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Parting Line
Both expandable and permanent moulds must separable in two or more parts
in order to permit with drawl of patterns.
The largest section of the casting should be located adjacent to the parting plane of
the mould and its size should be
reduced in moving to the extremities. Design must avoid over hangs or under cuts.
FIG.1(a,b,c,d,e)
fig 2(b)
fig 2(a)
For a bell-shaped casting of fig 2. Locating the parting line at the base of the
bell, as in fig 2(a), would eliminate the parting line reflection from the
body of the casting. However because the core cannot be vented at the top, tapped
gas may cause defects in casting metal.
Placing the casting on its side so that parting line is at right angles to the base, as in
fig.2(b) ,would permit the adequate venting of the core provide an improved means of
gating, and eliminate the need for second riser a parting line seam is unavoidable,
but it can easily removed.
Location of radii:
The casting seen in fig.3 shows how a minor design concession serves to
avoid possible mismatch and simplifies the removal parting line.Fig3(a) was
modified to eliminate radii and thus enabling parting line to located at top surface
of the casting as in fig3(b).
A similar concession applied to coring is shown in Fig.4 Here the possibility of
core shift may be a problem, but it can be avoided by eliminating the radius at the
end of the core. If such a radius is required, it can be provided easily by machining.
It is necessary to locate a boss some distance from the parting line. The
section shown in Fig. 4.1(a) illustrate the positioning a boss well below the flange
whose upper surface serves as a parting line. In this design a core is required to
permit removal of the pattern from the mould. In introducing a casting as shown,
accurate positioning of the core is difficult, and any shifting of core results in surface
irregularities. A less complicated design, shown in Fig4.1 (b) extends the boss to the
flange, eliminating the undercut and the need for core.
fig4.1(a)
fig4.1(b)
Design Considerations:
Here the datums are being checked on the prototype casting. With the use of the
CAD systems the accuracy of the final casting can be to a fine tolerance. If economy
and best results are to be obtained, it is very important that the designer of castings
give careful attention to several requirements of the process and, if possible,
cooperate closely with foundry. Frequently, minor and readily permissible changes in
design will greatly facilitate and simplify the casting of a component and will reduce
the percentage of defects.
One of the first features that must be considered by a designer is the location of the
parting plane, an important part of all processes that use segmented or separable
moulds. The location of the parting plane can affect each of the following:1. The number of cores,
2. The use of effective and economical gating,
3. The weight of the final casting,
4. The method of supporting the cores,
5. The final dimensional accuracy, and
Figure 6
FIGURE 7
Effect Of Rounded Edges On The Location Of The Parting Plane
Figure 8 (top left) Location of the parting plane specified by draft (top right) Part with
draft unspecified (bottom) Various options in producing that part
Figure 12: Method of eliminating unsound metal at the centre of heavy sections in
castings by using cored holes
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fig 15(a)
fig 15(b)
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original design
fig 16(a)
new design
fig 16(b)
As originally designed, fig16(a), the eight ribs and eight small bosses prevented
this casting from being molded with the parting line parallel to the axis of the hole.
Furthermore adjacent to the flange, the casting had a cross section smaller than
either the flange or the extreme end of the casting. The undercut section that was
thus formed prevented the pattern from being withdrawn from the mold in a
direction perpendicular to the mounting flange. A ring core , as shown was
necessary to produce the shape.
By revising the casting as shown in fig.16(b), the need for the ring core was
eliminated and the shape could be withdrawn easily from the mould. By broadening
the base of the tubular section the eight ribs were also eliminated. In the original
design , the small diameter of the tubular section at the junction with the flange
section was unable to withstand the forces of service. Eight strengthening ribs were
required , to assure satisfactory performance of the casting in application. As
redesigned, the broader base of the tubular section provided sufficient strength to
permit elimination of the ribs.
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Design Considerations
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For large castings which are difficult to mould, which are heavy and large are made
into or more castings and are joined after the castings are made. These components
are called as cast-weld components. This very large core eliminated and casting
simplify process.
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The rate of welding as related to the size of the weld to be made, determines to a
great degree the economics of the process. The manual arc process is most versatile,
but for large cast-weld construction it is limited in application because changing
electrodes and other interruptions typically limit the weld deposit rate to an average
of 0.9kg/h. the submerged arc process, on the other hand, due to its continuous
operation with wire electrodes, deposits metal at much higher rates, as do gas
shielded methods. Electroslag welding is accomplished at rates of approximately
14(kg/h) per electrode.
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Supplementary symbols:
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Form Design
Of Injection Moulded Components:
Introduction
The process:
These materials are formed to specific shape by injecting them when into a
mould from they their final shape as they cooled and solidify. The plastics normally
are received by the molder in granular form. They are placed in a hopper of an
injection-molding machine; from they are fed to a heated cylinder. As they heated in
a cylinder, they melt, plasticize. Atypical melting temperature is about 180C,
although this varies with different materials and molding conditions. The mold,
usually of steel, is clamped in the machine and water-cooled. A plunger force
plasticized material from into the mould. There it cools and solidifies the mold is
opened ,and the molded part with its attached runners is removed the process, with
the usual exception of part removal ,is automatic It requires about 45s/cycle,more or
less, with most of that time being devoted to the cooling of the material in the mould.
Very high pressure on the order of 70000 k pas. or more or require during injection.
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Design recommendations:
Gate and ejector pin location:
The designer should consider the location of these elements since they
can impair surface finish. Ejector pins can usually be located on the under side of a
part if it has an outside and an under side. Gates can be located in a number of
locations as illustratedFig.18.1.
Center gating of round and cylindrical parts and near center gating of other large
area parts or desirable for trouble free mould filling.
Holes:
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Ribs:
1. Reinforcing ribs should be thinner than the wall they are reinforcing to prevent
sink marks in the wall. A good rule of thumb is to keep rib width to one half or
wall thickness.
2. Rib should not be more than one and half wall thickness high, again to avoid sink
marks.
3. Rib should be perpendicular to the parting line to permit removal of the part from
the mould.
4. Rib should have a generous draft.
5. Methods for disguising sink marks. See fig 18.8
Bosses:
Undercuts:
Under cuts are possible with injection molded thermo plastic parts,
but they may require sliding cores or split moulds. External under cuts can be
placed at the parting line or extended to obviate the need for core pulls. See fig 18.10
Screw threads:
It is feasible, though a complicating factor, to mould screw threads in
thermo plastic parts.
1. Use a core, which is rotated after the molding cycle has been complicated. This
unscrews the part and unable it to be removed from the mould.
2. Put the axes of the screw at the parting line of the mould. This avoids a rotating
core but necessitates a very good fit between mould halves to avoid flash across
the threads. This suitable for external threads and higher cost and feasible.
3. Make the threads few, shallow, and of rounded form so that the part can be
stripped from the mould with out unscrewing. A coarse thread with a somewhat
rounded form is preferred for all screw threads because of ease of filling and
avoidance of farther edges even if it is removed by unscrewing. See figures
18.11,12,13.
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Inserts:
Draft:
Surface finish:
High gloss finishes are feasible if the mould is highly polished and if
molding conditions are correct. Painting of most thermoplastics is feasible but is not
recommended if the color can be molded in to the part.
Flat surfaces:
Flat surfaces, although feasible are some what more prone to show
irregularities than gently curved surfaces. Since later also produce more rigid parts
they are preferable.
Even injunction molding shows the effect of the mould parting line, the
junction of the two halves of the mould .The part and the mould should be designed
go so that the parting occurs in an area where it does not adversely affect the
appearance or function o the part . Parting lines should be straight the two mould
halves should meet in one plane only this obviously provides more economical mould
construction, but it may not be possible if the part design is irregular. If it is not
possible to put the parting line at the edge of the part, cleaning parting line flash is
facilitated by having a bead or other raised surface at the parting line. See fig 18.20
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Problems:
1. A cast iron bearing bracket is shown in figure 18.23 indicate preferred parting
line and any necessary sand cores. Offer a design modification that will
reduce or eliminate the need for sand cores.
2. Indicate the parting line for steel forked leaver casting seen in figure 18.24
and also the necessary sand cores. Maintaining as nearly as possible, the
existing weight of casting , offer a design modification that will alleviate the
sand core requirements.
3. For the pedestal housing shown in figure 18.25 indicate the probable parting
line and any necessary sand cores, accepting that the probable parting line is
the one involving the minimum sand cores. Maintaining as nearly as possible,
the existing weight of casting, offer a design modification that will alleviate the
sand core requirements.
4. There are two possible parting lines for v belt pulley. Figure 18.26 indicate
both of this with the appropriate sand cores . Accept that v grooves are
machined from a solid rim. Maintaining as nearly as possible , the existing
weight of casting , offer a design modification that will alleviate the sand core
requirements
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Fig 18.26
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