16ME208

MANUFACTURING AND MACHINING

TECHNOLOGY
Semester - 3
B.E Mechanical Engineering

Academic Year : 2018-19

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 VISION & MISSION OF THE COLLEGE

VISION
To develop into a leading world class
Technological University consisting of
Schools of Excellence in various disciplines
with a co-existent Centre for Engineering
Solutions Development for world-wide
clientele.

MISSION
To provide all necessary inputs to the
students for them to grow into knowledge 2
 VISION & MISSION OF THE DEPARTMENT

VISION

The Department of Mechanical Engineering excels in

Engineering Education and building enterprising
professionals commendable with creativity, research and
employability, meeting the requirements of potential
recruiters.

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VISION & MISSION OF THE DEPARTMENT
(Conti…)

MISSION

The Mission is to provide

quality engineering
education that equips the
students with adequate
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 PROGRAMME EDUCATIONAL
OBJECTIVES (PEOS)

The graduates will demonstrate the following, after few

years of their graduation
1.The graduates offer rationale solutions while designing and
manufacturing of mechanical as well as allied engineering
systems through the use of their knowledge in Mathematics,
Physical Science, Engineering and Technology.

2.The graduates demonstrate the professional skills with

confidence to seek solutions to the tasks with due
consideration on social, environmental, economical, and ethical
values.

The graduates communicate effectively and engage in life-long

learning for personal and professional growth.
3. 5
 PROGRAMME OUTCOMES (POS)

Engineering Graduates will

be able to

1.Engineering knowledge: Apply the

knowledge of mathematics, science,
engineering fundamentals, and an
engineering specialization to the
solution of complex engineering
problems. 6
PROGRAMME OUTCOMES (POS)
(Cont…..)

5. Modern tool usage: Create, select, and apply appropriate

techniques, resources, and modern engineering and IT tools
including prediction and modeling to complex engineering
activities with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the
contextual knowledge to assess societal, health, safety, legal
and cultural issues and the consequent responsibilities relevant
to the professional engineering practice.
7. Environment and sustainability: Understand the impact of
the professional engineering solutions in societal and
environmental contexts, and demonstrate the knowledge of, and
need for sustainable development.
8. Ethics: Apply ethical principles and commit to professional
ethics and responsibilities and norms of the engineering practice.7
PROGRAMME OUTCOMES (POS)
(Cont…..)

1.Individual and team work: Function effectively as an

individual, and as a member or leader in diverse teams, and in
multidisciplinary settings.

10.Communication: Communicate effectively on complex

engineering activities with the engineering community and with
society at large, such as, being able to comprehend and write
effective reports and design documentation, make effective
presentations, and give and receive clear instructions.

11.Project management and finance: Demonstrate knowledge

and understanding of the engineering and management
principles and apply these to one’s own work, as a member and
leader in a team, to manage projects and in multidisciplinary
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environments.
 PROGRAMME SPECIFIC OUTCOMES (PSOs)

Graduates of Mechanical Engineering at the time of

graduation will be able to
1.Design, model and analyze mechanical components as well
as systems using Engineering and computational tools

2.Identify and plan the manufacturing methods and processes

for mechanical components and systems with due
consideration on quality and economy

3.Analyze, evaluate and design thermal systems by applying

thermal engineering concepts and simulation methods.

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 16ME2E25 METAL JOINING PROCESSES
Course Outcomes

On successful completion of the course, the student will be able to

CO1 Illustrate the basic foundry processes and their
equipments.

CO2 Summarize the types of forming processes and their

applications.

CO3 Express about the various welding processes.

CO4 Outline the mechanism of metal cutting and chip

formation in machining.

CO5 Explain the machining processes and their applications.

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 PRE - REQUISITE COURSES

1. 16ME257-Basic Workshop Practices Laboratory

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 Module - I

FOUNDRY PROCESSES 10
Patterns: Types, Selection and Allowances. Moulding
Sands: Types and Properties, Core: Classification and
Requirements- Core Prints, Sand Moulding Process and
Gating systems
Melting Furnaces: Crucible – Cupola- Induction, Casting:
Classification -Investment Casting– Centrifugal Castings -
Die Casting, Fettling and Cleaning of Castings, Casting
Defects and Remedies

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 FOUNDRY PROCESSES AND
ITS EQUIPMENTS

A foundry is a factory that produces metal casting

Metals are cast into shapes by melting them into a liquid, pouring the metal in a
mold, and removing the mold material or casting after the metal has solidified as it
cools.
A mold or mould is a hollowed-out block that is filled with a liquid or pliable
material like plastic, glass, metal, or ceramic raw materials. The liquid hardens or
sets inside the mold, adopting its shape.

A mold is the counterpart to a cast

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Typical Foundry process

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Moulding Processess

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 Pattern

A Pattern is an element used for

making cavities in the mould, into
which molten metal is poured to
produce a casting.
The pattern is the principal tool
during the casting process. It is the
replica of the object to be made by
the casting process, with some
modifications. The main
modifications are the addition of
pattern allowances, and the provision
of core prints. If the casting is to be
hollow, additional patterns called
cores are used to create these
cavities in the finished product.
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Different types of patterns

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Solid or Single piece pattern

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Split piece or Parted Pattern

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Loose Piece Pattern

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Match Plate Pattern

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Sweep Pattern

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Gated pattern

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 Skeleton pattern
Followboard pattern

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Cope and Drag Pattern

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 Pattern Material

Patterns may be constructed from the following materials. Each

material has its own advantages, limitations, and field of application.
Some materials used for making patterns are: wood, metals and
alloys, plastic, plaster of Paris, plastic and rubbers, wax, and resins. To
be suitable for use, the pattern material should be:
• Easily worked, shaped and joined
• Light in weight
• Strong, hard and durable
• Resistant to wear and abrasion
• Resistant to corrosion, and to chemical reactions
• Dimensionally stable and unaffected by variations in temperature and
humidity
• Available at low cost

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Requirements (Selection) of
a good pattern

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Pattern allowances

◦ Shrinkage allowance
◦ Machining allowance
◦ Draft allowance
◦ Rapping or Shake allowance
◦ Distortion allowance

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 Contraction allowances /
Shrinkage allowance

The pattern needs to incorporate suitable allowances for

shrinkage; these are called contraction allowances, and their
exact values depend on the alloy being cast and the exact
sand casting method being used.
Shrinkage can again be classified into 
• liquid shrinkage and 
• solid shrinkage.

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Contraction allowances /
Shrinkage allowance contd..,

1.Liquid shrinkage is the reduction in volume during the

process of solidification, and
2.Solid shrinkage is the reduction in volume during the
cooling of the cast metal. Shrinkage allowance takes
into account only the solid shrinkage.
The liquid shrinkage is accounted for by risers.
Generally during shrinkage, all dimensions are going to be
altered uniformly, unless there is a restriction.
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Contraction allowances /
Shrinkage allowance contd..,

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 Contraction allowances /
Shrinkage allowance contd..,
Exercise 1
• The casting shown is to be made in cast iron using a
wooden pattern. Assuming only shrinkage allowance,
calculate the dimension of the pattern. All Dimensions are
in Inches 

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 Contraction allowances /
Shrinkage allowance contd..,
Solution
The shrinkage allowance for cast iron for size up to 2 feet is
o.125 inch per feet (as per  Table 1)
• For dimension 18 inch, allowance = 18 X 0.125 / 12 = 0.1875
inch »  0.2 inch
• For dimension 14 inch, allowance = 14 X 0.125 / 12 = 0.146
inch »  0.15 inch
• For dimension 8 inch, allowance   =  8 X 0.125 / 12 = 0.0833
inch »  0. 09 inch
• For dimension 6 inch, allowance   =   6 X 0.125 / 12 = 0.0625
inch »  0. 07 inch
• The pattern drawing with required dimension is shown below:

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Contraction allowances /
Shrinkage allowance contd..,

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 Draft allowance

When the pattern is to be removed

from the sand mold, there is a
possibility that any leading edges may
break off, or get damaged in the
process.
To avoid this, a taper is provided on
the pattern, so as to facilitate easy
removal of the pattern from the mold,
and hence reduce damage to edges.
The taper angle provided is called
the Draft angle. The value of the draft
angle depends upon the complexity of
the pattern, the type of molding (hand
molding or machine molding), height of
the surface, etc. Draft provided on the
casting 1 to 3 degrees on external
surface ( 5 to 8 internal castings)
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Draft allowance contd..,

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 Finishing or
Machining allowance
Finishing or Machining allowance
The surface finish obtained in sand castings is generally poor
(dimensionally inaccurate), and hence in many cases, the cast product is
subjected to machining processes like turning or grinding in order to
improve the surface finish. During machining processes, some metal is
removed from the piece. To compensate for this, a machining allowance
(additional material) should be given in the casting.

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 Finishing or
Machining allowance contd
• Exercise
The casting shown is to be made in cast iron using a
wooden pattern. Assuming only machining allowance,
calculate the dimension of the pattern. All Dimensions are
in Inches

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 Finishing or
Machining allowance contd
Solution
The machining allowance for cast iron for size, up to 12 inch is
o.12 inch and from 12 inch to 20 inch is 0.20 inch ( Refer Table)
• For dimension 18 inch, allowance = 0.20 inch
• For dimension 14 inch, allowance = 0.20 inch
• For dimension 8 inch, allowance   = 0.12 inch
• For dimension 6 inch, allowance   = 0.12 inch
The pattern drawing with required dimension is shown in Figure below

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 Rapping and Shake Allowance

• Rapping or Shake allowance

Usually during removal of the pattern
from the mold cavity, the pattern is rapped
all around the faces, in order to facilitate
easy removal. In this process, the final
cavity is enlarged. To compensate for this,
the pattern dimensions need to be reduced.
There are no standard values for this
allowance, as it is heavily dependent on the
personnel. This allowance is a negative 40
 Distortion or Camber Allowance

• Distortion allowance
During cooling of the mold, stresses developed in the solid metal
may induce distortions in the cast. This is more evident when the mold
is thinner in width as compared to its length. This can be eliminated by
initially distorting the pattern in the opposite direction

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 Moulding sand

This is the most important of the moulding materials.

In different forms, it has different uses and is given
different names, such as green sand, loam, facing
sand, core sand, brass sand. All moulding sands are
essentially mixtures of silica to give porosity and
clay to give tenacity.
Silica grains are refractory and have no cohesion.
Clay is a fine powder, is refractory and when wet is
adhesive and plastic. These two ingredients are
mixed in different proportions, the silica grains
varying in size, to make mixtures suitable for
different uses.

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Moulding sand properties and
its classification
Properties of moulding sand
1: porosity or permeability
 It is the property of sand which permits the steam and other gases to pass through the
sand mould. The porosity of sand depends upon its grain size, grain shape, moisture
and clay components are the moulding sand. If the sand is too fine, the porosity will be
low.
2: Plasticity
 It is that property of sand due to which it flows to all portions of the moulding box or
flask. The sand must have sufficient plasticity to produce a good mould.
3: Adhesiveness
 It is that properties of sand due to it adheres or cling to the sides of the moulding box.
4: Cohesiveness
 It is the property of sand due to which the sand grains stick together during ramming. It
is defined as the strength of the moulding sand.
5: Refractoriness
 The property which enables it to resist high temperature of the molten metal without
breaking down o r fusing.

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6 : Collapsibility :
After the molten metal in the mould gets solidified, the sand mould
must be ocllapsible so that free contraction of the metal occurs and this would
naturally avoid the tearing or cracking of the contracting metal. In absence of
collapsibility property the contraction of the metal is hindered by the mold and
thus results in tears and cracks in the casting. This property is highly required
in core+
7: Dry strength :
As soon as the molten metal is poured into the mould, the moisture in
the sand layer adjacent to the hot metal gets evaporated and this dry sand
layer must have sufficient strength to its shape in order to avoid erosion of
mould wall during the flow of molten metal. The dry strength also prevents the
enlargement of mould cavity cause by the metallostatic pressure of the liquid
metal.

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 Classification of moulding sand
according to its applications
1: Green sand
•  The sand in its natural or moist state is called green sand. It is also
called tempered sand. It is a mixture of sand with 20 to 30 percent
clay, having total amount of water from 6 to 10 percent. The mould
prepared with this sand is called green sand mould, which is used for
small size casting of ferrous and non-ferrous metals.
2: Dry Sand
• The green sand moulds when baked or dried before pouring the
molten metal are called dry sand moulds. The sand of this condition is
called dry sand. The dry sand moulds have greater strength, rigidity
and thermal stability. These moulds used for large and heavy casting.
3: Loam Sand
• A mixture of 50 percent sand grains and 50 percent clay is called
loam sand. It is used for loam moulds of large grey iron casting.
4: Facing Sand
• A sand which is used before pouring the molten metal, on the surface
is called facing sand. It is specially prepared sand from silica sand
and clay.

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5: Backing or Floor Sand
• A sand used to back up the facing sand and not used next to the pattern is called backing sand. The
sand which have been repeatedly used may be employed for this purpose. It is also known as black
sand due to its colour.
6: System Sand
• A sand employed in mechanical sand preparation and handling system is called system sand. This
sand has high strength, permeability and refractoriness.
7: Parting Sand
• A sand employed on the faces of the pattern before the moulding is called parting sand. The parting
sand consists of dried silica sand, sea sand or burnt sand.
8: Core Sand
• The cores are defined as sand bodies used to form the hollow portions or cavities of desired shape
and size in the casting. Thus the sand used for making these cores is called core sand. It is
sometimes called oil sand. It is the silica sand mixed with linseed oil or any other oil as binder.

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• Molding Sand Composition
• The main ingredients of any molding sand are:
– Base sand,Binder, and Moisture
• Base Sand
– Silica sand is most commonly used base sand. Other base sands that are also used for making mold
are zircon sand, Chromite sand, and olivine sand. Silica sand is cheapest among all types of base
sand and it is easily available.
• Binder
• Binders are of many types such as:
– Clay binders,Organic binders and Inorganic binders
Clay binders are most commonly used binding agents mixed with the molding sands to provide the
strength.
The most popular clay types are:
– Kaolinite or fire clay (Al2O3 2 SiO2 2 H2O) and Bentonite (Al2O3 4 SiO2 H2O)
Of the two the Bentonite can absorb more water which increases its bonding power.
• Moisture
Clay acquires its bonding action only in the presence of the required amount of moisture.
When water is added to clay, it penetrates the mixture and forms a microfilm, which coats the surface of
each flake of the clay. The amount of water used should be properly controlled. This is because a part of
the water, which coats the surface of the clay flakes, helps in bonding, while the remainder helps in
improving the plasticity

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Moulding sand mixing or
mulling

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Types of Moulding
 CLASSIFICATION OF MOULDING PROCESSES

(i) Classification based on the method used

(a) Bench moulding. (b) Floor moulding,
(c) Pit moulding. (d) Machine moulding.
(ii) Classification based on the mould material used:
(a) Sand moulding:
1. Green sand mould
2. Dry sand mould, (d) Loam moulding
3. Skin dried mould.
4. Core sand mould.
5. Cement bonded sand mould
6. Carbon-dioxide mould.
7. Shell mould.

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Classification based on
the method used
Bench Molding
This type of molding is preferred for small jobs. The whole molding operation is
carried out on a bench of convenient height. In this process, a minimum of two flasks,
namely cope and drag molding flasks are necessary. But in certain cases, the number of
flasks may increase depending upon the number of parting surfaces required.
Floor Molding
This type of molding is preferred for medium and large size jobs. In this method,
only drag portion of molding flask is used to make the mold and the floor itself is utilized
as drag and it is usually performed with dry sand.
Pit Molding
Usually large castings are made in pits instead of drag flasks because of their huge
size. In pit molding, the sand under the pattern is rammed by bedding-in process. The
walls and the bottom of the pit are usually reinforced with concrete and a layer of coke is
laid on the bottom of the pit to enable easy escape of gas. The coke bed is connected to
atmosphere through vent pipes which provide an outlet to the gases. One box is
generally required to complete the mold, runner, sprue, pouring basin and gates are cut
in it.

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Machine Moulding
For mass production of the casting, the general hand molding
technique proves un economical and in efficient. The main advantage of
machine molding, besides the saving of labor and working time, is the
accuracy and uniformity of the castings which can otherwise be only
obtained with much time and labor. Or even the cost of machining on the
casting can be reduced drastically because it is possible to maintain the
tolerances within narrow limits on casting using machine molding method.
Molding machines thus prepare the moulds at a faster rate and also
eliminate the need of employing skilled molders. The main operations
performed by molding machines are ramming of the molding sand, roll over
the mold, form gate, rapping the pattern and its withdrawal. Most of the
mold making operations are performed using molding machines 51
Pit Molding Floor Molding

Bench Molding Machine Molding 52

Green sand mould Dry sand mould Skin dried mould

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Core sand mould Carbon-Dioxide gas mould

Natrosilite with water+Carbon-dioxide->Silica gel +Sodium carbonate with water

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 ii) Classification based on
the mould material used
Green sand :

Green sand is an aggregate of sand, bentonite clay, pulverized coal and water. Its principal use is in

making molds for metal casting. The largest portion of the aggregate is always sand, which can be either

silica or olivine.

There are many recipes for the proportion of clay, but they all strike different balances between

moldability, surface finish, and ability of the hot molten metal to degas. The coal, typically referred to in

foundries as sea-coal, which is present at a ratio of less than 5%, partially combusts in the presence of

the molten metal leading to off gassing of organic vapors.

Green sand is not green in color, but "green" in the sense that it is used in a wet state (akin to green

wood). According to the Cast Metals Federation website, an alternative casting method is to heat-dry the

molded sand before pouring the molten metal. This dry sand casting process results in a more rigid mold

better suited to heavier castings. 55

Procedure involved in making Green Sand Mould Casting:
• Suitable proportions of silica sand (85-92%), bentonite binder (6-12%), water
(3-5%) and additives are mixed together to prepare the green sand mixture.
• The pattern is placed on a flat surface with the drag box enclosing it. Parting
sand is sprinkled on the pattern surface to avoid green sand mixture sticking
to the pattern.
• The drag box is filled with green sand mixture and rammed manually till its
top surface. The drag box is now inverted so that the pattern faces the top.
Parting sand is sprinkled over the mould surface of the drag box.
• The cope box is placed on top of the drag box and the sprue and riser pin
are placed in suitable locations. The green sand mixture is rammed to the
level of cope box.
• The sprue and the riser are removed from the mould. The cope box is lifted
and placed aside, and the pattern in the drag box is withdrawn by rapping it
carefully so as to avoid damage to the mould. Gates are cut using hand
tools to provide passage for the flow of molten metal.
• The mould cavity is cleaned and finished. Cores, if any are placed in the
mould to obtain a hollow cavity in the casting.
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• The cope is now placed on the drag box and both are aligned with the help
 Advantages and Disadvantages of
Green Sand Mould Casting
• Less expensive Method.
• Sand can be reused many times after reconditioning with clay and moisture.
• Preferred for simple, small and medium size castings.
• Suitable for mass production.

• Moulds prepared by this process lack in permeability, strength and stability.

• They give rise to many defects like porosity, blow holes etc. because of low
permeability and lot of steam formation due to their moisture content.
• Moulds cannot be stored for appreciable length of time.
• Not suitable for very large size casting.
• Surface finish and dimensional accuracy of castings are not satisfactory.
• Mould erosion is common in Green sand mould casting.
• Difficult to cast thin and intricate shapes 57
 Dry Sand Molding
• Dry sand mould is prepared in the same manner as that of green sand moulding, except
that the mould is baked in oven to remove the moisture present in the sand and also the
harden the moulds.
Advantages of Dry Sand Mould Casting:
• Strength and stability of dry sand moulds is high when compared to green sand moulds.
• Baking removes moisture and hence, defects related to moisture are eliminated.
• Dry sand moulds give better surface finish and dimensional tolerance of castings.
Disadvantages of Dry Sand Mould Casting:
• Consumes more time, labour and cost due to baking process. Hence, not suitable for
mass production.
• Not suitable for large and heavy size castings, as they are difficult to bake.
• High capital cost of bake ovens.
• Under baked or over baked moulds is another disadvantage.
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• Skin-dried Molds:
The effect of a dry-sand mold may be partially obtained by drying the mold surface to
some depth, 1/4 to 1 in. Skin drying may be performed by torches or electrical heating elements
directed at the mold surface. Skin-dried molds must be poured shortly after drying, so that moisture
from the undried sand will not penetrate the dried skin
• Carbon-Dioxide Gas Molding
• This process is widely used for rapid hardening the molds & cores made up of green sand.
• The mold making process is similar to conventional molding procedure except the mold material
which comprises of pure dry silica sand free from clay, 3-5% sodium silicate As binder and
moisture content generally less than 3%.
• A small amount of starch may be added to improve the green compression strength and a very
small quantity of coal dust, sea coal, dextrin, graphite and sugar can also be added to improve the
collapsibility of the molding sand.
• The prepared molding sand is rammed around the pattern in the mold box and mold is
prepared by any conventional technique.
• After packing, carbon dioxide gas at about 1.3-1.5 kg/cm2 pressure is then forced all-round the
mold surface to about 20 to 30 seconds using CO2 head or probe or curtain. Cores can be baked
this way.
• The sodium silicate presented in the mold reacts with CO2 and produce a very hard constituents
or substance commonly called as silica gel.

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• Carbon-Dioxide Gas Molding
• This hard substance is like cement and helps in binding the sand grains.
• Molds and cores thus prepared can be used for pouring molten metal for production of
both ferrous and non-ferrous casting.
• The operation is quick, simple require semi-skilled worker.
• The evolution of gases is drastically reduced after pouring the thus prepared mould.
• This process eliminates mold and core baking oven.
• Reclamation of used sand is difficult for this process.
• Cement bonded sand molds.
• A mixture of silica sand containing 8-12% cement and 4-6% water is used.
• When making the mold, the cement-bonded sand mixture must be allowed to harden
first, before the pattern is withdrawn. The mold obtained is then allowed to cure for
about 3-5 days.
• When the metal is poured, heat causes the water of crystallization of the cement to be
driven off, and thus steam must be allowed to pass off through the sand by means of
its porosity and suitably distributed vent holes.
• Large castings with intricate shapes, accurate dimensions and smooth surfaces are
usually produced by this method.
• The only shortcoming being the long time required for the molding process. v)
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Loam moulding

• Loam is a molding sand containing about 50 per cent sand grains and 50 per cent clay.
• Loam molding was much used in the past for making large bronze castings and is still practiced in
some shops, particularly in making huge manganese- bronze propellers.
• In this method a substrate is made of bricks, wood and other material to the approximate contour of
the casting. A very viscous slurry of water, clay and sand is daubed over the framework and worked to
proper shape with sweeps. The mold is dried by forced hot air or torches.
• No pattern is required, as sheet-steel sweeps are so shaped that they generate proper casting
contour as the sweep arm is moved back and forth over a fixed spindle.
• Such sweeps are used occasionally in making molds for large rolling-mill rolls where ordinary molding
sand is used instead of a slurry.
• The chief advantages of this process are savings in pattern cost and storage; pattern storage alone is
an important and expensive item in most foundries.
• Loam molding is slow and laborious, and special molders are required; all work must be done by hand
as the process is very much an art.

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 CORE AND CORE PRINTS

CORE
• A core is a device used in casting and moulding processes to produce
internal cavities and reentrant angles. The core is normally a disposable item
that is destroyed to get it out of the piece. They are most commonly used
in sand casting
CORE PRINTS
• A core must be supported in the mould cavity. Wherever possible, this is
done by providing core prints.
• Core prints are extensions of the core which rest in similar extensions of the
mould cavity so that core remains supported in the mould cavity without the
core falling to the bottom of the cavity

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Making a foundry Core

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Core ramming machines :

Cores can also be prepared by ramming core sands in the core boxes by machines based on

the principles of squeezing, jolting and slinging. Out of these three machines, jolting and

slinging are more common for core making.

Core drawing machines :

The core drawing is preferred when the core boxes have deep draws. After ramming sand in

it, the core box is placed on a core plate supported on the machine bed. A rapping action on

the core box is produced by a vibrating vertical plate. This rapping action helps in drawing off

the core from the core box. After rapping, the core box, the core is pulled up thus leaving the

core on the core plate. The drawn core is then baked further before its use in mold cavity to

produce hollowness in the casting. 64

 Core baking

• Continuous type ovens

• Batch type ovens
• Dielectric bakers
Core finishing

The cores are finally finished after baking and before they are finally set in
the mould. The fins, bumps or other sand projections are removed from the
surface of the cores by rubbing or filing

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66
Types of cores
Green sand Core Dry sand cores
 Unbalanced core
 Balanced Core
 Cover Core
 Horizontal Core
 Vertical Core
 Hanging Core
 Drop core
 Ram-up Core
 Kiss Core

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68
Chaplets

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Requirements of good core
 Green Strength:
In the green condition there must be adequate strength for handling.
 In the hardened state it must be strong enough to handle the forces of casting;
therefore the compression strength should be 100 to 300 psi (0.69 to 2.07 MPa).
 Permeability must be very high to allow for the escape of gases.
 Friability: As the casting or molding cools the core must be weak enough to break
down as the material shrinks. Moreover, they must be easy to remove
during shakeout
 Good refractoriness is required as the core is usually surrounded by hot metal
during casting or molding.
 A smooth surface finish
 minimum generation of gases during metal pouring.

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 GATING SYSTEM
ELEMENTS OF GATING SYSTEM IN MOLD

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 Elements of a Gating System
Pouring Basin:
This is where the molten metal employed to manufacture the part enters the mould. The pouring
basin should have a projection with a radius around it to reduce turbulence.
Down Sprue:
From the pouring basin the molten metal for the casting travels through the down sprue. This should
be tapered so its cross-section is reduced as it goes downward.
Sprue Base:
The down sprue ends at the sprue base. It is here that the casting's inner cavity begins.
Ingate/Choke Area:
Once at the sprue base the molten material must pass through the ingate in order to enter the inner
area of the mould. The ingate is very important in flow regulation during the metal casting operation.
Runners:
Runners are passages that distribute the liquid metal to the different areas inside the mould.
Main Cavity:
The impression of the actual part to be cast is often referred to as the main cavity.
Vents:
Vents help to assist in the escape of gases that are expelled from the molten metal during the
solidification phase of the metal casting process.
Risers:
Risers are reservoirs of molten material. They feed this material to sections of the mould to
compensate for shrinkage as the casting solidifies. There are different classifications for risers.

72
Melting furnaces

• Crucible
• Cupola
• Induction.

73
CRUCIBLE FURNACES

• Crucible furnace is for the melting of non ferrous

metals.
• Its capacity may range from 30 to 150 kg.
The types of crucible furnace are:
1) Pit furnace
2) Coke fired stationery furnace
3) Oil fired tilting furnace
4) Pot furnace

74
 1.PIT FURNACE
• The crucible is placed in a pit below
the floor level, it is fired with coke.
• The charge to be melted is placed in
crucible,coke is packed around the
crucible. Natural draft is provided by
a tall chimney.
• Many crucibles can be placed in a
single pit.
• After the metal is melted, the covers
are removed, the crucibles are lift
out with the help of tongs and taken
to pouring placed.
• This furnace is used for melting non
ferrous metals.
75
 2.COKE FIRED STATIONERY FURNACE

• This furnace is used for melting non ferrous

metals in small quantity.

• This furnace is placed above the floor level.

• The crucible is placed in the heating chamber.

• The heating chamber is lined with refractory's.

• Coke is used as fuel. Forced draft is used.

• A blower is used for supply of air.

76
 3.OIL FIRED TILTING
FURNACE
• This furnace is used for melting non ferrous metals in small
quantity and is fired by oil.
• This furnace is mounted on two pedestals above the floor
level.
• For pouring the molten metal, the furnace is rotated by the
geared hand wheel.
• Oil and air are admitted with pressure through a nozzle.
• The crucible is placed in the heating chamber and is heated
by the flame.
• The furnace can be stopped whenever needed &
temperature can be controlled easily.
• They give lesser pollution.

77
 4.POT FURNACE

• Pot furnace is used for melting non ferrous

metals like aluminum, magnesium, tin,
lead etc.
• The pot is made up of cast iron or steel.
• The furnace may be fired by gasoline oil or
coke.
• The molten metal is taken out of the pot
furnace
by using ladles.
• Normally the capacity of pot furnace is
around
500 kg.

78
 CUPOLA FURNACE

• For many years, the cupola was the primary method of melting used in iron

foundries. The cupola furnace has several unique characteristics which are

responsible for its widespread use as a melting unit for cast iron.

• Cupola furnace is employed for melting scrap metal or pig iron for production of

various cast irons. It is also used for production of nodular and malleable cast

iron. It is available in good varying sizes. The main considerations in selection of

cupolas are melting capacity, diameter of shell without lining or with lining, spark

arrester.

79
 Shape

A typical cupola melting furnace consists of

a water-cooled vertical cylinder which is
lined with refractory material

80
 Construction &
Various Zones of Cupola Furnace

 The construction of a conventional 1. Well

cupola consists of a vertical steel 2. Combustion zone
3. Reducing zone
shell which is lined with a 4. Melting zone
refractory brick. 5. Preheating zone
 The charge is introduced into the 6. Stack
furnace body by means of an
opening approximately half way up
the vertical shaft.
 The charge consists of alternate
layers of the metal to be melted,
coke fuel and limestone flux.
 The fuel is burnt in air which is
introduced through tuyeres
positioned The hot gases
generated in the lower part of the
shaft ascend and preheat the
descending charge.
81
 Working of Cupola Furnace

Charging of Cupola Furnace

• Before the blower is started, the furnace is uniformly
pre-heated and the metal and coke charges, lying in
alternate layers, are sufficiently heated up.
• The cover plates are positioned suitably and the
blower is started.
• The height of coke charge in the cupola in each layer
varies generally from 10 to 15 cms. The requirement
of flux to the metal charge depends upon the quality
of the charged metal and scarp, the composition of
the coke and the amount of ash content present in
the coke.
82
Working of Cupola Furnace

• The charge, consisting of metal, alloying ingredients, limestone, and coal

coke for fuel and carbonization (8-16% of the metal charge), is fed in
alternating layers through an opening in the cylinder.
• Air enters the bottom through tuyeres extending a short distance into the
interior of the cylinder. The air inflow often contains enhanced oxygen levels.
• Coke is consumed. The hot exhaust gases rise up through the charge,
preheating it. This increases the energy efficiency of the furnace. The charge
drops and is melted.
• Although air is fed into the furnace, the environment is a reducing one.
Burning of coke under reducing conditions raises the carbon content of the
metal charge to the casting specifications.

83
• As the material is consumed, additional charges can be added to the
furnace.
• A continuous flow of iron emerges from the bottom of the furnace.
• Depending on the size of the furnace, the flow rate can be as high as 100
tones per hour. At the metal melts it is refined to some extent, which
removes contaminants.
• This makes this process more suitable than electric furnaces for dirty
charges.
• A hole higher than the tap allows slag to be drawn off.
• The exhaust gases emerge from the top of the cupola. Emission control
technology is used to treat the emissions to meet environmental standards.
• Hinged doors at the bottom allow the furnace to be emptied when not in use
84
Induction Furnaces

Types of Induction Furnace :

1. Core-Type Induction Furnace

2. Coreless-type induction furnace

85
Cored-Type Induction Furnace

86
Coreless-type induction furnace

87
• Induction furnace has the same principle as a transformer.

• The principle of induction melting is that a high voltage electrical source from a primary coil induces

a low voltage, high current in the metal or secondary coil.

• Induction heating is simply a method of transferring heat energy.

• A high- frequency current is passed through a water-cooled coil which acts as the primary coil of a

transformer.
• Medium frequency 10-25 kHz and High frequency 150-350 kHz

• The charge i.e. steel scrap or other conductive metal, acts as the secondary coil of a transformer.

• The high-frequency alternating current passing through the primary coil generates a magnetic

flux which cuts the secondary coil i.e. the metallic charge and induces an electromotive force, emf,

in the charge and the charge gets heated up.

• When the temperature rises above the melting point of the metallic charge, it changes to liquid

phase and tapped out of the furnace for further processing

88
Traditional Manufacturing Processes

Casting
Forming

Sheet metal processing

Powder- and Ceramics Processing

Plastics processing

Cutting

Joining

Surface treatment

89
 Casting processes

Refractory mold  pour liquid metal  solidify, remove  finish

 VERSATILE: complex geometry, internal cavities, hollow sections

 VERSATILE: small (~10 grams)  very large parts (~1000 Kg)

 ECONOMICAL: little wastage (extra metal is re-used)

 ISOTROPIC: cast parts have same properties along all directions

90
 Different Casting Processes

Process Advantages Disadvantages Examples

Sand many metals, sizes, shapes, cheap poor finish & tolerance engine blocks,
cylinder heads
Shell mold better accuracy, finish, higher limited part size connecting rods, gear
production rate housings
Expendable Wide range of metals, sizes, patterns have low cylinder heads, brake
pattern shapes strength components
Plaster mold complex shapes, good surface non-ferrous metals, low prototypes of
finish production rate mechanical parts
Ceramic mold complex shapes, high accuracy, small sizes impellers, injection
good finish mold tooling
Investment complex shapes, excellent finish small parts, expensive jewellery

Permanent good finish, low porosity, high Costly mold, simpler gears, gear housings
mold production rate shapes only
Die Excellent dimensional accuracy, costly dies, small parts, gears, camera bodies,
high production rate non-ferrous metals car wheels
Centrifugal Large cylindrical parts, good quality Expensive, few shapes pipes, boilers,
flywheels

91
 INTRODUCTION-
Investment Casting:-
Investment Casting:-
• One of the oldest known metal-forming
Technique.
• Today high-technology waxes, refractory
material and specialist alloys used.
• Casting allow the production of
components with accuracy, repeatability,
versatility and integrity in a variety of
metals and high-performance alloys.
• Utilized it when complex detail, undercut
or non-machinable features and accurate
parts are required.
• It requires best significant lead time and
is best suited for low volume production
rate.

92
Sequential steps for investment casting
Produce a master pattern
Produce a master die
Produce wax patterns
Assemble the wax patterns onto a common wax sprue
Coat the tree with a thin layer of investment material
Form additional investment around the coated cluster
Allow the investment to harden
Remove the wax pattern from the mold by melting or
dissolving
Heat the mold
Pour the molten metal
Remove the solidified casting from the mold
93
94
 Investment casting (lost wax casting)

(a) Wax pattern (b) Multiple patterns

(injection assembled to wax
molding) sprue

(c) Shell built 

(d) dry ceramic immerse into ceramic
melt out the wax slurry
fire ceramic (burn  immerse into fine
wax) sand
(few layers)

(e) Pour molten metal (gravity)

 cool, solidify (f) Break ceramic shell
[Hollow casting: (vibration or water
pouring excess metal before blasting)
solidification

(g) Cut off parts

(high-speed friction
saw)
 finishing (polish) 95
 Manufacturing Process
Step I tooling:-
• Investment Casting is to create a die and form of part to the required
specifications.
• The die is used to inject paraffin wax, which is used to create the complex
shapes required manufacture component or part.
• Die is attached to a central sprue. Multiple die may be attached to same
sprue. The sprue is a channel which distribute the molten wax into each of
the die or forms.
• Tool is constructed from Aluminum or hot die steel material.
• For most applications single/multi cavity dies are used for high production
quantities.

96
Step II Shell Building:-
• The wax assembly is now dipped into a ceramic slurry, to obtain the shell
thickness desired.
• A layer of fine sand (zircon) is added on top of each ceramic layer.
• This process repeated until the desired shell or casting form is created.
Step III :-
• After the shell/casting form is created, the wax is removed.
• This is where the term Lost-wax process comes form.
• This leaves an impression or casting form which will create the desired
investment casting part, which will be filled with the desired metal or
material.
• Before beginning the casting, shell must be heated up in a furnace so
they do not fail due to differential temperature introduced pouring in the
molten metal or material.

97
.
Step IV :-
• The casting metal or material is poured into the pre-heated ceramic
shell.
• The casting material fills each part and feature of the investment
casting shell.
• The individual cast part will be removed after the mold cools and the
shell is removed.
• The shell is typically removed by water blasting, through alternative
methods are available.
• They are still attached to the sprue assembly or each other.
• Individual parts are removed by cold-break (dipping in liquid nitrogen
and breaking the parts off with hammer and chisel) or with alternative
manufacturing machine tools.

98
Step V :-
• The rough cast parts are now separated with each other and the sprue.
• First the gate or the place where parts was connected to the sprue, must
be removed.

Step VI :-
• Investment Casting yield exceedingly fine quality products made off all type
of metals.
• It has special application in fabrication very high temperature metal,
specially those which can not cast in metal or plaster molds and those
which are difficult to machine or work.

99
Type of material for which
the process is used

• A pattern of the component to be cast is produced by injection-molding

special waxes into a metal die.
• Pre-formed ceramic cores can be included in the wax pattern as it is
molded, which can create intricate hollows within the finished casting.
• As many as several hundred patterns may be assembled into a tree
around a wax runner system (riser and sprue). Once a tree has been
assembled, a pour cup is attached.

Shell for cast turbocharger rotor

100
• The completed tree is dipped or inverted by hand or via robotic control into
a ceramic slurry of ethyl silicate, colloidal silica.
• Fine sand is applied to the inverted tree in a fluidised bed, rain tower
sander or by hand.
• During primary coat the sand will be typically be a zircon-based, as
zirconium Is less likely to react with the molten metal when poured into the
shell.
• The stuccoed tree is then allowed to dry before re-dipping in slurry and
applying secondary coats of mullite, molochite, chamotte or fused silica
refractory material.
• This process is repeated until the shell is thick enough to withstand the
mechanical shock of receiving the molten metal. Dry times range from 24
to 48 hours, and total production from two days to one week.

View of the ceramic impression in a turbocharger shell

101
.
• After the shell has been constructed, the wax is removed in an
autoclave or furnace (hence, the lost-wax process).
• Most shell failures occur at this point, as the fragile stuccoed shell is
subjected to extremes of temp. and in an autoclave pressure.
• The shell is fired at temp. of around 1100 C to induce chemical and
physical changes in the set refractory materials forming a ceramic
shell.
• This leave a ceramic impression of the part to be cast.
• Most foundries remove the shells from the furnace while still hot and
pour the molten metal into the ceramic shell.
• Various methods of pouring the molten metal include vacuum
casting, anti-gravity casting, tilt casting, gravity pouring, pressure
assisted pouring, centrifugal casting.

102
 .
• After the molten metal cools, the shell is removed. This is generally done
with water jets, vibration, grit blasting or chemical dissolution.
• The cooled parts are removed from the tree by sawing them free or by
dipping them in liquid nitrogen and breaking them off with a hammer and
chisel.
• Many cast parts require grinding of the gate and runner bar attachments.
• Because molten metal cools slowly, it does not finish as hard as some
forging and machining processes.
• Cast parts often are subsequently hardened by heat treatment and surface
hardening.
• The parts are inspected by eye or in special cases by X-ray at the foundry
or by specialty firms.

Completed turbocharger rotor

103
A property of the material is
affect by the process

Thermo physical properties of wax

• The linear deformation of the sample, which was measured as a
function of temperature, was converted to thermal expansion and
density data.
• At temperatures below 55 °C, the wax behaved like a hard paste or
solid.
• As the wax was heated above 60 °C, the wax lost its strength,
became very soft, and flowed out into the surrounding silica powder.
The density at 110 °C was obtained using a hydrometer.

104
 Advantages
• Investment casting is a special propose manufacturing process, use in
jewelry.
• Through investment casting we can produce complex parts. Example-
turbine blades, aerospace, power generation, complete aircraft door
frames.
• It gives extremely good surface finish 80 to 120 micron inches.
• It is also widely used by firearms manufacturers to fabricate firearm
receivers, triggers, hammers, and other precision parts at low cost.
• Great design freedom.
• Feasibility of replacing two or more fabricated sub-assembling by a single
piece casting.
• Lighter, Stronger components may be designed, without a mismatch
giving an improved aesthetic appearance.
• The process permits a high level of consistency, batch to batch.

105
• Compared to other conventional way of manufacturing casting, with lost
wax process close dimensional tolerance of ± 0.13mm to 0.25mm.
• With the ability to produce special alloys to customers' requirements, the
choice of metallurgical specifications is virtually unlimited.
• The light stressed wax impression dies have a very long life and are not
costly considering design complexity.
• If required, minor design modification may be made economically without
going for few tooling.
• A high level of metallurgical integrity and Strength can be achieved in the
lost wax process.

106
Disadvantages

• Investment casting cost is high.

• Investment casting requires specialized equipment.
• In this costly refractories and binders.
• Many operations to make a mold so it is time taking process around
two to one week.
• Some time leave occasional minute defects like macro and micro
defects, includng shrinkage porosity, grain size and the extent of
surface (100 microm) of the casting solidifies after the bulk.

107
Centrifugal castings

108
• Centrifugal casting or rotocasting is a casting technique that is typically
used to cast thin-walled cylinders.
• the high quality of the results attainable, particularly for precise control of their
metallurgy and crystal structure. Unlike most other casting techniques,
centrifugal casting is chiefly used to manufacture stock materials in standard
sizes for further machining, rather than shaped parts tailored to a particular
end-use.
Its classified in to
1. True centrifugal castings
2. Semi centrifugal castings
3. Centrifuge castings
109
110
Process

• In centrifugal casting, a permanent mold

is rotated continuously about its axis at
high speeds (300 to 3000 rpm) as the
molten metal is poured. The molten
metal is centrifugally thrown towards the
inside mold wall, where it solidifies after
cooling.
• The casting is usually a fine-grained
casting with a very fine-grained outer 111
Features of centrifugal casting

• Castings can be made in almost any length, thickness and diameter.

• Different wall thicknesses can be produced from the same size mold.
• Eliminates the need for cores.
• Resistant to atmospheric corrosion, a typical situation with pipes.
• Mechanical properties of centrifugal castings are excellent.
• Only cylindrical shapes can be produced with this process.
• Size limits are up to 3 m (10 feet) diameter and 15 m (50 feet) length.
• Wall thickness range from 2.5 mm to 125 mm (0.1 - 5.0 in).
• Tolerance limit: on the OD can be 2.5 mm (0.1 in) on the ID can be
3.8 mm (0.15 in).
• Surface finish ranges from 2.5 mm to 12.5 mm (0.1 - 0.5 in) rms.

112
113
Centrifugal Casting Machine
Developed ~1923

114
Semi-Centrifugal Casting

•Semicentrifugal

casting
115
116
Centrifuging
• Centrifuging is used for forcing metal from a
central axis of the equipment into individual mold
cavities that are placed on the circumference.
• This provides a means of increasing the filling
pressure within each mold and allows for
reproduction of intricate details.
• This method is often used for the pouring of
investment casting pattern.

117
118
 Applications

• Typical parts made by this process are

• pipes,
• boilers,
• pressure vessels
• flywheels, cylinder liners and other parts that are axi-
symmetric.
• It is notably used to cast cylinder liners and sleeve valves for
piston engines, parts which could not be reliably
manufactured otherwise.

119
Advantages
• Castings acquire high density, high mechanical strength
and fine grained structure
•   Inclusions and impurities are lighter
• Gates and risers are not needed     
• High output
• Formation of hollow interiors without cores

Disadvantages 
• An inaccurate diameter of the inner surface of the casting.
•  Not all alloys can be cast in this way.

120
DIE CASTING

121
 The Die casting process is subdivided
into two distinct subgroups:

Classification of die casting:

(a)Gravity Die Casting (also called permanent mould process)

(b)Pressure Die Casting

1. Low pressure Die-Casting

2. High pressure Die-Casting

1. Hot Chamber Die casting

2. Cold Chamber Die casting

122
 Gravity Die Casting

• Gravity Die Casting is a permanent mould casting process

• The molten metal is poured from a vessel or ladle into the mould.
• The cavity fills with no force other than gravity, filling can be controlled
by tilting the die.
• This process gives a better surface finish than sand casting as well as
better mechanical properties, both due to rapid solidification

123
124
• low gas porosity and fine grain sizes can be achieved.
Advantages
• Compared to sand casting, this process requires less finishing and fettling and gravity die
casting tends to produce the highest quality product.
• Accuracy achievable is limited with minimum wall of thickness of 3 to 5mm.
• Castings can be heat treated to improve their physical properties by approximately 30%.
• No need for applied pressure, so mould designs tend to be quite simple
• Scrap metal can be recycled
• Quick set up times

• High percentage of scrap metal

Disadvantages
• High occurrence of porosity, but this can be minimized by slower pouring
• Only good for simple 3D shapes, cannot be used for complex shapes

125
 The Low-Pressure Die Casting Process

• Low-pressure die casting is a process best suited for

aluminum components that are symmetric around an
axis of rotation.
• Vehicle wheels, for example, are often fabricated
through low-pressure die casting. In this type of
process, the mold is situated vertically above the molten
metal bath and connected via a riser tube.
• When the chamber is pressurized (usually between 20
and 100kPa), the metal is pulled upward and into the
mold. The elimination of feeders from this type of die
casting process delivers the high casting yields.

126
127
 The High-Pressure Die Casting Process

The Hot-Chamber Die Casting Process 

• Hot-chamber die casting, sometimes called gooseneck casting, is the more popular
of the two die casting processes.
• The cylinder chamber of the injection mechanism is completely immersed in the
molten metal bath. A gooseneck metal feed system draws the molten metal into the
die cavity.
• While direct immersion in the molten bath allows for quick and convenient mold
injection.
• hot-chamber die casting process is best suited for applications that utilize metals
with low melting points and high fluidity.
• Good metals for the hot-chamber die casting process include lead, magnesium, zinc
and copper. 
128
129
130
 The Cold-Chamber Die Casting Process 

• The cold-chamber die casting process is very similar to hot-chamber

die casting. With a design that focuses on minimizing machine corrosion
rather than production efficiency.
• The melted metal is automatically- or hand-ladled into the injection
system. This eliminates the necessity for the injection mechanism to be
immersed in the molten metal bath.
• For applications that are too corrosive for the immersion design of hot-
chamber die casting, the cold-chamber process can be an excellent
alternative.
• These applications include the casting of metals with high melting
temperatures, such as aluminum and aluminum alloys. 
131
132
133
 Die casting materials

 Zinc: the easiest alloy to cast; high ductility; high impact

strength; easily plated; economical for small parts;
promotes long die life.

 Aluminum: lightweight; high dimensional stability for

complex shapes and thin walls;.

 Magnesium: the easiest alloy to machine; excellent

strength-to-weight ratio; lightest alloy commonly die cast.

• Copper: high hardness; high corrosion resistance; highest

mechanical properties of alloys die cast; excellent wear
resistance. 134
 The main benefits of the
die casting process include 

High quality: Parts created through die casting deliver a long service life.

High reliability: Uniformity of mass-produced parts is exceptional.

Quick production: Die cast tooling requires minimal maintenance.

Versatile design: Die casting can create virtually any size, part geometry,
surface texture or luster.

Minimal assembly: Assembly features such as studs, drill holes and

bosses can be integrated into mold design. 

135
Advantages:
• Excellent dimensional accuracy
• Smooth cast surfaces (1—2.5 μm rms).
• Thinner walls can be cast
• Inserts can be cast-in (such as threaded inserts, heating elements )
• Reduces or eliminates secondary machining operations.
• Rapid production rates.
• tensile strength as high as 415 MPa .
Disadvantages:
• Casting weight must be between 30 grams and 10 kg
• Casting must be smaller than 600 mm
• High initial cost.
• Limited to high-fluidity metals.
• A certain amount of porosity is common.
• Thickest section should be less than 13 mm
• A large production volume is needed to make this an economical .
136
Cleaning & Fettling

137
• After the metal has solidified and cool in the mold.
• These molds go to a shake out station where the sand and casting are dumped
from the flask.
• The casting are shaken free from the molding and some dry sand cores are
knocked out.
• This process of shake out is called the cleaning of castings.
• Actually shake out is done by two methods, manually or mechanically.
• Generally mechanical shake out are used for large scale work.
• This unit consists of heavy mesh screen fixed to a vibrating frame.
• The screen vibrate mechanically and quick separation of sand from other
parts. 138
• The manually work is done for small castings.
• In this work the stationary gratings are mounted and
molds are break by dropping the molds over gratings.
• After that the sand is return to the storage bin , flasks
are sent to the molding sections and castings
(production) go to the cleaning department for fettling.
FETTLING
• The complete process of cleaning of castings called
fettling.
• It involves the removal of the cores, gates, sprues,
runners, risers and chipping of any of unnecessary
projections on the surface of the castings.
• The fettling operation may be divided in to different 139
 Removal of gates and risers. Gates and risers can be removed from
casting by several methods depending upon size and metal used.
 With chipping hammer. It is particularly suited in case of grey iron
castings and brittle materials.
• The gates and risers can easily be broken by hitting the hammer.
 With cutting saw. These saws may be hand saw and power saw are
used for cutting the ferrous like steel, moldable iron and for non ferrous
materials except aluminum.
• Mostly the hand saws are used for small and medium but when power
and used for large work.
 With flame cutting. This type of method is specially used for ferrous
materials of large sized castings where the risers and gates are very
heavy.
• In this the gas cutting flames and arc cutting methods may be
employed .(it is not applicable for small castings.)

140
For sprue cutting. The shear is
specially made tool on punch press
base .
–In this there is heavy matching
steel jaws are fitted.
–It is mostly used for meltable iron
soft and medium , hard steel brass
bronze Al, Mg. 141
• The fins and other small projections may easily be chipped off with
the help of either hand tools or pneumatic tools.
• But for smoothing the rough cut gate edges either the pedestal or
swing frame grinder is used depends upon the size of castings.
• For cleaning the sand particles sticking to the casting surface sand
blasting is normally used.
• In this method the casting is kept in a closed chamber and a jet of
compressed air with a blast of sand grains or steel grit is directed
against the casting surface which thoroughly cleans the casting
surface.
• The shots used are either chilled cast iron grit or steel grit.
• Chilled iron is less expensive but is likely to be lost quickly by
fragmentation.
• In this process the operator should be properly protected.
• Unlike this method is adopted for small as well as for large and more
efficient and ensure good polish. 142
• This work is dangerous due to harm full dust, but today the
• An other use full method for cleaning the casting
surface is the tumbling.
• This is an oldest machine method for cleaning the
casting surfaces.
• In this method the castings are put in large sheet
shell or barrel along with the castings and small
piece of white cast iron called stars.
• The barrel is supported on horizontal turn ions and
is related at the speed varying from 25-30rpm for
15-30 minutes.
• It causing the castings to tumble over to another,
rubbing against the castings and the stars.
143
• Thus by continuous peeing action not only are the
Repairing the castings.
– Defects such as blow holes ,gas holes ,cracks may
often occur in castings.
– Some times castings are broken , bent or deformed
during shake out or because of rough handling.
– The castings are wrapped during heat treatment or
while it cools down in the molds.
 Such defective castings are not be rejected out right
for reasons of economy.
– They are therefore repaired by suitable means and
put to use unless the defects are such that they
cannot be remedied.
– In this regard the large size cracks blow holes can144
Casting defects

– Casting defects are usually not an accident but

they occur because steps in the preparation of
molds are not properly controlled.
– Actually several types of defects may occur
during casting considerably reducing the total
out put of casting besides increasing the cost of
their production.
– It is there fore essential to under stand the
causes behind these defects so that they may
be suitably eliminated.
– Casting defects may be defined as those 145
Casting defects

146
147
148
THANK YOU

149