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    Foundry 1

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    Raghav Mohta
    A foundry is a factory where metal casting is done. The casting process involves creating a pattern, using the pattern to form a mold, melting metal, pouring the molten metal into the mold, and allowing it to solidify into the desired shape. Casting allows the production of complex metal parts with internal cavities or hollow sections in a cost-effective manner. While castings have some disadvantages like potential defects from solidification and lower strength than other fabrication methods, they offer versatility for a wide range of part geometries and materials.

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    Foundry 1

    Uploaded by

    Raghav Mohta
    23 views17 pages
    A foundry is a factory where metal casting is done. The casting process involves creating a pattern, using the pattern to form a mold, melting metal, pouring the molten metal into the mold, and allowing it to solidify into the desired shape. Casting allows the production of complex metal parts with internal cavities or hollow sections in a cost-effective manner. While castings have some disadvantages like potential defects from solidification and lower strength than other fabrication methods, they offer versatility for a wide range of part geometries and materials.

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    A foundry is a factory where metal casting is done. The casting process involves creating a pattern, using the pattern to form a mold, melting metal, pouring the molten metal into the mold, and allowing it to solidify into the desired shape. Casting allows the production of complex metal parts with internal cavities or hollow sections in a cost-effective manner. While castings have some disadvantages like potential defects from solidification and lower strength than other fabrication methods, they offer versatility for a wide range of part geometries and materials.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    23 views17 pages

    Foundry 1

    Uploaded by

    Raghav Mohta
    A foundry is a factory where metal casting is done. The casting process involves creating a pattern, using the pattern to form a mold, melting metal, pouring the molten metal into the mold, and allowing it to solidify into the desired shape. Casting allows the production of complex metal parts with internal cavities or hollow sections in a cost-effective manner. While castings have some disadvantages like potential defects from solidification and lower strength than other fabrication methods, they offer versatility for a wide range of part geometries and materials.

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    Foundry A place or a factory where metal products (castings) are

    produced.
    Its consists of: pattern mold (gating and riser system) furnace
    (molten metal) pouring molten metal in mold casting cleaning.

    Casting:
    Process in which molten metal flows by gravity or other force into a mold cavity
    where it solidifies in the shape of the mold cavity.

    Steps:
    1. Melt the material in suitable furnace
    2. Pour it into a mold
    3. Solidification/Cooling

    DifferentComponentsDifferentAspects

    Capabilities and Advantages


    Versatile: complex geometry, internal cavities, hollow sections
    Versatile: small (~10 gms) to very large parts (~1000 Kg)
    Engine blocks and heads, machine frames, railway wheels, pipes, church, bells etc.
    Dental crowns, jewelry, small statues, frying pans

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


    ISOTROPIC: cast parts have same properties along all directions
    Some casting methods are suited to mass production
    All varieties of metals can be cast, ferrous and nonferrous
    High complexity with few steps (usually)
    Castings offer cost and performance advantages because of their shape.
    The molten metal is poured or injected and allowed to cool. The
    composition, structure, and properties can be tailored for a specific end
    product.

    Disadvantages of Casting
    Limitations on mechanical properties (Castings have lower strength than

    formed parts).
    Poor dimensional accuracy and surface finish for some processes;
    e.g., sand casting
    Safety hazards to workers due to hot molten metals
    Environmental problems
    Expensive and time-consuming patterns/molds/dies
    Solidification issues: shrinkage, porosity, ~low strength, brittleness
    Some methods require many steps

    Green Sand molding/casting

    Classification of casting processes

    Pattern Mold Pour Cool Remove Inspect

    When the mold is used for single casting, it made of sand and known as
    expendable mold

    When the mold is used repeatedly for number of castings and is made of metal
    or graphite are called permanent mould

    For making holes or hollow cavities inside a casting, cores made of either sand
    or metal are used.

    Requirements
    Mold : single or multiple use
    Melting Process
    Pouring Technique
    Solidification Process
    Mold removal
    Clean, Finish, Inspection

    Patterns
    Variety of patters are used in casting and the choice depends on the
    configuration of casting and number of casting required
    Single-piece pattern
    Split pattern
    Follow board pattern
    Cope and drag pattern
    Match plate pattern
    Loose-piece pattern
    Sweep pattern
    Skeleton pattern

    (a)Split pattern
    (b) Follow-board
    (c) Match Plate
    (d) Loose-piece
    (e) Sweep
    (f) Skeleton pattern

    Pattern Material Characteristics


    Pattern materials:
    Wood - common material because it is easy to work, but it
    warps
    Metal - more expensive to make, but lasts much longer
    Plastic - compromise between wood and metal

    Types of patterns used in sand castings:


    (a) solid pattern, (b) split pattern, (c) match-plate pattern (d) cope and
    drag pattern

    Pattern allowances

    Shrinkage allowance

    Draft allowance (taper, angle)

    Machining allowance

    Distortion allowance

    Patternmakers account for solidification shrinkage and thermal contraction


    by making mold cavity oversized
    Amount by which mold is made larger relative to final casting size is called
    pattern shrinkage allowance
    Casting dimensions are expressed linearly, so allowances are applied
    accordingly

    Shrinkage allowance for sand molds


    (10mm/m to 20mm/m)

    Solidification
    Solidification:
    Transformation of molten metal back into solid state
    Influence shape, size, uniformity and chemical composition
    Types
    Pure Metal
    Alloys
    Eutectic Alloy

    (1) Cooling of melt by heat flow outward through the mold walls
    (2) Nucleation of crystals, accompanied with additional heat loss
    in the form of latent heat.
    (3) Growth of crystals, either opposite or parallel to heat flow
    direction, which results in overall morphological changes

    The material is a single crystal inside a dendrite, just like a grain.

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