Questions and Answers
What is a foundry?
A plant where castings are made.
What is casting?
A manufacturing process where a liquid material is poured into a mold and allowed to solidify.
The process of metal casting usually involves __________ the metal, pouring it into a mold, allowing it to cool, and then removing the solidified component.
melting
The solidified piece of metal taken out of the mold is referred to as a 'casting'.
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What is the purpose of a pouring basin?
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Match the following terms with their definitions:
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The __________ are metallic objects placed in the molds to increase the cooling rate of castings.
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What must be done to the castings to prepare them for further work after solidification?
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The pattern used in casting is an exact replica of the desired casting.
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A pattern has projections or bosses called __________.
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Study Notes
Sand Casting Process
- Casting is a manufacturing method where liquid material is poured into a mold to solidify into a desired shape.
- Four basic steps in casting: melting metal, pouring into a mold, allowing it to cool and solidify, and removing the finished casting.
- The solid piece obtained from the mold is called a “Casting” and the facility where castings are produced is known as a “Foundry.”
Characteristics of Metal Casting
- Metal casting relies on the property of liquids to adopt the shape of their containing vessel.
- Molds are typically made from materials such as sand, creating cavities that mirror the final product.
Key Components of Molds
- Flask: Holds the sand mold in place.
- Drag: The bottom part of the molding flask.
- Cope: The upper part of the molding flask.
- Parting Line: The separation line between the drag and cope.
- Core: Used to create hollow sections in castings.
- Pouring Basin: Funnel-shaped cavity for molten metal.
- Sprue: Passage for molten metal from the pouring basin to the mold cavity.
- Runner: Regulates flow of molten metal in the parting plane.
- Gate: Entry point for molten metal into the mold.
- Chaplet: Supports cores inside the mold cavity.
- Chill: Metal objects to increase cooling rate and uniformity.
- Riser: Reservoir allowing molten metal to flow back during solidification.
- Core Print: Recess for supporting cores in the mold cavity.
Steps in Casting
- Pattern Making: Create a replica of the final product; designed based on blueprints.
- Moulding and Core Making: Prepare molds using sand; cores allow for hollow sections; molds are baked for strength.
- Melting & Casting: Correct metal composition is melted; poured into molds to solidify; castings are removed by breaking molds.
- Fettling: Cleaning and cutting off unwanted projections from castings; prepares for further processing.
- Testing & Inspection: Ensures castings meet specifications before dispatching.
Patterns in Casting
- Patterns make cavities in molds for pouring molten metal; they are larger than the desired casting due to allowances (e.g., shrinkage).
- Patterns are designed with core prints, runners, and gates for effective molding.
Requirements for Good Patterns
- Ensure accurate shape and size of castings.
- Should be economical and easily repairable.
- Simple design facilitates manufacturing.
- Lightweight for ease of handling.
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Description
Explore the essential processes of foundry work, focusing on pattern making, molding, and casting techniques. This unit dives deep into sand casting and the steps involved, including melting metal and pouring it into molds. Understand the ancient art of manufacturing metallic components through casting methods.
