sand Casting Other Processes Some Facts First casting: 5000-3000 BC Bronze, iron age, light metal age? Versatility Many types of metals Rapid production Wide range of shapes and sizes Complex parts as an integral unit Example – Sand Casting Example – Die Casting Example – Investment Casting Casting Process Physics and Constraints Phase Change Density Solubility Diffusion rates High melting temperature Chemical activity High latent heat Handling Analysis of Casting Processes Fluid mechanics for mold filling Heat transfer for solidification Thermodynamics, mass transfer and heat transfer for nucleation and growth Materials behavior for structure-property relationships Mold Filling Cooling for Sand Mold Conductivity / Diffusivity Solidification Time : Sand Casting Solidification Time : Die Casting Comparison:Sand Mold vs Metal Mold Microstructure Formation Formation of Dendrites Constitutional Supercooling Green Sand Casting Green Sand Mold Pattern Design Considerations (DFM) Shrinkage allowance Machining allowance Distortion allowance Parting line Draft angle Typical Shrinkage Allowance Typical Pattern Machining Allowance Gating System: Sprue, Runner, and Gate Rapid mold filling Minimizing turbulence Avoiding erosion Removing inclusions Controlled flow and thermal conditions Minimizing scrap and secondary operations Riser: Location and Size Casting shrinkage Directional solidification Scrap and secondary operation Progressive Solidification in Riser Draft in Pattern Investment Casting Investment Casting (cont.) Advantages of Investment Casting Intricate geometry Close dimensional tolerance Superior surface finish High-melting point alloys Die Casting Advantages of Die Casting High production rates Closer dimensional tolerances Superior surface finish Improved mechanical properties Lost Foam Casting Lost Foam Casting Advantages of Lost Foam Casting No parting line No