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Manufacturing Process Module 1, Kerala university, S4 Mechanical
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S4 MECHANICALSTIST
1
MODULE 1
KSC-STIST
Sand Muller
KSC-STIST 2
Sand Mullers
KSC-STIST 3
MOULDING METHODS
•Bench moulding
• Floor moulding
•Pit moulding
•Machine moulding
KSC-STIST 4
Types of Moulds• Green Sand Mould
• Dry Sand Mould
• Skin-Dried Sand Mould
• Air-Dried Sand Mould
• Core Sand Mould
• Loam Mould
• Shell Mould
• Cement Bonded Sand Mould
• Ceramic Mould
• Plaster Mould
• Sodium Silicate- CO2 Mould
KSC-STIST 5
Types of Moulding• Green Sand Moulding
• Dry Sand Moulding
• Skin-Dried Sand Moulding
• Core Sand Moulding
• Loam Moulding
• Shell Moulding
• Cement Bonded Sand Moulding
• Ceramic Moulding
• Plaster Moulding
• Sodium Silicate- CO2 Moulding
KSC-STIST 6
Sodium Silicate- CO2 Moulding
Na2 SiO3 + CO2 Na2CO3 + SiO2
Sodium Silicate Silica Gel
KSC-STIST 7
SHELL MOULDING
KSC-STIST 8
Plaster Mould Casting
KSC-STIST 9
Ceramic Slurry
KSC-STIST 10
MOLD MAKING
11
HAND MOLDING EQUIPMENTS
1. Bellow
2. Brush
3. Lifter
4. Dust bag
5. Gaggers
6. Peen Rammer
7. Hand Ramer
8. Floor Rammer
9. Hand Riddle
10. Sprue Pin
11. Sprue Cutter
12. Spray- Gun
13. Spirit Level
14. Sprigs and Nails
15. Swab
16. Trowels
17. Shovel
18. Vent Wire
19. Strike off bar
20. Draw Spike
21. Gate Cutter
22. Draw Screws
12
CORE
Required Casting
13
Pattern
CORE
14
Properties of CORE Sand Green Strength
Dry strength
Hardness
Permeability
Refractoriness
Collapsibility
Should generate minimum amount of gases during
pouring of molten metal
Bench life (should be able to retain its properties during
storage.)
15
Core Sand Ingredients1. Granular Refractories
1. Silica Sand (Dry, Clean & Pure)
2. Zircon
3. Carbon
2. Core Binders
a) Organic
i. Core oil
ii. Water soluble binders
iii. Synthetic resins, thermosetting
iv. Wood floor
b) Inorganic
i. Fire clay
ii. Silica floor
iii. Iron oxide
c) Other binders
a) Portland cement
b) Sodium silicate
3. Water
4. Special additives
16
Core Box 17
CORE BAKINGEQUIPMENTS USED FOR THE BAKING OF CORES
1. Core Ovens
a) Batch type
i. Drawer type
ii. Rack type
b) Continuous type
2. Dielectric Bakers
3. Radiant Bakers
18
FINISHING OF CORE
1. Cleaning
a) Trimming
b) Brushing
c) Coating
d) Mudding
2. Sizing
3. Core Assembly
19
Core Shifting & Chaplets20
Permanent Mold Casting
(Gravity Die Casting)21
22KSC-STIST
23KSC-STIST
BLOW HOLES
CASTING DEFECTS
24KSC-STIST
BLOW HOLES
25KSC-STIST
MISRUNS
26KSC-STIST
COLD SHUT
27KSC-STIST
MISMATCH
28KSC-STIST
FINS OR FLASH
29KSC-STIST
SHRINKAGE CAVITY
30KSC-STIST
METAL PENETRATION & SURFACE ROUGHNESS
31KSC-STIST
HOT TEAR
32KSC-STIST
SLAG INCLUSIONS
33KSC-STIST
SWELL
REQUIRED CASTING DEFECTED CASTING
Swelled section
34KSC-STIST
INSPECTION & TESTING OF CASTINGS• VISUAL INSPECTION
• DIMENSIONAL INSPECTION
• PRESSURE TESTING• WATER PRESSURE TEST
• AIR PRESSURE TEST
• RADIO-GRAPHICAL TESTING• X-RAY TESTING
• γ-RAY TESTING
• EDDY CURRENT INSPECTION
• ULTRASONIC TESTING
35KSC-STIST
Radio-Graphical Testing
36KSC-STIST
37KSC-STIST
LIQUID PENETRANT TEST
1 2
3 4
1. Section of material with a crackthat is not visible to the nakedeye.
2. Penetrant is applied to the surface.3. Excess penetrant is removed.4. Developer is applied, rendering the crack visible.
38KSC-STIST
EDDY CURRENT INSPECTION
39KSC-STIST
ULTRASONIC TESTING
40KSC-STIST
41KSC-STIST
42
• Pouring Cup• Sprue• Sprue Base/Well• Runner• Gate• Riser
KSC-STIST
FUNCTIONS OF A GATING SYSTEM
•Fill the mould cavity before solidification starts
•Reduce the turbulence of molten metal
•Minimize wastage of metal
43KSC-STIST
44KSC-STIST
ELEMENTS OF GATING SYSTEM• Pouring basin/cup: Funnel shaped cup which forms the top portion of
the sprue.
• Sprue: A vertical passage, usually tapered to minimize turbulence. It connects the poring basin to runner via sprue well
• Sprue well: Deep and enlarged portion beneath the sprue
It absorbs shocks of the molten metal and retainsinclusions
• Runner: Horizontal passage which connects sprue well & Gates
• Gate: Passage that finally leads molten metal from runner in themould cavity
• Riser: A riser is a vertical passage or opening through the cope
45KSC-STIST
46KSC-STIST
PRINCIPLES OF RISERING• A riser or a feeder head is a passage of sand made in the
mould.
• The molten metal rises in the feeder head after the mouldcavity is filled up.
FUNCTIONS OF RISER:
• Act as a vent for gases
• Helps to confirm that the mould is completely filled
• Act as a reservoir of molten metal to feed and compensatefor shrinkage during solidification of a casting.
47KSC-STIST
48
OPEN RISERBLIND RISER
KSC-STIST
BLIND RISER
• Advantages:• Smaller in size, less wastage of metal
• Slow solidification of molten metal
• Disadvantages:• Difficult to mould
• Does not indicate the filling of mould cavity
OPEN RISER
• Advantages:• Easy to mould
• Disadvantages:• Larger in size, more wastage of metal
• Difficult to remove from the casting 49KSC-STIST
CHILLS
50
• External Chills• Direct chills• Indirect chills
• Internal chills
KSC-STIST
GATING RATIOSprue Well area : Runner cross sectional area : Gate cross sectional area
1 : 3 : 3
1: 0.75 : 0.50
51KSC-STIST
TYPES OF GATING SYSTEM
• Pressurized Gating System• The total cross sectional area decreases towards the mold cavity
• Unpressurized Gating System• The total cross sectional area increases towards the mold cavity
52KSC-STIST
CENTRIFUGAL CASTING
53KSC-STIST
54KSC-STIST
•CENTRIFUGAL CASTING•True Centrifugal casting•Semi-Centrifugal Casting•Centrifuged Casting
55KSC-STIST
TRUE CENTRIFUGAL CASTING
56KSC-STIST
57
SEMI CENTRIFUGAL CASTING
KSC-STIST
58
CENTRIFUGED CASTING
KSC-STIST
59
CONTINOUS CASTING
KSC-STIST
CONTINOUS CASTING
60KSC-STIST
61KSC-STIST
62KSC-STIST
KSC-STIST 63