Sand Casting - Engineering Materials.PPTVIP

HOME ASSIGNMENT PART II SAND CASTING Sunil Sutar MTech (Design Engineering) M P Gururajan Assistant Professor Applied Mechanics Department Presented to- Prepared By- Different Components…Different Aspects Small Simple Big Complex Courtesy: Google images 23 feet, 6 tonnes , 99.72% iron, No rust since 5th century AD Iron pillar Casting Casting = Pattern making + Mold making + Pouring Molten Metal + Cooling + Removal + Inspection Types of Casting : Expendable Mold, Multiple Use Mold Sand Casting : Expendable Mold casting process uses sand as molding material Casting Terminology Parting line Courtesy: efunda Pattern Making What is pattern? Approximate duplicate of product Pattern material: Wood, Metals, Urethanes etc. Types of Patterns: One Piece or solid pattern, Split Pattern, Match-plate pattern, Drag Cope Pattern Allowances: Shrinkage, Machining, Draft, Distortion Pattern Making One piece or Solid Pattern Cope Drag Pattern Match Plate Pattern Split Pattern Mold Making Consists : Sand Preparation and Mold Making Sand Properties : Refractoriness, Cohesiveness, Permeability, Collapsibility How to get these properties? Mold Making Methods: Hand Ramming, Sand Slinger, Jolting, Squeezing, Combination Pouring Pouring System: Pouring cup/Basin: Rectangular Shape-No vortex-No suction of Gases Sprue: Short-Less KE –Less turbulence-Tapered shape Sprue Well : Dissipate KE-Prevent splashing –less turbulence Pouring Need : Directional Solidification Feeding molten metal to compensate for solidification shrinkage Criteria: Riser should solidify after the casting. Types: Riser Image Courtesy: wiki Cooling/Solidification Cooling Curve for a Pure Metal: Pouring Temp.: Temp of first liquid entering Mold cavity Start of Solidification End of Solidification Alloy-Distinct M.P.-freezing range High Cooling Rate-fine structures-good mechanical properties Chvorino’s rule : ts=B(V/A)n B=Mold constant n=1.5 to 2 Effect