WORKSHOP PRACTICE

R. S. Vidyarthy
PhD (IIT R)
Assistant Professor
BITS Pilani Mechanical Engineering Department
Hyderabad Campus BITS Pilani, Hyderabad Campus, India
WELCOM
E
ME F112

WORKSHOP PRACTICE
FIRST SEMESTER 2020-2021
2
Casting Processes

Production of parts by Casting processes, Pattern making.

3 T1-11
casting processes Moulding, Moulding sands.
Pattern allowances, Examples. Yield,
4 Casting processes T1-11
Cooling rate, defects

T1: B S Nagendra Parashar and R K Mittal, Elements of Manufacturing Processes,

Prentice Hall of India, 2008.

BITS Pilani, Hyderabad Campus

 Example

A job shown in the Figure is to be made of

steel by casting process. The mould for this
job is made from a wooden pattern.
Determine the dimensions of the wooden
pattern. Assume machining allowance of 2
mm on each side, shrinkage allowance of
2% and a taper allowance of 1 degree.
Part to be casted

80

20

50
 Continued

• It is given that machining allowance

of 2 mm on each side is to be given.
Thus, each side is increased by 2
mm resulting in the basic dimension
of the pattern as shown in Figure (a).
The required casting is shown with
dotted lines.
Dimension of the Pattern after
Machining Allowance

84

24

54
 Continued

The taper allowance value x is

calculated from the geometry of
the Figure (b) as x = 24 tan 1 =
0.419 mm.

Thus, the top surface dimension is

increased to provide for draft
allowance from 54  84 mm to
54.838  84.838 mm.
Dimension with machining and draft
allowance

x
84
24 24

54
(a) (b)
Adding shrinkage allowance..
Now, the dimensions of pattern are increased
by 2% on all sides. That is, dimension 54 mm
will become
54 + (54*2)/100 = 55.08mm or 55.1mm
The dimension 54.838 will become
54.838 + (54.838*2)/100 = 55.9mm

Similarly, all other dimensions are calculated

and the final dimensions of the pattern are
shown in Figure
Final dimension of the Pattern

55.9

86.5

85.7
24.5

55.1
Question

How the material flows into

the cavity in casting process?

BITS Pilani, Hyderabad Campus

GATING SYSTEM

Gating System refers to

the passageway through
which molten metal
passes to enter mould
cavity.
BITS Pilani, Hyderabad Campus
GATING SYSTEM

Pouring
cup
Riser

Sprue

Casting

Sprue base

Runner
Gate

BITS Pilani, Hyderabad Campus

Pouring cup

Pouring
cup
Riser

Sprue

Casting

Sprue base

Runner
Gate

BITS Pilani, Hyderabad Campus

Sprue

Pouring
cup
Riser

Sprue

Casting

Sprue base

Runner
Gate

BITS Pilani, Hyderabad Campus

Straight and tapered sprue

Metal pouring cup

Liquid metal

Metal pulling
down
Low pressure Sprue
Corners zone
Gate Gate

(a) Straight sprue (b) Tapered sprue

BITS Pilani, Hyderabad Campus

Sprue base

Pouring
cup
Riser

Sprue

Casting

Sprue base

Runner
Gate

BITS Pilani, Hyderabad Campus

Runner

Pouring
cup
Riser

Sprue

Casting

Sprue base

Runner
Gate

BITS Pilani, Hyderabad Campus

Gates

Pouring
cup
Riser

Sprue

Casting

Sprue base

Runner
Gate
BITS Pilani, Hyderabad Campus
Riser

Pouring
cup
Riser

Sprue

Casting

Sprue base

Runner
Gate

BITS Pilani, Hyderabad Campus

MOULDING TOOLS
 (b) Riddle (d) Trowel
(e) Sprue pin

(a) Shovel

(g) Draw spikes

(c) Hand rammers (f) Vent rod
MOULD MAKING
MOULD MAKING

Pattern (first half)

Drag

Molding
(a) board
MOULD MAKING

Sprue pin
Pattern (second half)

Cope

Drag

Vent
Sand
holes

(b)
MOULD MAKING

Pouring
basin
Cavity

Gate

Sand

(c)
How material is melted?
Furnace

BITS Pilani, Hyderabad Campus

 CORES

Core
Cavity
Required casting
Gating
system

Pattern

Sand

Core box Sand mould in two-piece flask

DIRECTIONAL SOLIDIFICATION

Riser

B A C
D

(a) (b) (c)

SOLIDIFICATION TIME

2
 volume 
t = c  
 surface area 
CASTING YIELD

Wc
Cy =  100 %
Wc + Wg
Wc= weight of the casting
Wg= weight of the material in getting system (sprue, runner,
gate, riser etc.
DEFECTS IN CASTING
 General Defects: Misrun
A casting that has solidified before
completely filling mold cavity

Figure 11.22 Some common defects in castings: (a) misrun

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
BITS Pilani, Pilani Campus
 General Defects: Cold Shut
Two portions of metal flow together but there is
a lack of fusion due to premature freezing

Figure 11.22 Some common defects in castings: (b) cold shut

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
BITS Pilani, Pilani Campus
 General Defects: Shrinkage Cavity
Depression in surface or internal void caused by
solidification shrinkage that restricts amount of
molten metal available in last region to freeze

Figure 11.22 Some common defects in castings: (d) shrinkage cavity

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of
Modern Manufacturing 3/e
BITS Pilani, Pilani Campus
 Sand Casting Defects: Sand Blow

Balloon-shaped gas cavity caused by

release of mold gases during pouring

Figure 11.23 Common defects in sand castings: (a) sand blow

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
BITS Pilani, Pilani Campus
 Sand Casting Defects: Pin Holes
Formation of many small gas cavities at or
slightly below surface of casting

Figure 11.23 Common defects in sand castings: (b) pin holes

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of
Modern Manufacturing 3/e
BITS Pilani, Pilani Campus
 Sand Casting Defects: Penetration
When fluidity of liquid metal is high, it may
penetrate into sand mold or core, causing
casting surface to consist of a mixture of sand
grains and metal

Figure 11.23 Common defects in sand castings: (e) penetration

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of
Modern Manufacturing 3/e
BITS Pilani, Pilani Campus
 Sand Casting Defects: Mold Shift
A step in cast product at parting line caused
by sidewise relative displacement of cope
and drag

Figure 11.23 Common defects in sand castings: (f) mold shift

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
BITS Pilani, Pilani Campus
 Inclusion
• Any undesirable foreign material
present within the metal casting is
known as inclusion.

Useful link:
https://www.youtube.com/watch?v=2CIcvB72dmk&ab_channel=CastingtheFuture