1. Production Process I

2. Introduction
A. Syllabus, paper pattern

4. Introduction B. Introduction to the subject Market need Concept design
Detailed design
Manufacturing
Sell
B. Introduction to the subject

5. Introduction
B. Introduction to the subject
1. What is manufacturing?

6. Introduction
C. Classification of manufacturing processes

7. Solidification Process

8. Particulate Process

9. Deformation Process

10. Material removal Process

11. Module I Metal casting process

12. Metal Casting Process A. Fundamental of metal casting Open Mold
3. Pattern
Open Mold
Closed Mold
Casting is a process in which the molten metal flows by gravity or forced into a mold, where it solidifies and finally after cooling, it acquires the shape of the mold cavity.

13. Metal Casting Process 2. Mold
2.1 Mold materials
2.2 Constituent of Molding Sand
2.3 Kinds of Molding Sand
2.4 Properties of Molding Sand
2.5 Steps involved in making Sand Mold
2.6 Venting of Molds
3. Pattern
Depending upon the extraction of cast product, the casting process in divided into
Expendable mold - casting process
Permanent mold - casting process
Sand mold casting
Shell mold casting
Vacuum mold casting
Investment casting
Carbon dioxide mold casting
Die casting
Centrifugal casting

14. Metal Casting Process 2. Mold 2.1 Mold materials 1. Casting 2. Mold
2.2 Constituent of Molding Sand
2.3 Kinds of Molding Sand
2.4 Properties of Molding Sand
2.5 Steps involved in making Sand Mold
2.6 Venting of Molds
3. Pattern
2.1 Mold materials
Metal
Cast Iron
Mild Steel
Alloy steels
Non Metal
Plaster of Paris
Graphite
Ceramics
Molding Sand

15. Sand Casting Process A. Fundamental of sand casting Casting Terms :
2. Mold
3. Pattern
Casting Terms :
Mold: It contains a cavity whose geometry determines the shape of the cast part.
Cope: It is the upper half of the mold.
Drag: It is the bottom half of the mold.
Flask: A metal or wood frame, without fixed top or bottom, in which the mold is formed.

16. Sand Casting Process A. Fundamental of sand casting
2. Mold
3. Pattern
Parting line: This is the dividing line between the two molding flasks that makes up the mold.
Pattern: It is the replica of the final object to be made. The mold cavity is made with the help of pattern.
Molding sand: Sand, which binds strongly without losing its permeability to air or gases. It is a mixture of silica sand, clay, and moisture in appropriate proportions.

17. Sand Casting Process A. Fundamental of sand casting
2. Mold
3. Pattern
Facing sand: The small amount of carbonaceous material sprinkled on the inner surface of the mold cavity to give a better surface finish to the castings.
Core: A separate part of the mold, made of sand and generally baked, which is used to create openings and various shaped cavities in the castings.
Chaplets: Chaplets are used to support the cores inside the mold cavity to take care of its own weight.

18. Sand Casting Process A. Fundamental of sand casting
2. Mold
3. Pattern
Pouring basin: A small funnel shaped cavity at the top of the mold into which the molten metal is poured.
Sprue: The passage through which the molten metal, from the pouring basin, reaches the mold cavity.
Runner: The channel through which the molten metal is carried from the sprue to the gate.
Gate: is that portion of runner through which the molten metal enters the mold cavity.

19. Sand Casting Process 1. Fundamental of sand casting
2. Mold
3. Pattern
Riser: it serves as reservoirs to supply the molten metal necessary to prevent shrinkage during solidification.
Vent: Small opening in the mold to facilitate escape of air and gases.

20. Metal Casting Process 2.2 Constituent of Molding Sand
2.1 Mold materials
2.2 Constituent of Molding Sand
2.3 Kinds of Molding Sand
2.4 Properties of Molding Sand
2.5 Steps involved in making Sand Mold
2.6 Venting of Molds
3. Pattern
2.2 Constituent of Molding Sand
The main constituents of molding sand involve silica sand, binder, moisture content and additives.
Silica sand (88%-92%)
Silica sand form the main constituent of molding sand having enough refractoriness which can impart strength, stability and permeability to molding and core sand.
The silica sand can be specified according to the size (small, medium and large silica sand grain) and the shape (angular, sub-angular and rounded).
But along with silica small amounts of iron oxide, alumina, lime stone, magnesia, soda and potash are present as impurities.

21. Metal Casting Process 2.2 Constituent of Molding Sand Binder (6%-12%)
2.1 Mold materials
2.2 Constituent of Molding Sand
2.3 Kinds of Molding Sand
2.4 Properties of Molding Sand
2.5 Steps involved in making Sand Mold
2.6 Venting of Molds
3. Pattern
2.2 Constituent of Molding Sand
Binder (6%-12%)
In general, the binders can be either inorganic or organic substance.
The inorganic group includes clay, sodium silicate etc.
In foundry shop, the clay acts as binder which may be Ball Clay, Fire Clay, Limonite, Fuller’s earth and Bentonite.
Organic group binders are dextrin, molasses, cereal binders, linseed oil and resins like phenol formaldehyde, urea formaldehyde etc.
Among all the above binders, the bentonite variety of clay is the most common.

22. Metal Casting Process 2.2 Constituent of Molding Sand Moisture (3%-6%)
2.1 Mold materials
2.2 Constituent of Molding Sand
2.3 Kinds of Molding Sand
2.4 Properties of Molding Sand
2.5 Steps involved in making Sand Mold
2.6 Venting of Molds
3. Pattern
2.2 Constituent of Molding Sand
Moisture (3%-6%)
The effect of clay and water decreases permeability with increasing clay and moisture content.
The green compressive strength first increases with the increase in clay content, but after a certain value, it starts decreasing.

23. Metal Casting Process 2.2 Constituent of Molding Sand Additives
2.1 Mold materials
2.2 Constituent of Molding Sand
2.3 Kinds of Molding Sand
2.4 Properties of Molding Sand
2.5 Steps involved in making Sand Mold
2.6 Venting of Molds
3. Pattern
2.2 Constituent of Molding Sand
Additives
Some common used additives for enhancing the properties of molding and core sands are discussed as under.
Coal dust
Corn flour
Dextrin
Sea coal
Pitch
Wood flour
Silica flour

24. Metal Casting Process 2.3 Kinds of Molding Sand Green sand Dry sand
2.1 Mold materials
2.2 Constituent of Molding Sand
2.3 Kinds of Molding Sand
2.4 Properties of Molding Sand
2.5 Steps involved in making Sand Mold
2.6 Venting of Molds
3. Pattern
2.3 Kinds of Molding Sand
Green sand
Dry sand
Loam sand
Facing sand
Backing sand
System sand
Parting sand
Core sand

25. Metal Casting Process 2.4 Properties of Molding Sand Refractoriness
2.1 Mold materials
2.2 Constituent of Molding Sand
2.3 Kinds of Molding Sand
2.4 Properties of Molding Sand
2.5 Steps involved in making Sand Mold
2.6 Venting of Molds
3. Pattern
2.4 Properties of Molding Sand
Refractoriness
Permeability
Green Strength
Dry Strength
Collapsibility
Cohesiveness
Reusability

26. Metal Casting Process 2.5 Steps involved in making Sand Mold
2.1 Mold materials
2.2 Constituent of Molding Sand
2.3 Kinds of Molding Sand
2.4 Properties of Molding Sand
2.5 Steps involved in making Sand Mold
2.6 Venting of Molds
3. Pattern
2.5 Steps involved in making Sand Mold
The first step in making mold is to place the pattern on the molding board.
The drag is placed on the board
Dry facing sand is sprinkled over the board and pattern to provide a non sticky layer.
Molding sand is then riddled in to cover the pattern with the fingers; then the drag is completely filled.
The sand is then firmly packed in the drag by means of hand rammers. The ramming must be proper i.e. it must  neither be too hard or soft.
After the ramming is over, the excess sand is leveled off with a straight bar known as a strike rod.
With the help of vent rod, vent holes are made in the drag to the full depth of the flask as well as to the pattern to facilitate the removal of gases during pouring and solidification.

27. Metal Casting Process 2.5 Steps involved in making Sand Mold
2.1 Mold materials
2.2 Constituent of Molding Sand
2.3 Kinds of Molding Sand
2.4 Properties of Molding Sand
2.5 Steps involved in making Sand Mold
2.6 Venting of Molds
3. Pattern
2.5 Steps involved in making Sand Mold
The finished drag flask is now rolled over to the bottom board exposing the pattern.
Cope of the pattern is then placed over the drag pattern with the help of locating pins.  
The dry parting sand is sprinkled all over the drag and on the pattern.
A sprue pin for making the sprue passage is located at a small distance from the pattern. Also, riser pin, if required, is placed at an appropriate place.
The operation of filling, ramming and venting of the cope proceed in the same manner as performed in the drag.
The sprue and riser pins are removed first and a pouring basin is scooped out at the top to pour the liquid metal.

28. Metal Casting Process 2.5 Steps involved in making Sand Mold
2.1 Mold materials
2.2 Constituent of Molding Sand
2.3 Kinds of Molding Sand
2.4 Properties of Molding Sand
2.5 Steps involved in making Sand Mold
2.6 Venting of Molds
3. Pattern
2.5 Steps involved in making Sand Mold
Then pattern from the cope and drag is removed and facing sand in the form of paste is applied all over the mold cavity and runners which would give the finished casting a good surface finish.
The mold is now assembled. The mold now is ready for pouring

29. Metal Casting Process 3. Pattern
2. Mold
3. Pattern
3.1. Objective of pattern
3.2. Type of pattern
3.3 Common pattern materials
3.4. Pattern Allowance
3. Pattern
Pattern is the replica of the final object to be made by the casting process, with some modifications.
The main modifications are the addition of pattern allowances . If the casting is to be hollow, additional patterns called cores are used to create these cavities in the finished product.
The quality of the casting produced depends upon the material of the pattern, its design, and construction.

30. Metal Casting Process 3.1. Objectives of the Pattern
2. Mold
3. Pattern
3.1. Objective of pattern
3.2. Type of pattern
3.3 Common pattern materials
3.4. Pattern Allowance
3.1. Objectives of the Pattern
A pattern prepares a mold cavity for the purpose of making a casting..
Runner, gates, and risers used for feeding molten metal in the mold cavity may form a part of the pattern.
Patterns properly made and having finished and smooth surfaces reduce casting defects.
A properly constructed pattern minimizes the overall cost of the castings.

31. Metal Casting Process 3.2. Types of Pattern Single piece/solid pattern
2. Mold
3. Pattern
3.1. Objective of pattern
3.2. Type of pattern
3.3 Common pattern materials
3.4. Pattern Allowance
3.2. Types of Pattern
Single piece/solid pattern
Two piece/split pattern
Multi piece pattern
Cope & drag pattern
Loose piece pattern
Match plate pattern
Follow board pattern
Gated pattern

32. Metal Casting Process 3.2. Types of Pattern 1. Casting 2. Mold
3.1. Objective of pattern
3.2. Type of pattern
3.3 Common pattern materials
3.4. Pattern Allowance
3.2. Types of Pattern

33. Metal Casting Process 3.2. Types of Pattern 1. Casting 2. Mold
3.1. Objective of pattern
3.2. Type of pattern
3.3 Common pattern materials
3.4. Pattern Allowance
3.2. Types of Pattern

34. Metal Casting Process 3.3. Pattern material
2. Mold
3. Pattern
3.1. Objective of pattern
3.2. Type of pattern
3.3 Common pattern materials
3.4. Pattern Allowance
3.3. Pattern material
Some materials used for making patterns are:
Wood
Metals and alloys like cast iron, brass & bronze, Aluminium alloys
Plaster of Paris,
Plastic and rubbers,
Wax, and resins.

35. Metal Casting Process 3.3. Pattern material
2. Mold
3. Pattern
3.1. Objective of pattern
3.2. Type of pattern
3.3 Common pattern materials
3.4. Pattern Allowance
3.3. Pattern material
To be suitable for use, the pattern material should be:
Easily worked, shaped and joined
Light in weight
Strong, hard and durable
Resistant to wear and abrasion
Resistant to corrosion, and to chemical reactions
Dimensionally stable and unaffected by variations in temperature and humidity
Available at low cost

36. Metal Casting Process 3.4. Pattern Allowance
2. Mold
3. Pattern
3.1. Objective of pattern
3.2. Type of pattern
3.3 Common pattern materials
3.4. Pattern Allowance
3.4. Pattern Allowance
Shrinkage or contraction allowance
Liquid Shrinkage & Solid Shrinkage
Draft or taper allowance
Positive allowance of 10mm to 20mm/m
Machining or finish allowance
Positive allowance of 3mm to 18mm
Distortion allowance
Rapping allowance
Negative allowance of 0.5mm to 1mm

39. RISER Considerations for Designing Riser (A) Freezing time
(B) Feeding range
(C) Feed Volume Capacity

40. SOLIDIFICATION TIME Chvorinov’s Rule
Chvorinov’s rule indicates that a casting with a higher volume-to-surface area ratio will cool and solidify more slowly than one with a lower ratio.

41. CASTING DEFECTS

43. Metal Casting Process Advantages:
2. Mold & its types
3. Patterns
3. Advantages and disadvantages
Advantages:
The metal casting process is extensively used in manufacturing because of its many advantages.
Molten material can flow into very small sections so that complicated shapes can be made by this process. As a result, many other operations, such as machining, forging, and welding, can be minimized or eliminated.
It is possible to cast practically any material that is ferrous or non-ferrous.
As the metal can be placed exactly where it is required, large saving in weight can be achieved.
The necessary tools required for casting molds are very simple and inexpensive. As a result, for production of a small lot, it is the ideal process.
There are certain parts made from metals and alloys that can only be processed this way.
Size and weight of the product is not a limitation for the casting process.

44. Metal Casting Process A. Fundamental of metal casting 1. Casting
2. Mold & its types
3. Advantages and disadvantages
Limitations:
Dimensional accuracy and surface finish of the castings made by sand casting processes are a limitation to this technique. Many new casting processes have been developed which can take into consideration the aspects of dimensional accuracy and surface finish. Some of these processes are die casting process, investment casting process, vacuum-sealed molding process, and shell molding process.
The metal casting process is a labor intensive process

45. Shell mold casting

46. Vacuum mold casting

47. Investment casting

48. Permanent mold casting

49. The basic permanent-mold process

50. DIE CASTING - Hot chamber die casting

51. DIE CASTING - Cold chamber die casting

52. Centrifugal casting