Casting process and steps for making a casting

Casting process:

Casting Process: Casting process involves different types of steps. Casting is one of the oldest methods we use. Casting is the process of making a required product, which is done by using the mold cavity. We can get a product by pouring a liquid metal into a mold cavity and allow it to solidify. we get a product of the desired shape after solidifying it.
The solidified one is known as Casting. There are different types of casting materials we use like Metals of different types and Plastic, Clay, Concrete, Expoxy etc..
The mold is two types Open and Closed.
In the open mold, the molten material is directly poured into the main cavity. But in the closed one, there is a delivery system by this the molten material enters the main cavity.

The steps for making a casting:

• Pattern Making.
• Molding.
• Melting the metal and pouring
• Solidification.
• Removing the casting.
• Machining
• Stress relive.
• Finishing.

Pattern Making:

• To get a final object Pattern is made into an accurate shape. or this is done to an accurate to obtain a desired shape of the product.
• A pattern can be made from woods, different types of Materials, Plaster of perils etc.

Molding:

Molding: Molding is a large process involved in it. The Molding table is placed with the drag which is placed inverted on it. and the pattern is placed in the drag. The sand using is different types. Pattern and used to spray a small amount on patter and along the drag. facing sand is used to spray only on the pattern. finally, Backing sand is used to fill up to the level. Making to escape the air vent holes are used. After making this, reverse the drag. we want to keep the cope, spur, and riser at there places. cope is placed above the drag and the riser and spur are placed in the cope. in this riser must be above the pattern and spur is placed beside the pattern.

The same process should be done with different types of sands and this spru and riser should be removed and we should cut the shape of pouring basin from where the molten metal is poured in it.
After completing the coping process, it must be lifted from drag, due to removing the pattern from drag after removing the drag the cope should be placed above the drag. By this, we can get molding.

Melting the metal and Pouring:

• The metal should be melted in oil furnace to get into a required temperature to melt and this should be poured with uniform velocity.

Solidification:

• In this process, we need to wait until it gets to cool at this time the induced stress is reduced.

Removing the Casting and cleaning:

• This process is done after solidification, it is to remove the casting and Clean it from sand particles.

Machining:

• This is done due to the extra parts on it like sprue, riser etc.

Stress relieve:

• The induced stress is removed by this heat treatment.

Finishing:

• Finishing is done to get a smooth surface and to get exact dimensions.

Applications:

• This is used for heavy working items like engine blocks, Aeroplane engines, pistons, frames, and beds.
• Used for hydraulic turbines, blades for jet engines, fitting materials, pipes etc.

Advantages:

• This product obtained is accurate.
• It has a good surface finish.
• Any type of shapes can be made.
• Cost of machining is reduced.
• Plastic can be cast easily.
• This product has good mechanical properties.

Disadvantages:

• This process takes more time than the other types.
• It takes time for melting the metal and high energy is used to melt this.

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