Casting Manufacturing Process, Study Guides, Projects, Research of Manufacturing Processes

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Manufacturing process

CASTING

Submitted to Ma’am Hibba

Roll # 2015 - ME- 57

2015 - ME- 59

2015 - ME- 60

2015 - ME- 73

2015 - ME- 74

Section [B]

Manufacturing and processing Lab

Project

Contents

**1. Description of industry

2. Component being casted
3. Foundry
4. Raw material
5. Pattern
6. Mold Formation
7. Melting of metal**  Electric furnace  Thermocouple  Ladle **8. Mold filling
8. Mold breaking & Cooling**

10.Cleaning  Shot blast machine  Grinding 11.Inspection  Visual inspection  Dimensional inspection . . . .

o Machining Operations:

The operations in which the rough surfaces of the casting are smoothened. Removing flashes also comes in it.

Components being casted:

Although a lot of components are being manufactured but the component which is being under consideration for study is a Differential Case.

o Differential case:

The differential case is a carrier for planetary gear train. A differential is a gear with three shafts that has the property that the angular velocity of one shaft is the average of the other shafts or a fixed multiple of that average.

 Differential:

The automotive differential is designed to drive a pair of wheels while allowing them to rotate at different speeds. In vehicles without a differential gear both wheels will be forced to move at the same speed which is usually the case in which axle is driven by a simple chain – drive mechanism

 Function:

Wheels receive power from the engine through a drive shaft. The wheels that receive power and make the vehicle move forward are called the drive wheels. The main function of the differential

gear is to allow the drive wheels to turn at different rpms while both receiving power from the engine.

Foundry:

Foundry is basically a place where metal casting are being produced metal casts are produced by melting the iron and then adding it in the mold for solidification into the desired casting.

Raw Material:

Before moving to casting itself let us talk about the material used in making of mold. following materials are used in making the mold material:  Sand  Binder (organic)  Water

Scrap metal:

Pattern: Pattern is basically a copy of the casting which is to prepare the cavity in which the molten metal is to be poured. There several types of pattern given below:  Solid pattern

 Split pattern  Match plate pattern  Cope – drag pattern

The pattern being used in EEHAB Engineering Ltd. for making the mold is a Cope-Drag pattern in which the pattern consists of two plates each of which having half of the casting pattern on it. The benefit for cope - drag is that the worker don’t have to worry about the parting line which in turn reduces the chance of mold shifting defect.

Drag pattern (lower half):

Cope patter (upper half):

The mold after preparation looks like as below:

Melting of metal:

Melting of the metal is associated with a lot of things like:  Furnace  thermocouple  Pouring temperature  Ladle o Electric furnace:

The furnace that is used to melt metal in EEHAB engineering Ltd. is the electric furnace in which the metal is melted using the induction heat. The machine the produces heat operates at a voltage of 300V.This machine easily melts the metal.

The picture of the machine is given below:

o Thermocouple:

It is a device that is use to take account of the changing temperature of the molten metal so that we can easily check whether the molten metal have attain the pouring temperature or not if yes then it is ready to be poured in to the ladle. Construction: it consists of a stick with digital reader on one end and the dipping part on the other.

o Ladle:

It is simply a large vessel into which the molten metal ,when attains the pouring temperature ,is poured. In this vessel the worker also add magnesium for magnesium treatment. The benefit of this treatment is that the magnesium reacts with water in the green sand mold and it liberates

Mold filling: Mold filling is a simple yet dangerous step where you have to handle the molten metal in the smaller ladle handled by two workers manually and then taking the molten metal from larger ladle we pour the metal into the smaller ladle and then to the molds. Worker while filling the molds:

Mold breaking and cooling:

After the mold is being filled it is cooled for nearly 10 to 15 minutes and then it is broken from the mold with a lot of sand still attached to it. As shown below:

After breaking the mold it is placed in open air for nearly 5 to 6 hours. Where it cools properly and solidifies completely after which it is to be machined. Casts placed in open air are shown below:

Cleaning:

In cleaning operations after the cooling of 5 to 6 hours in open air the casting then is placed into the machine named shot blast machine where the sand is removed.

o Shot blast machine:

Although the sand is being removed but there are still flashes (as indicated) which are to be removed before proper machining operations.

o Grinding :

The flashes are removed in this step where a machine named grinder (as shown below) is used to remove the flashes.

After the removal of the flashes the part is either sent to the customer as it is

after some painting or is sent to the machining section where the surface is

finished.

Finished part after all the foundry related processes:

Inspection :

Inspection is done by two methods one in which the worker checks the whole component just by naked eye. Second in which the worker uses a Vernier Calliper and a screw gauge to check the dimensional measurements. If there is a deviation ,than the required dimensions ,more then 5-6% then the whole component is sent back to foundry to be casted again from the start.