6 Types Of Casting Processes - PowerPoint PPT Presentation

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6 Types Of Casting Processes

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Continue reading to know more about each stage of the casting process. The product may subsequently be subjected to various finishing processes, depending on its intended use. – PowerPoint PPT presentation

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Title: 6 Types Of Casting Processes


1
Basic Steps Involved In The Casting Process
2
  • There are various methods for mass-producing
    metal parts. While 3D printing is all the rage,
    traditional investment casting is superior for
    high-volume runs. Why? Investment casting is a
    more cost-effective and reliable method of
    producing traditional castings. Casting
    manufacturers in India uses the latest
    technologies in the casting process to generate
    metal alloy shapes.
  • The molten metal is then cooled and hardened
    before being retrieved in a hardened state from
    the mold. Patternmaking, molding, melting and
    pouring, shakeout, and heat treatment and
    inspection are the five processes in the casting
    process. Continue reading to learn more about
    each stage.

3
Advantages of the Casting Method
  • There are several additional metal shaping
    methods than casting, such as welding, forging,
    stamping, extrusion, and machining. Before you
    choose to cast over these other options, you
    should first learn about the advantages of the
    procedure. The casting procedure is as follows
  • 1. Casting may create items with extremely
    complicated shapes and internal cavities
  • 2. It can be used to create parts ranging from a
    few hundred kg to several kilograms (thousand of
    kilograms).
  • 3. Any complex shape can be created.
  • 4. Any ferrous or non-ferrous material can be
    cast.
  • 5. It is cost-effective, with little waste
    excess metal from each casting is re-mentalized
    and re-used.

4
Types Of Casting Processes
  • 1. Die casting
  • Die casting is the process of pumping molten
    metal into a die or mold under high pressure to
    create pieces or designs. Casting manufacturers
    in India has turned to die casting to make
    printing plates for huge machines in a defunct
    printing method known as linotype. Its
    advancement superseded or supplemented the
    gravure method that came before it. Linotype
    machines became obsolete as computers became more
    advanced and replaced more efficient technical
    means.
  • 2. Plaster casting
  • Plaster casting is a non-ferrous alloy
    manufacturing process that produces smooth, even
    finished pieces. This plaster casting is
    typically used to create precise, intricate
    pieces with dimensional correctness. The template
    for the casting, like many modern designs, is
    developed in CAD or some form of software and
    contains shrinkage tolerances.

5
  • 3. Sand casting
  • Casting manufacturers in India specializes in
    sand casting using various pattern types. It is a
    standard manufacturing method for metal parts of
    various sizes and weights, and it can make
    complicated, intricate parts from any metal
    alloy. Although sand casting is a low-cost and
    low-volume process, it can manufacture
    high-quality parts. The components utilized in
    the procedure are all re-used and recyclable,
    contributing to the low cost.
  • 4. Investment casting
  • A wax design is coated with a ceramic substance
    that hardens to the casting shape in investment
    casting. The wax is melted away when the ceramic
    has set, and molten metal is poured into the
    empty chamber. The casting is shattered when the
    metal solidifies, releasing the metal portion.
    It's also known as lost wax processing, and it's
    a method that's been around for over 5000 years,
    dating back to the Egyptians and Chinese.

6
  • 5. Permanent mold casting
  • Like die and centrifugal casting, permanent mold
    casting uses reusable molds and has a wide range
    of applications for activities that need mass
    production or replication. Casting manufacturers
    are appropriate for the fabrication of parts for
    significant industrial activities, despite being
    more expensive than other types of casting.
  • 6. Centrifugal casting
  • Centrifugal casting, commonly known as the
    deLavaud technique, employs a spinning mold to
    make pipe lengths by applying G force to the mold
    as it rotates fast. Dimitri SensauddeLavaud, a
    French engineer, developed the notion as a more
    efficient technique of making iron pipes.

7
Steps In The Casting Process
  • While each casting technique has its obstacles
    and improvements, all techniques follow the same
    basic stages. A manufacturer must first develop a
    physical model before creating a casting mold.
    Patternmaking is the term for the process of
    making this model.
  • The manufacturer constructs the dimensions and
    geometry using computer-aided design (CAD)
    technology and then packs an aggregate material
    around the pattern, such as sand, concrete, or
    plastic. After the design has been removed, the
    sand mold cavity can be filled.

8
  • 1. Making patterns
  • A physical model of casting, i.e., a pattern, is
    used to construct the mold in pattern making. The
    mold is constructed by placing easily formed
    aggregated materials around the pattern, such as
    sand molding.
  • When the pattern is removed, its imprint is left
    in the mold cavity, eventually filled with metal
    to form the casting. Additional patterns, known
    as cores, are utilized to generate these cavities
    in cases when the castings are required to be
    hollow, such as in the case of pipe fittings.
  • 2. Creating the core
  • Casting manufacturers in India to provide cores
    in the casting mold. Solid materials are inserted
    into the mold chamber to create the internal
    surfaces of the casting. For example, to form the
    hollow internal architecture of a metal pipe
    fitting, a cylindrical core must be placed inside
    the mold cavity.

9
  • 3. Molding
  • The manufacturer can now start working on the
    casting mold. Expendable mold casting techniques
    use sand, plaster, or wax, whereas non-expendable
    mold casting techniques use metal and other
    durable materials. After the material has filled
    the casting mold model and hardened, the producer
    removes it from the cavity, allowing the casting
    of the component to commence.
  • 4. Pouring and Melting
  • Before being placed in the mold, a metal must be
    sufficiently heated. It is usually accomplished
    with the use of a crucible. Crucibles are
    melt-resistant pots constructed of porcelain or
    similar melt-resistant material in which a
    manufacturer can heat a metal past its melting
    point. The molten metal is placed into the
    casting mold to cool and harden after suitably
    melting.
  • 5. Finishing
  • Because metal can fill in fractures in a casting
    mold or the sprues, the mold's pouring channel,
    producers must frequently polish the metal after
    casting. A range of finishing procedures,
    including sanding, grinding, and buffing, can be
    used to achieve this. Additional post-treatment
    techniques such as painting or electroplating may
    be required for some applications once the
    desired appearance and surface texture have been
    obtained.

10
Conclusion
  • The remaining casting should match the original
    pattern exactly. The product may subsequently be
    subjected to various finishing processes,
    depending on its intended use. Castings made for
    heavy industrial application, for example, are
    frequently heat-treated to endure freezing
    temperatures, moist environments, or excessive
    weight. To ensure wear and abrasion resistance,
    tool steel casting will blend carbon and alloy
    steels.
  • Our casting will be subjected to extensive
    testing to ensure its structural and physical
    integrity as per casting manufacturers norms.

11
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