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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
Processes
Sand Shell Plaster Ceramic Investment Lost foam Pressure Vacuum Die Centrifugal Squeeze Semi-solid Single crystal Directional solidification Slush Continuous
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
Breakdown of Castings
Ingots for bulk deformation processing 85% Cast to near net shape - 15%
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
Ingots
Iron or steel molds Water-cooled molds Continuous casting
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
Shapes
Permanent mold (cavity)
die casting hot chamber cold chamber
Expendable Molds
sand shell slurry investment
lost wax lost foam
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
Shapes
Centrifugal
pipes spinning
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
Capabilities
Dimensions
sand casting - as large as you like small - 1 mm or so
Tolerances
0.005 in to 0.1 in
Surface finish
die casting 8-16 micro-inches (1-3 mm) sand casting - 500 micro-inches (10-25 mm)
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011 10
Casting Steps
quick route from raw material to finished product
Melt metals Pour / force liquid into hollow cavity (mold) Cool / Solidify Remove Finish
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011 11
Melting
Raw material (charge)
scrap, alloying materials
Heat
Furnace Atmosphere
Atmosphere Heating
Raw materials
Air (oxygen), vacuum, inert gas (argon) External - electric, gas, oil Internal - induction, mix fuel with charge
steel making in blast furnace -mix coke with iron
Furnace material
refractory ceramics
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011 12
Furnaces
Blast furnace
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
Furnaces
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
Furnaces
Induction Furnace
Electric Furnace
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Sand Casting
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Sand Casting
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Sand Casting
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Die Casting
Cold chamber
Hot chamber
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Continuous Casting
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Investment Casting
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Vacuum Casting
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Centrifugal Casting
horizontal
vertical
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Centrifugal Casting
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Directional Solidification
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Casting Characteristics
Table 5.6 Typical materials cast
All All
Weig ht (kg)
Process
Sand Shell Expendable mold pattern Plaster mold
Minimum
0.05 0.05
Maximum
No limit 100+
Porosity*
4 4
Minimum
3 2
Maximum
No limit --
All Nonferrou s (Al, Mg, Zn, Cu) All (High melting pt.) All Nonferrou s (Al, Mg, Zn, Cu) All
0.05
No limit
5-20
No limit
0.05
50+
1-2
1-2
--
0.005 0.5
100+ 300
1-3 2-3
3 2-3
1 3-4
1 1
1 2
75 50
Die Centrifugal
<0.05 50 1-2 1-2 3-4 1 -5000+ 2-10 1-2 3-4 3 *Relative rating: 1 best, 5 worst. Note : These ratings are only general; significant variations can occur, depending on the methods use d.
0.5 2
12 100
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Microstructure
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Microstructure - Dendrites
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Microstructure - Dendrites
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Fluidity
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Casting Defects
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Shrinkage
TABLE 5.1 Volumetric solidification contraction (%) 6.6 6.3 3.8 2.53 4 4.9 Volumetric solidification contraction (%) 4.5 4 Expansion to 2.5 4.2 45.5 6.5
Metal or alloy Aluminum Al4.5%Cu Al12%Si Carbon steel 1% carbon steel Copper Source: After R. A. Flinn.
Metal or alloy 70%Cu30%Zn 90%Cu10%Al Gray iron Magnesium White iron Zinc
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Differential Cooling
Transition between thicker and thinner sections can lead to porosity
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Pipe Defect
Due to shrinkage giving rise to a funnel-like cavity Solutions
insulate top (glass wool) heat top (exothermic mixture thermit)
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Chills
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Car Rims
Stamped
Cast
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Casting costs
TABLE 5.10 Cost* Process Die Sand L Shell-mold LM Plaster LM Investment MH Permanent mold M Die H Centrifugal M * L, low; M, medium; H, high. Equipment L M-H M L-M M H H Labor LM LM MH H LM LM LM Production rate (Pc/hr) <20 <50 <10 <1000 <60 <200 <50
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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Process economics
ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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ME 4210: Manufacturing Processes and Equipment Prof. J.S. Colton GIT 2011
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