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Introduction To Casting Processes by Stead Fast Engineers Pvt Ltd – part 1
one of the leading Induction heating system manufactures
Advantages• Complex forms, low cost• Certain shapes cannot be
machined• One piece parts vs. multiple
piece parts• Design changes are easily
incorporated• High volume, low skilled
labor• Large, heavy parts can be
made easily
Disadvantages• Problems with internal
porosity• Dimensional variations
due to shrinkage• Trapped impurities,
solids and gasses• High-tolerance, smooth
surfaces not possible• More costly than
stamping or extruding in some cases
Cupola Furnaces
Five Zones• Stack• Charging Zone• Melting Zone• Tuyers (Air Intake)• Crucible or Hearth
Foundries• Pattern and Mold
Making– Computer Aided
Design– Manufacturing– Rapid Prototyping
• The Casting Process– Metal Melting– Metal Compositions– Impurities– Pouring into molds
Foundry Automation
• Pouring into Molds• Cleaning• Heat Treatment• Inspection• Automated Guided
Vehicles– Automatic Storage– Moving Cores and
patterns– Etc.
Reasons For Automation
• Increased Manufacturing Efficiency
• Reducing Costs• Reliability in Harsh
Environments • Release of Skilled Man
Power• Maximize Space• Improved Quality
Why Fluid Flow?
• When Heated Metal Becomes Liquid
• Important in Cast Design- Sprue - Well - Runner- Gate
Fluidity of Metals
• Viscosity • Surface Tension• Inclusions• Mold Design• Degree of Super Heat• Mold Material
- Thermal Conductivity
- Surface Roughness• Heat Transfer
Tests for Fluidity
• There are several different fluidity tests
• All use the same principle
• Useful in simulating how metal will react
• See how far the metal will travel before solidification