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24 views

Lab Report 3

Uploaded by

brfox2123
Copyright
© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
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ISE 2500

Casting Lab

Brenden Fuchs
10:20-11:15 (A)
February 19, 2024
Introduction:
Metal casting, one of the oldest and most fundamental manufacturing
processes, remains indispensable in modern industry for its versatility,
scalability, and cost-effectiveness. By pouring molten metal into a shaped
cavity, metal casting enables the production of complex parts with intricate
geometries and varying sizes, ranging from small components to massive
structures. The process finds applications across diverse industries, including
automotive, aerospace, construction, and consumer goods.
The purpose of this lab is to provide experience with metal casting, exploring
its advantages, and limitations. Through hands-on experience and theoretical
study, we gain a comprehensive understanding of the metal casting process,
from design considerations to production planning and quality assessment.
Metal casting offers a multitude of benefits, including the ability to create
intricate shapes, optimize material usage, and achieve cost-effective
production for high-volume runs. However, it also presents challenges such
as surface imperfections, porosity, and dimensional tolerances. By immersing
ourselves in the intricacies of metal casting, we aim to grasp not only its
technical intricacies but also its broader implications for manufacturing
design, process optimization, and product quality.
Procedure:

During the lab, we followed the basic procedure for sand casting. First, we cut
rectangular pieces of styrofoam using a hot wire and glued them onto our
desired part (provided as styrofoam) to create a downsprue and a runner. We
made sure to glue the runner to the bottom of the desired part to ensure that
the molten metal would flow up instead of splashing down. Next, we started
filling the flask with sand. Once we had a base of sand, we put in our pattern
and sifted some sand around it and then added a few more scoops and made
a divot at the top of the sand next to the downsprue as a pouring cup. While
we did all of this, the aluminum was melting in the induction heater. We
checked the temperature, and it was hot enough for what we needed (around
600 degrees Celsius if I remember correctly). One person put their heat
protective suit on and carried the bucket of molten metal using metal clamps
over to the flask, and poured it in the pouring cup at a steady pace. With what
was left after the sand mold had filled, he poured some in to the permanent
mold, and then the rest into an open mold. Professor demonstrated how
much faster the permanent mold solidified since the mold was made of metal
and heat dissipated faster. The part was quenched and we inspected for
defects. We waited 10 or so minutes before we could quench the part from
the sand mold, and then did so and inspected for defects. Our cup mold had
failed, and we believe its due to the walls being too thin, the sand collapsed,
or the metal solidified before it reached the top.
Results:
Sand casting:
We had a good pour for our sand casting, but we believe that the cups walls
were too thin, and either the sand collapsed in on it or the metal solidified
before it could completely fill in. Nonetheless, we had a good learning
experience, and it was beneficial to be a part of the process and see how it is
done in the real world.
Permanent mold casting:
Again, we had a good pour for the permanent mold casting, and our part had
little to no defects. However, we noticed on some of the parts in the past that
there were holes on many of them because there was a section that was
much thinner than the rest, so it solidified faster and was left with a hole.
Further, some of them had a dent that could have been caused by shrinkage,
or trapped air. It was very interesting to see how this process takes much less
time than sand casting.
Questions:
1. The benefits of sand casting include its ability to produce complex shapes,
its cost-effectiveness for smaller production runs since the mold doesn’t have
to be machined, and its suitability for a wide range of metals and alloys.
Drawbacks may include longer production time, labor intensive, surface
roughness, weaker mechanical properties due to larger grains from long
solidification time, limitations on dimensional accuracy, the part might need
machined further after casting, and the burning of styrofoam lets off a gas that
is harmful to breath, and wastes styrofoam.
The benefits of permanent mold casting include quick production time,
smoother surface finish, better dimensional accuracy, better mechanical
properties due to smaller grains from shorter solidification time, and no
harmful gas emissions. Drawbacks may include the mold needs to be
machined, which is costly. This means that in order for this process to be
worthwhile, the mold needs to be used many times, so large production run.
Other drawbacks include less complex shapes, mold needs to be able to split
apart, and the molten metal needs to be under the melting temperature for
the mold material.

2.
a)

b) The production rate for our sand casting process is 1 part per 46 minutes.
(Pattern/mold making and melting done simultaneously)
20+2+5+10+5+4=46 minutes
To increase production rate by 3 times to achieve 1 part per 15.3 minutes, I
would recommend a higher strength induction oven (with a built in
thermometer) to melt metals faster and eliminate time for temperature
reading. Further, I suggest upgrading the flask to one with water, or coolant,
flowing through to cut solidification time, and adding a sifter bucket to the
flask so that instead of dumping it out every time, you can simply raise the
sifter bucket, sift the sand, and you will be left with all impurities in the bucket
plus your part that needs quenched. All of these combined should achieve a
production rate 3 times faster than the current one.
3.
a) Key attributes in a metal casting process include material composition,
mold design, mold volume, melting temperature, pouring temperature, and
solidification rate.
b) These issues are evaluated through material testing, process monitoring,
and inspection of finished castings.
c) The required area at the base of the sprue to avoid aspiration of the
molten metal is 675 mm^2
V1*A1=V2*A2 ——-> (V1*A1)/(V1+sqrt(2*g*h))=A2
(10000 mm/sec * 800 mm^2)/(10000 mm/sec+sqrt(2*9.8*.175)*1000
mm/sec)= 675 mm^2

Real World Examples:


1. An example of a real component manufactured using the metal casting
process is the engine block of an automobile.
2. The design of the engine block must balance factors such as strength,
weight, and heat dissipation, while also considering constraints
imposed by the casting process, such as mold complexity and casting
defects. Furthermore, the cylinder walls of the engine block need to be
extremely smooth to provide as little friction as possible, so they need
to be machined afterwards. However, sand casting still makes the most
sense for manufacturing engine blocks, as a permanent mold is likely
not able to be complex enough to create an engine block. I’d like to note
its very interesting to learn this, and ill be checking my engine block to
see if I can see the styrofoam pattern.

Conclusion:
In conclusion, this lab provided valuable insights into metal casting
processes, their advantages, limitations, and real-world applications. By
understanding the fundamentals of metal casting, we can make informed
decisions in manufacturing design and process optimization. The lab
demonstrated the importance of process planning, design optimization, and
quality control in ensuring the success of metal casting operations. From the
initial design considerations to the final product evaluation, every step in the
metal casting process demands attention to detail, critical thinking, and
problem-solving skills, as often there is little room, or time, for error. By
experiencing the process of metal casting, we have gained a deeper
appreciation for the science of manufacturing. We have learned not only the
technical side of the metal casting process but also its broader implications
for product design, material selection, and production efficiency. Casting has
a great impact on modern industry and society. From the engines that power
our vehicles to the infrastructure that shapes our cities, metal casting plays a
vital role in shaping the world around us. Moving forward, the knowledge and
skills acquired in this lab will serve as a foundation for our continued
exploration of manufacturing processes and technologies.

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