Transcript METAL CASTING &JOINING - National Institute of Technology

CAST PRODUCTS
:
1.CYLINDERS:
(I)
CYLINDER LINERS ( DRY & WET) : Cylinder Liners (Dry & Wet)
manufactured by the "Centrifugal Cast Process" is acknowledged to be
the best method. It possesses the bearing metal qualities that cause skin
healing after abrasion and a structure that is readily wetted by oil and
retains an oil film. Corrosion resistance is further improved by adding
Chromium in the metal. In the centrifugal casting process, the molten metal
is poured into a metal mould or die which is revolving at a high speed. The
centrifugal force causes the metal to distribute itself evenly around the die.
The resulting casting are of much finer grain and free from blow holes or
porosity. A further important advantage is that the impurities, being lighter
than the iron, are forced centrifugally to the bore surface from which they
are removed by machining .
DRY LINERS :The Dry Liner is in direct contact with engine block. The
Outer Diameter is to be very precise and perfect without contours.
WET LINERS :The Wet Liner is with sealing grooves for ‘O’ rings and
always in direct contact with water. A Wet Liner is generally Heavy & Thick
walled.
RANGE
: Diesel, Petrol, Marine & Compressor Engine for Light &
Heavy commercial vehicles, Cars, Tractors & Utility vehicle.
CAPACITY
:1. QUANTITY : Centrifugal Castings : 300 Ton p.m.
2. MACHINING : 65000 Pcs. p.m.
(ii) AIR COOLED BLOCK:
• .
AIR COOLED CYLINDER BARRELS made from special
"SHELL MOULDING PROCESS" causes wear resisting
close grained iron casting and this ensures long life and
efficient cooling
(iii) VALVE GUIDE :
Delight Valve Guides are grounded to a surface finish of 0.80
Micro Ra on its Outer Diameter and with in a tolerance of 13
Microns. These are also provided with Thread and Spiral in its
Inner Diameter to retain oil for long time. Thus increases the life
of both Valve Guide and the Valve. Delight Valve Guide has
microstructure of Pearlitic matrix with 5% maximum free ferrite
5% maximum free carbides an d10% maximum steadite in
cellular or discontinuous form and Valve Guide has Hardness of
210-260 BHN
• Casting of "Delight" Cylinder
Liners & Sleeves are made only
CENTRIFUGAL CASTING
by centrifugal casting process by
Semi - Automatic Horizontal /
Vertical centrifugal Casting
machine to have a extra fine
balanced Graphite structure
ensuring the desired metal free
from casting defects. .
• Due to centrifugal force the
impurities are spun to the outer
surface, which is then machined
off. The speed of the rotation and
metal pouring rate vary with the
alloy and size and shape being
cast.
• Perfectly shaped spun Cast
Cylinder Liners resist distortion
and vibration reducing the risk of
cavitations. The castings are
removed from the mould at a
temp. of 500 degree Celsius
2.SHUTTLE RACE
Shuttle Race 2530
(for House Hold
Sewing Machine)
Shuttle Race 24415
(for 31K Leather Stitching
Sewing Machine
Shuttle Race Open Type
3.INVESTMENT CASTING PRODUCT
Carbon
Steel
(Machine
Parts)
Cutting Tool (Vise)
Low Thermal Expansion Steel (Sensor Parts)
Heat Resistant Steel
(Engine Parts)
Stainless Steel (Piping Parts )
Electromagnetic Material (DOT Printer Parts)
Low Alloy (Bicycle Parts)
Two Phase Stainless Steel (Flow meter Parts )
HIGH SPEED STEEL (CUTTER)
Ni Base Super Alloy (Turbo Charger Parts)
INVESTMENT CASTING
• Investment casting is the production of industrial parts through the of
metallic replication wax models. Industrial manufacturers often
choose the investment casting process when complex parts or large
quantities of parts are needed during production. The casting
process remains structured and precise, resulting in a polished finish
resembling the initial model down to the most intricate detail. In
addition, an abundance of casting metals exists, and an extensive
number of cast sizes and shapes can be created. Steps involved
• Pattern creation - Initially, an injection-molded wax pattern is used
to create a model of the proposed finished product. Wax is injected
into an aluminum die, a tool consisting of a cavity into which the wax
can be poured.
• Molding - The resulting wax pattern is used to create a ceramic
mold; the mold can be created using the ceramic mold process or
the solid mold process.
Continued……….
• Casting - The molds are heated to remove leftover wax and to
prepare the mold for casting. The mold is then filled with molten
metal, which will harden into the final product.
• Cleaning - The mold is broken away once the metal has cooled.
The casting is then subjected to other treatments as necessary,
which include additional heating, polishing, and refinishing.
• Investment casting materials are quite plentiful. Numerous ferrous
and nonferrous substances can be cast, including steel, irons,
titanium, nickel- and cobalt-based alloys, bronze alloys, brass,
aluminum, stainless steel, and nickel-boron alloys. Investment
casting is used to create an assortment of parts in all sizes, shapes,
and weights. Investment-cast parts include dental braces,
automotive engine parts, medical equipment, and satellite
communications hardware. Although the weight of parts ranges from
one ounce to one ton, the majority of investment castings remain
under twenty pounds. Because of the wide application of
manufactured metal parts, parts created using investment casting
are found within almost every industry, including the automotive,
military, dental, mining, music, food processing, sports, and
telecommunication industries.
LOST FOAM CASTING
GM 4.2L foam cylinder block
Foam cylinder head & block
Cylinder block
Lost Foam Process - This Process is similar to "Lost
Wax", better known as Investment Casting, in that both the
casting mediums are expended, either melted or
evaporated away, leaving the cast part .Make sure to visit
"Lost Foam" Casting Process in the Exploded Drawings
Sections. or Views
Lost foam casting simplifies the process immensely. The key to
the process is the plug. It is made of Styrofoam. An external
mould is made and filled with Styrofoam. The Styrofoam part is
removed and it looks exactly like the final part to be made. The
Styrofoam plug is placed in the metal container and sand is
poured around it. No resin is needed because the Styrofoam
plug is not removed. The complete mould is vibrated to ensure
the sand has filled all the cavities and there are no voids.
Finally, molten aluminum is poured into holes in the top
dissolving the Styrofoam, and the fumes go out the vent holes.
Open the mould and the sand falls away, leaving the production
part ready for machining
The lost foam casting process is much quicker than
conventional casting. The mold does not have to be separated
and the plug removed. Aligning two halves of the container is
not necessary. The sand does not need to be broken away
from the final casting.
GATE & ENGINE PARTS
DIE CASTING
this process is for high volume, high detail, value added, economy priced, cast parts.
A metal tool is built, and it is attached to a furnace of molten metal, this molten metal is
mechanically poured…injected into the metal mold, the mold cools for a brief time, it opens the
parts come out… the process repeats, over and over and over. Advantage is very high
production with great duplication, with great tolerances.
GATE
Aluminum Die Casting - is a process where molten aluminum alloy is
injected into a closed vessel called a casting die or mold, under high pressure
and at a controlled temperature. The mold has sections which include the
"cover" or hot side and the "moveable" or the ejector side. The die may also
have additional moveable segments called slides or pulls which are used to
create features such as undercuts or holes which are parallel to the parting line.
Aluminum die casting molds operate in cold chamber die casting machines.
These machines run at the required temperatures and pressures to produce a
quality part to net-shape or near net-shape specifications. Aluminum die castings
can be readily machined, anodized, painted or powder coated.
Examples of usage would be: cabinets for the electronics industry, hand and
power tools for industrial and home use, general hardware appliances, pump
parts, plumbing parts, parts for the automotive industry, sports and leisure, home
appliances, a lot of communications equipment, the list is endless.
Zinc die castings - poured from Zamak #3,#5 or #7 or a zinc-aluminum
alloy casting made from ZA-8, are made very similar to aluminum die casting
.The molten metal is injected into a closed vessel called a casting die or mold
under high pressure and at a controlled temperature. The metal is cooled rapidly
until the solidified part is sufficiently solid enough, to permit it to be ejected from
the mold. The mold has sections which include the "cover" or hot side and the
"moveable" or ejector side. The die may also have additional moveable
segments called slides, or pulls which are use to create features such as
undercuts or holes which are parallel to the parting line.
Zinc die casting dies or molds operate in hot chamber die casting machines.
These machines run at the required temperatures and pressures to produce a
quality part, to net-shape or near net-shape specifications. Zinc die castings, can
be readily machined, plated, painted or powder coated.
S
MOLD
ENGINE PARTS
CYLINDER HEAD
PERMANENT MOLD CASTING
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The permanent mold casting process is the production of castings by pouring molten
metal into permanent metal molds under gravity pressure. Castings produced in
permanent molds have finer grain structure and better strength properties than those
cast from similar alloys in sand casting and die casting.
Metal molds (or dies) usually are made of high-alloy iron or steel and have a
production life of up to 120,000 or more castings.
.
Due to the chilling nature of a solid steel permanent mold tool, the castings are
sounder than sand castings. For pressure-tight and nonporous castings, the
permanent mold process is excellent. Permanent mold castings can be stronger than
die and sand castings and less porous than die-castings.
Permanent mold aluminum castings generally range from a few ounces to more than
100 lbs. Aluminum castings weighing several hundred pounds have been produced
commercially by the permanent mold process.
Permanent mold castings usually need less finish machining and polished than sand
castings. If the parting lines on the outside of a casting can be held to a minimum,
high quality as-cast finishes approaching 100 rms. can be achieved and many
aluminum castings with these good as-cast finishes are used without subsequent
finishing for cooking utensils, hardware items, automotive parts, highway bridge
railings and ornamental
AUTOBIKE PARTS
MACHINE PARTS
MACHINE PARTS
FORMING PRODUCTS
HOT FORMING TOOLS
COLD FORMING TOOL
INJECTION MOLDING PRODUCTS
SAND MOLDING
DRY SAND MOLDING – large components are very difficult to cast to exact size and dimensions. Hence, some
foundries use dry sand molds to produce such parts. Dry sand molding is the green sand process modified by
baking the mold at prescribed temperature. Engine blocks, large gears, big housings, construction parts, are
examples of dry sand process candidates. Ferrous and non-ferrous metals are cast in this method. The key to this
process is the proper baking time in relation to the binder and the moisture content
. The other factors are the size, weight, and
mass, of the component being cast. Wynn
Danzur can explain the profitable advantages of
this process to you. Some good examples are,
the great strength of the part cast, exactness in
dimension, much smoother finish, etc., but most
important is how these processes will benefit
your casting jobs.
CAST PRODUCT
CAST PRODUCT
FOR DECORATION PURPOSE
BRONZE CASTING
CAST PRODUCT
AUTO PARTS
POWDERED METAL CASTING – this process is also sometimes referred to as the
sintered metal process, we will always refer to this as Powdered Metal Casting. Casting
Industry professionals across industry depend on Powdered Metal, for cost effective
production of parts .The Powdered Metal Casting Process is the absolute choice for parts
that require high mechanical properties with repeatable close tolerances. That's why this
modern technology is so popular today.
REFERENCE
tmwww.anandenterprise.com
www.dukheung.co.kr
www.klcast.com.tw
www.investment-castings.net
www.allproducts.com