introduction to casting processes by stead fast engineers pvt ltd – part 2
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Introduction to casting processes by stead fast engineers pvt ltd – part 2.choose here Induction Furnace manufacturers,Induction heater manufacturers,Induction Billet heater Manufacturers,Induction Melting furnace manufacturers,Induction Furnace Manufacturers in India,Induction Billet heater manufacturers in India,Induction heating system,Induction Melting Furnace for your needs.TRANSCRIPT
Introduction To Casting Processes by Stead Fast Engineers Pvt Ltd –
part 2
one of the leading Induction heating system manufactures
Design, Materials and Economics
Design Considerations in Casting• Design of the part
• Casting process and material
• Locate parting line• Locate design gates• Locate mold features
such as sprue, screens and risers
Design Consideration of Cast Parts
• Corners, angles, section thickness– Avoid sharp
corners angles and fillets
– Stress raisers, cracking, and tearing
– Sections should be blended smoothly
Design Consideration of Cast Parts
Design Consideration of Cast Parts• Flat Areas
– Large flat areas may warp during cooling
– Poor surface finish from uneven flow in pouring
– Resolve with ribs, and serrations
• Circles and Rounds– Lower cooling rate in
circles induces hot spots– Shrinkage cavities and
porosity
Design Consideration of Cast Parts• Shrinkage
– to avoid cracking during the cooling process there should be shrinkage allowance
– Staggered ribs, change the intersection geometry
• Patternmaker’s Shrinkage Allowance– 10-20 mm/m
Design Consideration of Cast Parts• Draft
– Used to enable easy removal of pattern without damage to mold
– Range from 5 to 15mm/m
– Angles of 0.5° to 2°• Dimensional Tolerances
– As wide as possible within limits of good performance
– Letters and markings
Locating the Part Line• Part line – separates upper
and lower mold– Flat plane, along
corners or edges– This will avoid
flash at the parting lines
Locating and Designing Gates• Gates
– Connections between runners and the part
– Multiple gates preferred
– Feed into thick sections of the castings
• Runners– Distribution channel
for molten metal from the sprue into the gates
Casting Alloys• Nonferrous Alloys– Aluminum,
magnesium, copper, zinc, tin, lead
– Good electrical conductivity and resistant to corrosion
– Most of these alloys share characteristics of good machinability and can all be welded
Casting Alloys• Ferrous alloys
– Cast irons• Largest quantity of all
metals cast• Good wear resistance,
hardness and machinability
– Cast Steels • Material used under
extreme heat conditions
• Railroad, mining and construction
Casting Economics• Cost– Depends on materials,
equipment, and labor– Preparations require raw
materials, time and effort– Melting, pouring, heating,
cleaning, inspections– Equipment cost lowers
with large # of castings– Solutions to alleviate
unneeded cost are being looked into• Rapid prototyping
Molten Metal Pour
Solidification
Solidification Temperatures
Dimensional Change
Pinholes
Blowhole
Scab
Pinholes
Rough Surface
Thank you…