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METAL CASTING

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CAST PRODUCTS 1.CYLINDERS: CYLINDER LINERS ( DRY & WET) : Cylinder Liners (Dry & Wet) manufactured by the – PowerPoint PPT presentation

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Date added: 19 May 2020
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Title: METAL CASTING


1






  • CAST PRODUCTS
  • 1.CYLINDERS
  • CYLINDER LINERS ( DRY WET) Cylinder
    Liners (Dry Wet) manufactured by the
    "Centrifugal Cast Process" is acknowledged to be
    the best method. It possesses the bearing metal
    qualities that cause skin healing after abrasion
    and a structure that is readily wetted by oil and
    retains an oil film. Corrosion resistance is
    further improved by adding Chromium in the metal.
    In the centrifugal casting process, the molten
    metal is poured into a metal mould or die which
    is revolving at a high speed. The centrifugal
    force causes the metal to distribute itself
    evenly around the die. The resulting casting are
    of much finer grain and free from blow holes or
    porosity. A further important advantage is that
    the impurities, being lighter than the iron, are
    forced centrifugally to the bore surface from
    which they are removed by machining .
  • DRY LINERS    The Dry Liner is in
    direct contact with engine block. The Outer
    Diameter is to be very precise and perfect
    without contours.
  • WET LINERS   The Wet Liner is with
    sealing grooves for O rings and always in
    direct contact with water. A Wet Liner is
    generally Heavy Thick walled.
  • RANGE           Diesel, Petrol,
    Marine Compressor Engine for Light Heavy
    commercial vehicles, Cars, Tractors Utility
    vehicle.
  • CAPACITY       1. QUANTITY 
    Centrifugal Castings 300 Ton p.m.
    2. MACHINING 65000 Pcs. p.m.

2
(ii) AIR COOLED BLOCK
AIR COOLED CYLINDER BARRELS made from special
"SHELL MOULDING PROCESS" causes wear resisting
close grained iron casting and this ensures long
life and efficient cooling
  • .
  •  

(iii) VALVE GUIDE


Delight Valve Guides are
grounded to a surface finish of 0.80 Micro Ra on
its Outer Diameter and with in a tolerance of 13
Microns. These are also provided with Thread and
Spiral in its Inner Diameter to retain oil for
long time. Thus increases the life of both Valve
Guide and the Valve. Delight Valve Guide has
microstructure of Pearlitic matrix with 5
maximum free ferrite 5 maximum free carbides an
d10 maximum steadite in cellular or
discontinuous form and Valve Guide has Hardness
of 210-260 BHN
3
CENTRIFUGAL CASTING
  • Casting of "Delight" Cylinder Liners Sleeves
    are made only by centrifugal casting process by
    Semi - Automatic Horizontal / Vertical
    centrifugal Casting machine to have a extra fine
    balanced Graphite structure ensuring the desired
    metal free from casting defects. .
  • Due to centrifugal force the impurities are spun
    to the outer surface, which is then machined off.
    The speed of the rotation and metal pouring rate
    vary with the alloy and size and shape being
    cast.
  • Perfectly shaped spun Cast Cylinder Liners resist
    distortion and vibration reducing the risk of
    cavitations. The castings are removed from the
    mould at a temp. of 500 degree Celsius

4
2.SHUTTLE RACE
Shuttle Race 2530 (for House Hold  Sewing
Machine)
Shuttle Race 24415 (for 31K Leather
Stitching Sewing Machine
Shuttle Race Open Type
5
3.INVESTMENT CASTING PRODUCT
                                                                                                                                                                                                                                                                                                         

                                                                                                                                                                                                                                                                                              
Carbon Steel (Machine Parts)                                                                                                                                                      Cutting Tool (Vise)



Heat Resistant Steel (Engine Parts)

Low Thermal Expansion Steel (Sensor Parts)
6
Stainless Steel (Piping Parts )
Low Alloy (Bicycle Parts)

Electromagnetic Material (DOT Printer Parts)
Two Phase Stainless Steel (Flow meter Parts )


7
HIGH SPEED STEEL (CUTTER)Ni Base
Super Alloy (Turbo Charger Parts)
8
INVESTMENT CASTING
  • Investment casting is the production of
    industrial parts through the of metallic
    replication wax models. Industrial manufacturers
    often choose the investment casting process when
    complex parts or large quantities of parts are
    needed during production. The casting process
    remains structured and precise, resulting in a
    polished finish resembling the initial model down
    to the most intricate detail. In addition, an
    abundance of casting metals exists, and an
    extensive number of cast sizes and shapes can be
    created. Steps involved
  • Pattern creation - Initially, an injection-molded
    wax pattern is used to create a model of the
    proposed finished product. Wax is injected into
    an aluminum die, a tool consisting of a cavity
    into which the wax can be poured.
  • Molding - The resulting wax pattern is used to
    create a ceramic mold the mold can be created
    using the ceramic mold process or the solid mold
    process.

  • Continued.

9
  • Casting - The molds are heated to remove leftover
    wax and to prepare the mold for casting. The mold
    is then filled with molten metal, which will
    harden into the final product.
  • Cleaning - The mold is broken away once the metal
    has cooled. The casting is then subjected to
    other treatments as necessary, which include
    additional heating, polishing, and refinishing.
  • Investment casting materials are quite plentiful.
    Numerous ferrous and nonferrous substances can be
    cast, including steel, irons, titanium, nickel-
    and cobalt-based alloys, bronze alloys, brass,
    aluminum, stainless steel, and nickel-boron
    alloys. Investment casting is used to create an
    assortment of parts in all sizes, shapes, and
    weights. Investment-cast parts include dental
    braces, automotive engine parts, medical
    equipment, and satellite communications hardware.
    Although the weight of parts ranges from one
    ounce to one ton, the majority of investment
    castings remain under twenty pounds. Because of
    the wide application of manufactured metal parts,
    parts created using investment casting are found
    within almost every industry, including the
    automotive, military, dental, mining, music, food
    processing, sports, and telecommunication
    industries.

10
LOST FOAM CASTING
Lost Foam Process - This Process is similar to
"Lost Wax", better known as Investment Casting,
in that both the casting mediums are expended,
either melted or evaporated away, leaving the
cast part .Make sure to visit "Lost Foam" Casting
Process in the Exploded Drawings Sections. or
Views
GM 4.2L foam cylinder block
Lost foam casting simplifies the process
immensely. The key to the process is the plug. It
is made of Styrofoam. An external mould is made
and filled with Styrofoam. The Styrofoam part is
removed and it looks exactly like the final part
to be made. The Styrofoam plug is placed in the
metal container and sand is poured around it. No
resin is needed because the Styrofoam plug is not
removed. The complete mould is vibrated to ensure
the sand has filled all the cavities and there
are no voids. Finally, molten aluminum is poured
into holes in the top dissolving the Styrofoam,
and the fumes go out the vent holes. Open the
mould and the sand falls away, leaving the
production part ready for machining
Foam cylinder head block
The lost foam casting process is much quicker
than conventional casting. The mold does not have
to be separated and the plug removed. Aligning
two halves of the container is not necessary. The
sand does not need to be broken away from the
final casting.
Cylinder block
11
GATE ENGINE PARTS
DIE CASTING


this process is for high volume, high
detail, value added, economy priced, cast parts.
A metal tool is built, and it is attached to a
furnace of molten metal, this molten metal is
mechanically pouredinjected into the metal mold,
the mold cools for a brief time, it opens the
parts come out the process repeats, over and
over and over. Advantage is very high production
with great duplication, with great tolerances.

GATE
12
S
  • Aluminum Die Casting - is a process
    where molten aluminum alloy is injected into a
    closed vessel called a casting die or mold, under
    high pressure and at a controlled temperature.
    The mold has sections which include the "cover"
    or hot side and the "moveable" or the ejector
    side. The die may also have additional moveable
    segments called slides or pulls which are used to
    create features such as undercuts or holes which
    are parallel to the parting line. Aluminum die
    casting molds operate in cold chamber die casting
    machines. These machines run at the required
    temperatures and pressures to produce a quality
    part to net-shape or near net-shape
    specifications. Aluminum die castings can be
    readily machined, anodized, painted or powder
    coated.
  • Examples of usage would be cabinets for
    the electronics industry, hand and power tools
    for industrial and home use, general hardware
    appliances, pump parts, plumbing parts, parts for
    the automotive industry, sports and leisure, home
    appliances, a lot of communications equipment,
    the list is endless.
  • Zinc die castings - poured from
    Zamak 3,5 or 7 or a zinc-aluminum alloy
    casting made from ZA-8, are made very similar to
    aluminum die casting .The molten metal is
    injected into a closed vessel called a casting
    die or mold under high pressure and at a
    controlled temperature. The metal is cooled
    rapidly until the solidified part is sufficiently
    solid enough, to permit it to be ejected from the
    mold. The mold has sections which include the
    "cover" or hot side and the "moveable" or ejector
    side. The die may also have additional moveable
    segments called slides, or pulls which are use to
    create features such as undercuts or holes which
    are parallel to the parting line.
  • Zinc die casting dies or molds operate in
    hot chamber die casting machines. These machines
    run at the required temperatures and pressures to
    produce a quality part, to net-shape or near
    net-shape specifications. Zinc die castings, can
    be readily machined, plated, painted or powder
    coated.

13
MOLD

ENGINE PARTS CYLINDER HEAD
14
PERMANENT MOLD CASTING
  • The permanent mold casting process is the
    production of castings by pouring molten metal
    into permanent metal molds under gravity
    pressure. Castings produced in permanent molds
    have finer grain structure and better strength
    properties than those cast from similar alloys in
    sand casting and die casting.
  • Metal molds (or dies) usually are made of
    high-alloy iron or steel and have a production
    life of up to 120,000 or more castings.
  • .
  • Due to the chilling nature of a solid steel
    permanent mold tool, the castings are sounder
    than sand castings. For pressure-tight and
    nonporous castings, the permanent mold process is
    excellent. Permanent mold castings can be
    stronger than die and sand castings and less
    porous than die-castings.
  • Permanent mold aluminum castings generally range
    from a few ounces to more than 100 lbs. Aluminum
    castings weighing several hundred pounds have
    been produced commercially by the permanent mold
    process.
  • Permanent mold castings usually need less finish
    machining and polished than sand castings. If the
    parting lines on the outside of a casting can be
    held to a minimum, high quality as-cast finishes
    approaching 100 rms. can be achieved and many
    aluminum castings with these good as-cast
    finishes are used without subsequent finishing
    for cooking utensils, hardware items, automotive
    parts, highway bridge railings and ornamental




15
AUTOBIKE PARTS
MACHINE PARTS
MACHINE PARTS
16
FORMING PRODUCTS
HOT FORMING TOOLS
17
COLD FORMING TOOL
18
INJECTION MOLDING PRODUCTS
19
SAND MOLDING
DRY SAND MOLDING large components are very
difficult to cast to exact size and dimensions.
Hence, some foundries use dry sand molds to
produce such parts. Dry sand molding is the green
sand process modified by baking the mold at
prescribed temperature. Engine blocks, large
gears, big housings, construction parts, are
examples of dry sand process candidates. Ferrous
and non-ferrous metals are cast in this method.
The key to this process is the proper baking time
in relation to the binder and the moisture content
. The other factors are the size, weight, and
mass, of the component being cast. Wynn Danzur
can explain the profitable advantages of this
process to you. Some good examples are, the great
strength of the part cast, exactness in
dimension, much smoother finish, etc., but most
important is how these processes will benefit
your casting jobs.
CAST PRODUCT
20
CAST PRODUCTFOR DECORATION PURPOSE
BRONZE CASTING
21
CAST PRODUCT
22
AUTO PARTS
POWDERED METAL CASTING this process is also
sometimes referred to as the sintered metal
process, we will always refer to this as Powdered
Metal Casting. Casting Industry professionals
across industry depend on Powdered Metal, for
cost effective production of parts .The Powdered
Metal Casting Process is the absolute choice for
parts that require high mechanical properties
with repeatable close tolerances. That's why this
modern technology is so popular today.
23
REFERENCE
tmwww.anandenterprise.com
www.dukheung.co.kr
www.klcast.com.tw
www.investment-castings.net
www.allproducts.com
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