1)manufacturing and casting process

8/2/2019 1)Manufacturing and Casting Process

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What is manufacturingThe word manufacturing is derived from the Latin, manu factus, which

means made by hand.

Manufacturing is not only the making of product; it is the integration

of product demand, product design, material selection, manufacturing

processing, product assembly, and management to produce a desired

product at a competitive price at the desired time.

Manufacturing is the use ofmachines, tools and labor to producegoods for use or sale. The term may refer to a range of human activity,

from handicraft to high tech, but is most commonly applied

to industrial production, in which raw materials are transformed

into finished goods on a large scale. Such finished goods may be used

for manufacturing other, more complex products, suchas aircraft, household appliances or automobiles, or sold

to wholesalers, who in turn sell them to retailers, who then sell them

to end users the "consumers"
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Manufacturing processManufacturing processing is the procedure by

which materials are formed into the desired

shapes.A sequence of operations and processes

designed to create a specific productThe process of turning materials into a product


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Manufacturing process is the effective use of

the resources for the required product

The resources are

- Man

- Material

- Money

- Machine


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In modern context it involves making products from raw material

by using various processes, by making use of hand tools,

machinery or even computers.

Advance manufacturing engineering involves the followingconcepts

1. Process planning. 2. Process sheets.

3. Route sheets. 4. Tooling.

5. Cutting tools, machine tools (traditional, numerical control (NC),and computerized numerical control (CNC).

6. Jigs and Fixtures. 7. Dies and Moulds.

8. Manufacturing Information Generation.

9. CNC part programs.

10. Robot programmers.

11. Flexible Manufacturing Systems (FMS), Group Technology (GT)

and Computer integrated manufacturing (CIM).


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CLASSIFICATION OF MANUFACTURING PROCESSES(1). primary shaping processes :(1)Casting, (2) Powder metallurgy, (3) Plastic

technology, (4) Gas cutting, (5) Bending and(6) Forging.(2). secondary or machining processes are:

(1) Turning, (2) Threading, (3) Knurling, (4) Milling,(5) Drilling, (6) Boring, (7) Planning, (8) Shaping,(9) Slotting, (10) Sawing, (11) Broaching, (12) Hobbing,(13) Grinding, (14) Gear cutting, (15) Thread cuttingand (16) Unconventional machining processes namelymachining with Numerical Control (NC) machines toolsor Computer Numerical Control (CNC) machinestools using ECM, LBM, AJM, USM setups etc.Importance of safety


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Different types of manufacturing processes

1 Casting

2 Molding

3 Forming4 Machining

5 Joining

6 Rapid manufacturing7 Unconventional machining processes

8 Powder metallurgy
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Casting processCasting is one of the oldest and best-known manufacturingprocesses. It consists of pouring a liquid material, usually a metal,into a mold and letting it cool and solidify into the desired shape.


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Principle of castingIt consist of introducing the molten metal into acavity and mould of the desired shape and

allowing it to solidify.Advantages- No limit to the sizes- Shape and intricacy of the article can be

produced- It gives high strength and rigidity even to

intricate part which are difficult to produce by

other methods of manufacturing- Any shape can be casted- Avoids the problem which arise due to joining

assembly together


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Major area of casting processPattern making: This includes the modification of the desired partshape to include draft, shrinkage, and machining allowances aswell as to provide the gating and risering design. The pattern hasthe shape of the casting, and it is used to make the cavity in themold into which the metal is poured.Molding and core making: This includes the production of themolds and cores, the insertion of the ores in the mold, and the

closing of the mold. Cores typically are sand masses that form theinternal surfaces of the part, whereas the mold forms the externalsurface of the part. The use of cores permits the formation ofirregularly shaped internal surfaces in castings, which is extremelydifficult for the other forming processes.

Melting: This includes the melting of the metal and the pouring ofthe molten metal into the mold cavity.Cooling and solidification: The cooling and solidification, whichare determined by the mold material and riser location, affect thematerial properties and quality of the casting.


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PATTERNA pattern is a model or the replica of the object (to be casted).

OBJECTIVES OF A PATTERN1 Pattern prepares a mould cavity for the purpose of making acasting.2 Pattern possesses core prints which produces seats in form of extra

recess for core placement in the mould.3 It establishes the parting line and parting surfaces in the mould.4 Runner, gates and riser may form a part of the pattern.5 Properly constructed patterns minimize overall cost of the casting.6 Pattern may help in establishing locating pins on the mould and

therefore on the casting with a purpose to check the castingdimensions.7 Properly made pattern having finished and smooth surface reducecasting defects.


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PATTERN MATERIAL1. Wood2. Metal

3. Plastic4. Wax etc.FACTORS EFFECTING SELECTION OF PATTERN MATERIAL1. Number of castings to be produced. Metal pattern arepreferred when castings are required large in number.

2. Type of mould material used.3. Kind of molding process.4. Method of molding (hand or machine).5. Degree of dimensional accuracy and surface finish

required.6. Minimum thickness required.7. Shape, complexity and size of casting.8. Cost of pattern and chances of repeat orders of thepattern


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TYPES OF PATTERNThe types of the pattern and the description of

each are given as under.1. One piece or solid pattern2. Two piece or split pattern3. Cope and drag pattern

4. Three-piece or multi- piece pattern5. Loose piece pattern6. Match plate pattern7. Follow board pattern8. Gated pattern9. Sweep pattern10. Skeleton pattern11. Segmental or part pattern


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PATTERN ALLOWANCES1.Shrinkage allowance2.Machining allowance

3.Draft or taper allowance4.Rapping allowance5.Distortion allowance


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Cores and core printCores are compact mass of core sand that when

placed in mould cavity at required location withproper alignment does not allow the moltenmetal to occupy space for solidification in thatportion and hence help to produce hollowness

in the casting.Types of cores1. Horizontal2. Vertical

3. Balanced4. Wing5. Hanging core6. Cover core


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SandNatural and synthetic sandMain constituents1. Silica sand2. Binder (organic group are dextrin, molasses, cereal

binders, linseed oil and resins like phenolformaldehyde, urea formaldehyde etc)3. Moistures4. Additives (coal dust, corn flour, dextrin, sea coal etc.)

Types of sands1. Green sand2. Loam sand

3. Facing sand4. Baking sand5. System sand6. Parting sand

7. Core sand


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Properties of the moulding sand1.Permeability2.Cohesiveness3.Adhesiveness4.Plasticity5.Refractoriness6.Chemical resistivity7.Flowability8.Binding property9.Green strength


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Mould making


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Mould


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FACTORS CONTROLING GATING DESIGNThe following factors must be considered while designing gatingsystem.(i) Sharp corners and abrupt changes in at any section or portion in

gating system should be avoided for suppressing turbulence and gasentrapment. Suitable relationship must exist between different cross-sectional areas of gating systems.(ii) The most important characteristics of gating system besides sprueare the shape, location and dimensions of runners and type of flow. Itis also important to determine the position at which the molten metalenters the mould cavity.(iii) Gating ratio should reveal that the total cross-section of sprue,runner and gate decreases towards the mold cavity which provides achoke effect.(iv) Bending of runner if any should be kept away from mold cavity.

(v) Developing the various cross sections of gating system to nullifythe effect of turbulence or momentum of molten metal.(vi) Streamlining or removing sharp corners at any junctions byproviding generous radius, tapering the sprue, providing radius atsprue entrance and exit and providing a basin instead pouring cup

etc.


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CLASSIFICATION OF MOLDING PROCESSESMolding processes can be classified in a number of ways. Broadlythey are classified either on the basis of the method used or on thebasis of the mold material used.(i) Classification based on the method used(a) Bench molding. (b) Floor molding,(c) Pit molding. (d) Machine molding.(ii) Classification based on the mold material used:(a) Sand molding:

1. Green sand mould2. Dry sand mould,3. Skin dried mould.4. Core sand mould.5. loam mould

6. Cement bonded sand mould7. Carbon-dioxide mould.8. Shell mould.

(b) Plaster molding,(c) Metallic molding.(d) Loam molding


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Casting process review


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1)manufacturing and casting process

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