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© R. Jerz 2 3/27/2006
Process Equipment and CostProcess Equipment and Cost
FoundryFurnaces• (previous video – Ludken)
© R. Jerz 3 3/27/2006
Types of Melting FurnacesTypes of Melting Furnaces
Figure 11.26 Two types of melting furnaces used in foundries: (a) crucible, and (b) cupola.
© R. Jerz 4 3/27/2006
Process OverviewProcess Overview
Produce part in single step (“near-net”shape)Can produce a wide variety of shapes and sizesComplex shapes are possibleInternal cavities are possible
© R. Jerz 5 3/27/2006
Six Basic FactorsSix Basic Factors
1. Mold cavity2. Melting process3. Pouring technique4. Solidification process5. Removal of casting6. Cleaning/finishing
© R. Jerz 9 3/27/2006
Die-Casting DiesDie-Casting Dies
Figure 11.19 Various types of cavities in a die-casting die. Source: Courtesy of American Die Casting Institute.
© R. Jerz 10 3/27/2006
Cleaning & FinishingCleaning & Finishing
Remove coresRemove gates and risersRemove fins, flashClean the surfaceRepair defects.Tumbling machines
© R. Jerz 11 3/27/2006
Defects Defects
Metal projectsCavitiesDiscontinuitiesDefective surfaceIncomplete castingIncorrect dimensions or shapeInclusions (unwanted material)Porosity• Shrinkage/gas
© R. Jerz 12 3/27/2006
General Casting Design RulesGeneral Casting Design RulesDesign the part to cast easily.Select the correct casting processLocate the parting line carefullyLocate and design the gates, runners, sprues, screens and risersCheck for proper controls and good practices