Casting is one of the earliest manufacturing processes where molten metal is poured into a mold and solidified to form the desired shape. Patterns are used to make molds and cores, which are then filled with molten metal. The casting is then cleaned and inspected. Allowances must be provided on patterns to account for shrinkage, machining needs, draft for mold removal, shake from sand adhesion, and potential distortion.
Casting is one of the earliest manufacturing processes where molten metal is poured into a mold and solidified to form the desired shape. Patterns are used to make molds and cores, which are then filled with molten metal. The casting is then cleaned and inspected. Allowances must be provided on patterns to account for shrinkage, machining needs, draft for mold removal, shake from sand adhesion, and potential distortion.
Casting is one of the earliest manufacturing processes where molten metal is poured into a mold and solidified to form the desired shape. Patterns are used to make molds and cores, which are then filled with molten metal. The casting is then cleaned and inspected. Allowances must be provided on patterns to account for shrinkage, machining needs, draft for mold removal, shake from sand adhesion, and potential distortion.
Casting is one of the earliest manufacturing processes where molten metal is poured into a mold and solidified to form the desired shape. Patterns are used to make molds and cores, which are then filled with molten metal. The casting is then cleaned and inspected. Allowances must be provided on patterns to account for shrinkage, machining needs, draft for mold removal, shake from sand adhesion, and potential distortion.
• Casting is one of the earliest manufacturing processes known to human beings.
r la Value Addition Processes
Raw materials te Finished Product • In casting molten metal is solidified to the desired shape and size. Es • Casting is often the cheapest and most direct way of shaping the metal. • Practically any intricate shape can be produced. • With normal sand casting process the dimensional accuracies and surface finish is poor. • Defects are inevitable. 2 Steps in Casting
r la 1. Pattern Making te 2. Mould and Core Making 3. Melting and Pouring of metal Es 4. Taking the casting 5. Cleaning (Fettling) out of mould and Inspection 3 Pattern
r • Pattern is the replica of casting to be made with certain modifications.
la Pattern size = casting size ± allowances. • Allowances • • • Shrinkage Allowance Machining Allowance Draft Allowance te Es • Shake allowance • Distortion Allowance
Pattern with Allowances
4 Shrinkage Allowance
r • Shrinkage of metal during casting will takes place in three stages
la 1. Shrinkage of molten metal when reducing from pouring temp to freezing temp. Liquid 2. Shrinkage of molten metal during Shrinkage freezing.
te 3. Shrinkage solid metal when reducing from freezing temp to room temp. Solid Es Shrinkage Pouring Temp. = Melting Temp.+ (150-200
Steps in Metal Solidification
5 5 Liquid Shrinkage
r • Liquid shrinkage is always specified by percentage over volume. • Highest liq. shrinkage = Aluminium (6.60 %)
la • Liquid shrinkage is compensated by providing riser during mould making.
te Solidification Es • Metal in the riser should solidify in the end. • Riser volume must be sufficient for compensating shrinkage in casting. 6 Solid Shrinkage
r • Shrinkage allowance is provided on the pattern to compensate the solid shrinkages.
la Solid shrinkage where oefficient of thermal expansion of metal.
te • Shrinkage allowance is specified as: mm/m over each linear dimension. • In case of internal dimensions the material has a tendency to contract towards the centre. Es e.g. Internal diameter of cylinder is to be increased.
7 !!Think!!
r • Why are different arrangements for compensating liquid and solid shrinkages? • Is “providing allowances on pattern” not sufficient to compensate both
la shrinkages?
te Es Shrinkage Cavity on Casting Courtesy: BackyardMetalCasting.com 8 Exercise
r • Example: The casting shown in fig. is to be made in plain-carbon steel using a wooden pattern. Assuming the shrinkage allowance only, calculate the
la dimensions of the pattern. Solution:
te Shrinkage allowance for steel is 21.0 mm/ m. For dimension 200, Allowance is 200 × 21.0 / 1000 = 4.20 mm For dimension 150, Casting Es allowance is 150 × 21.0 / 1000 = 3.15 ≈ 3.20 mm For dimension 100, allowance is 100 × 21.0 / 1000 = 2.10 mm For dimension 80, allowance is 80 × 21.0 / 1000 = 1.68 ≈ 1.70 mm. Pattern 9 Shrink rules
r • Special scales where unit dimensions shown are actually longer then the original unit
la dimension by a measure equal to the shrinkage allowance. • Different shrink rules for different materials are used. e.g. te For plain carbon steel casting of dimensions Es 200mm x 150mm x100mm, the pattern size using shrink rule will be 200mm x 150mm x 100mm. Shrink rules 10 Machining Allowance
r • Extra dimension provided on the pattern to compensate the subsequent machining required on casting.
la • Purpose: • To achieve the desired finish on the casting product.
te • To accommodate the variation in dimensions due to variation in room temp during solidification. • Machining allowance is specified by 'x' mm/side Es Machining allowance 11 Draft Allowance
r • Provision of inclination to the vertical surfaces of pattern is called draft allowance. • It is provided for easy removal of pattern from mould.
la Pattern without draft te Es Pattern with draft
• Draft allowance varies with the complexity of the job.
• Inner details of the pattern require higher draft than outer surfaces. • In casting process if the pattern is made by using wax, mercury then no draft allowance is required. 12 Shake Allowance
r • Moulding sand adheres to the pattern walls while moulding.
la • Shake allowance is the wrapping done all around the vertical faces of the pattern. • It is provided to avoid the damages taking place walls. te due to adhering of molding sand to the pattern
• It is highly dependent on mould making person.
Es • As it reduces the dimension of pattern so it is taken as negative allowance. Wrapping the pattern • If the pattern is made by using the materials like wax, mercury, polystyrene as Pattern material, no 13 shake allowance to be provided. Distortion Allowance
r • Does not required on all the castings. But it is mainly required in casting of `U' or 'V' shaped castings.
la • In case of V or U shape castings because of existence of differential shrinkages at different locations of cavity, the legs will bend outwards producing inclined legs.
te • The shape of the pattern itself is given a distortion of equal amount in the opposite direction of the likely distortion direction. Es Distortion Allowance • Done by trial-and-error basis to get the distortion amount.
