Experiment :3

AIM: Demonstration of Various Casting Processes.

Competency and Practical Skills:
1. Learning of various casting processes
2. Understand the basic terminology Casting
3. Selection of casting process as per requirement/application.

Relevance CO :
CO-1 (Interpret foundry practices like pattern making, mold making, Core
making and Inspection of defects.)
Objectives:
1. Understanding the basics of casting process
2. Understanding the types of casting processes
3. Learn the advantages and disadvantages of casting process.

 TYPES OF CASTING PROCESSES

With advancement in technology different casting processes have been developed. Shell
moulding, centrifugal casting, die casting, investment casting, magnetic casting, vacuum
casting.
 CENTRIFUGAL CASTING PROCESS
In the centrifugal casting process molten metal is poured into mould while the latter are
revolving. The metal falling into the center of the mould at the axis of its rotation is whirled
out by the centrifugal force towards the periphery and the impurities being lighter in weight
are left behind at the center.
[Due to the application of centrifugal force, the casting are completed free from any porosity
defect, denseness and strength, these castings have been proved as strong as similar forgings.]
 Figure: Centrifugal casting

Different methods of centrifugal casting

TRUE CENTRIFUGAL CASTING: -
In this process, axis of rotation and of casting is same. The axis may be horizontal, vertical or
inclined at any suitable angle. The metal is poured and internal shape is produced by under the
action of centrifugal force. The metal solidifies, forming a hollow casting without the use of a
central core. To prevent the metal from escaping at the ends ‘end cores’ are used.
Method is ideal for hollow cylindrical castings, such as bushings, gun barrels, cast iron pipes
and hollow propeller shaft.

SEMI CENTRIFUGAL CASTING: -

This method is employed for making large sized castings which are symmetrical about their
own axis for example pulleys, spoke or disked wheels, gear and propellers. While the mould
rotates about a vertical axis in a properly balanced state, the metal is poured into a central sprue
from where it first enters the hub and then is forced outwards to the rim by centrifugal force.

CENTRIFUG CASTING: -
When a group of small moulds are arranged in a circle (to balance each other) around the central
axis of the flask, connected by gates to a common sprue and flask is rotated about the vertical
axis the process is called “centrifuge casting”.
The axis of castings and axis of rotation do not coincide with one another. Method is applied
for in casting of plugs, valve bodies, valve bonnets, pillow blocks.

 INVESTMENT CASTING
Investment casting also called the lost wax process or precision casting process uses a
pattern of an expendable material, such as wax or polystyrene. The mould called “investment”
is prepared by surrounding the pattern with refractory slurry that can set at room temperature.
The mould is then heated so that the pattern melts and flows out, leaving a clean cavity behind.
Heating further hardens the mould and the molten metal is then poured while it is still hot.
When casting is solidified the mould is broken to take out the casting.
Investments castings produced by this process have a good surface finish and are exact
reproduction of the master pattern. This method is used for casting turbine blades, parts of
motorcar, sewing machines, typewriters and calculating machines, costume jewellery, dentures
and special metal implants for orthopedic surgery, parts for food and beverage machinery.

Figure: Steps of investment casting process.

 DIE CASITNG
In die casting process, molten metal is forced by pressure into a metal die or mould. The
dies or mould are of split type. After solidification, the casting is removed by disassembling of
dies. The die-casting is used for small size and mass production because initial cost is very
high. Die casting gives good surface finish and close dimensional accuracy.
Die-casting is basically of two types:
1. Gravity die-casting
2. Pressure die-casting
Again Pressure die-casting is subdivided in two;
1. Hot chamber die-casting]
a. Submerged plunger die-casting
b. Air blown or Goose neck die-casting
2. Cold chamber die-casting

ADVANTAGES OF DIE-CASTING

1. Very high rate of production is possible at low cost.

2. Close dimensional tolerances of the order of  0.025 mm
3. Surface finish is high i.e. about 0.8 microns.
4. No machining is required so it saves machining cost and material
5. Complex shapes and the fine details can be produced in castings.
6. Casting defects are minimum, strong dense metal structure is possible
7. Less floor space is required as compared to sand mould casting for the same scale of
production.

LIMITATIONS OF DIE-CASTING
1. High initial cost of equipment and dies so it is suitable for mass production work only.
Minimum economical quantity is considered to be about 20,000 pieces of same product.
2. There is a rapid decrease in the life of dies due to molten metal temperatures.
3. There is a limitation to the size of product produced by die casting due to limitation in
the size of the dies and die-casting.
4. Castings usually contain some porosity due to entrapping of air in the dies.
5. Die-casting has been limited to non-ferrous metals and alloys.

 SHELL MOULDING
Shell moulding is a process in which the mould is formed from a mixture of sand and
thermosetting resin as binder. This mixture is placed against a heated metal pattern. When the
mixture is heated in this manner, the resin cures, causing the sand grains to adhere to each other
forming sturdy shell that conforms exactly to the dimensions and shape of the pattern and
constitutes half of a mould. It way another half is made and these two halves are assembled
together to prepare complete mould. Following are the advantages of shell moulding,
1. Close tolerances 0.2 mm to 0.5 mm in the dimensions of products can be obtained.
2. There is low cleaning cost
3. Smoother surface is obtained

4. Very little skill is necessary on the molders part unskilled labour can be used.
5. Moulding sand requirement is lower than green sand casting.
6. Greater production to automatic production.

 VACUUM MOULDING
In this process, the use of binder is eliminated in moulding sand. The ordinary silica sand,
in special moulding boxes, special pattern and vacuum pump are used to make a mould by
vacuum.
A thin plastic sheet on top of the specially designed hollow pattern is used. The sheet is drawn
tightly by creating vacuum in the hollow pattern by sucking out air as shown in fig. The
vacuum-moulding box (cope) is placed on top of the above pattern. Moulding sand is properly
filled along with gating system. A second sheet is placed on top of the above moulding box
and vacuum is created in the mould by sucking out the air. Due to this moulding sand gets
consolidated. Similarly, the drag could be prepared.

Advantages of vacuum moulding,

1. Castings are free from air and moisture related defects.
2. No binders are used. This has many advantages.
3. Cost of binder eliminated.
4. No fumes are generated due to burning of binders.
5. The moulding sand may be reused again and again.
Disadvantages of vacuum moulding,
1. This process needs special skills
2. Special patterns are to be proposed
3. Special moulding box and vacuum system is needed to be installed.
  MAGNETIC MOULDING
In this process iron powder is used along with the moulding sand. This mixture filled
over the pattern. On application of magnetic field mixture takes up the contour of pattern.
Pattern is removed thus mould is created. During the pouring of molten metal magnetic field
is kept in action to retain mould cavity. After metal solidifies magnetic field is switched off
and sand collapses. Again the cycle is repeated with the same moulding mixture.
 TYPES OF CASTING METALS
Classification of casting metal is describe as under
A. Ferrous metal
B. Non-ferrous metal
FERROUS METAL: -
1. Cast iron
a. Grey cast iron
b. Malleable cast iron
c. Nodular cast iron
d. White cast iron
2. Steel
a. Plain carbon steel
b. Low alloy steel
c. High alloy steel
d. Stainless steel
NON-FERROUS METAL: -
1. Copper alloys
2. Aluminum alloys
3. Magnesium alloys
4. Zinc alloys
5. Nickel alloys
INDIAN STANDARDS RELATED TO CASTING PROCESS: -

Steel casting for general engineering

IS : 1030 – 1972
purposes
Carbon steel casting for surface
IS : 2707 – 1964
Hardening
 Gray iron casting IS : 210 – 1970
White heart malleable iron castings IS : 2109 – 1962
High tensile steel castings IS : 2644 – 1969
Cupola furnace for foundry IS : 5032 – 1969

MCQ Exercises:

1. What is the main advantage of die casting?

a. High production rates
b. High degree of flexibility
c. Low cost of tooling
d. Large size parts

Answer: a. High production rates

2. Which casting process is most suitable for producing small, complex shapes with high
accuracy?
a. Sand casting
b. Investment casting
c. Die casting
d. Centrifugal casting

Answer: b. Investment casting

3. Which of the following casting processes is not a metal casting process?

a. Injection molding
b. Vacuum casting
c. Sand casting
d. Investment casting

Answer: a. Injection molding

4. What is the primary disadvantage of sand casting?

a. Poor surface finish
b. High cost of tooling
c. Limited range of materials
d. Low production rates

Answer: a. Poor surface finish

5. What is the main advantage of investment casting?

 a. High production rates
b. Low cost of tooling
c. Large size parts
d. High accuracy and detail

Answer: d. High accuracy and detail

6. Which casting process is most suitable for producing large, thin-walled parts?
a. Sand casting
b. Investment casting
c. Die casting
d. Centrifugal casting

Answer: d. Centrifugal casting

7. Which casting process is most suitable for producing complex shapes with tight
tolerances?
a. Sand casting
b. Investment casting
c. Die casting
d. Centrifugal casting

Answer: c. Die casting

8. Which casting process is most suitable for producing very large, heavy parts?
a. Sand casting
b. Investment casting
c. Die casting
d. Continuous casting

Answer: a. Sand casting

9. Which of the following casting processes is used for producing hollow parts?
a. Investment casting
b. Sand casting
c. Die casting
d. Centrifugal casting

Answer: d. Centrifugal casting

10. What is the primary advantage of continuous casting?

a. High production rates
b. Low cost of tooling
c. Large size parts
d. High accuracy and detail

Answer: a. High production rates

Rubrics:
1. MCQ Exercises
2. Assignment Completion
3. Attendance
4. Submission
5. Attention in Laboratory

Rubric wise marks obtained:

Rubrics 1 2 3 4 5 Total
Marks

Signature of Subject Teacher