Manufacturing Process Casting

Manufacturing is processing raw materials or parts into finished goods through the use of tools,
human labor, machinery
Manufacturing processes can be classified into various types based on the methods used, such
as shaping, joining, finishing,
1. What is mean by casting? explain any one type of casting process with neat
sketch.
The casting process is a manufacturing method that produces desired-shape metal parts by pouring
molten metal into a mold and solidifying and cooling it to the room temperature
it’s capable of producing complex and intricate parts, irrespective of their sizes. there are different types
of casting that differ by the material and mold used.
BASIC STEPS OF CASTING PROCESS:

Mostly, casting processes follow some basic steps like pattern making, mold making, selection and
pouring of metal alloys and finally, finishing of the casted part.
1. CREATE A MOLD
The first step is to create the mold for the casting. A sand mold is formed by packing sand into each half
of the mold (learn more about types of sand used in sand casting). The sand is packed around the
pattern, which is a replica of the external shape of the casting. When the pattern is removed, the cavity
that will form the casting remains. The top and bottom halves of the mold are known as the “cope” and
“drag”, respectively.
2. PREPARE AND CLAMP THE MOLD
Once the mold has been made, it must be prepared for the molten metal to be poured. The surface of
the mold cavity is first lubricated to help with the removal of the casting (the type of lubricant will
depend on the type of sand and metal used), then the mold halves are closed and securely clamped
together. It is essential the mold halves remain securely closed to prevent the loss of any material. In this
photo, “jackets” are used to secure the two halves together.
3. POUR MOLTEN METAL INTO MOLD
Molten metal is poured into the mold through a gating system, or gap leading from the casting cavity to
the outside of the mold.
4. ALLOW METAL TO COOL
The molten metal that is poured into the mold will begin to cool and solidify once it enters the cavity.
When the entire cavity is filled and completes the metal solidification process, the final shape of the
casting is formed. The mold can’t be opened until the proper cooling time has elapsed.
5. REMOVE HARDENED CASTING FROM MOLD
After the solidification time has passed, the sand mold can simply be broken, and the casting removed
Different Types of Casting Process

There are different types of casting processes, and each process has its own advantages and
disadvantages as per the user requirement.
1. Sand Casting Process:
Sand casting is a versatile casting process that can be used to cast any metal alloy, ferrous or non-ferrous.
It is widely used for mass production in industrial units, such as automotive metal casting parts, like
engine blocks, cylinder heads, crankshafts, etc.
The process uses a mold that’s made of silica-based materials, such as naturally-bonded or synthetic
sand form the smooth mold surface. The mold surface has 2 parts, cope (the upper half) and drag (the
lower half). Molten metal is poured into the pattern using a pouring cup and left to solidify to take the
final shape. Finally, trimming off extra metal is done for the finishing of the final metal casting product.
Sand casting has its advantages and disadvantages.
Advantages Disadvantages
Relatively inexpensive in terms of Lower degree of accuracy as compared to

production costs, especially in low-volume
alternate methods
production
Difficult to use this method for products with

Fabrication of large components
pre-determined size and weight specifications
The process yields products with a rough surface

Casting both ferrous and non ferrous alloys
finish
Recycling ability
Processing of metals with high melting

temperatures, such as, steel and titanium
2. CENTRIFUGAL CASTING:
Centrifugal casting, also known as roto casting, is a process for industrially manufacturing cylindrical
parts with centrifugal forces. This type of metal casting uses a preheated spinning die in which the
molten metal is poured. The centrifugal forces help to distribute the molten metal within the die at high
pressure.
Three variations of centrifugal casting exist; true centrifugal casting process, semi centrifugal casting
process, and vertical centrifugal casting process. Semi centrifugal casting, unlike true centrifugal casting,
has the mold completely filled using a sprue. However, in true centrifugal casting, molten metal sticks to
the sides due to continuous rotation. On the contrary, vertical centrifugal casting, as the name suggests,
uses directional molding following the same process as true centrifugal casting.
Typically, centrifugal casting produces rotational shapes like cylinders. In particular, parts like bush
bearings, clutch plates, piston rings, and cylinder liners, etc. Also, the pouring of metal in the center of
the mold helps in reducing defects such as blow holes, shrinkage, and gas pockets. However, it is not
suitable for all kinds of metal alloys.
Improved process yields and reduced wastage Centrifugal casting requires high investments
Casting has high density and almost no defects Requirement of skilled labor
The process is convenient to manufacture barrel

Specific shapes production
and sleeve composite metal castings
No requirement of gates and risers
Investment casting is a manufacturing process in which a wax pattern is coated with a refractory ceramic
material. Once the ceramic coating material is dry and hardened, the wax is melted out and leaves an
internal cavity the shape of the final product’s geometry. Molten metal is poured into the cavity where
the wax pattern was. The metal solidifies within the ceramic cavity, cools, and the ceramic is removed
from the metal casting
It can produce parts with thin walls, more

Requires labor for use
complexity and high surface quality
Reduces the need for post-casting

Production cycle is longer
machining
Can cast hard-to-melt alloys such as

Higher manufacturing costs of molds
stainless steel, thin steel, etc.
Due to breaking away of the shell mold, it New die requirement for the creation of
allows for castings with 90-degree angles wax patterns for each casting cycle
High dimensional accuracy in products
Shrinkage allowance in the mold

Manufacturing Process Casting

Uploaded by

Copyright:

Available Formats

Manufacturing Process Casting

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manufacturing Process Casting

Uploaded by

Copyright:

Available Formats

Manufacturing is processing raw materials or parts into finished goods through the use of tools,

human labor, machinery

BASIC STEPS OF CASTING PROCESS:

2. PREPARE AND CLAMP THE MOLD

3. POUR MOLTEN METAL INTO MOLD

4. ALLOW METAL TO COOL

Different Types of Casting Process

1. Sand Casting Process:

Sand casting has its advantages and disadvantages.

Relatively inexpensive in terms of Lower degree of accuracy as compared to

Difficult to use this method for products with

The process yields products with a rough surface

Processing of metals with high melting

The process is convenient to manufacture barrel

No requirement of gates and risers

It can produce parts with thin walls, more

Reduces the need for post-casting

Can cast hard-to-melt alloys such as

High dimensional accuracy in products

Shrinkage allowance in the mold

You might also like