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Casting process (continued)

Casting process (continued). Casting. Principle of the process Structure Process modeling Defects Design and DFM Process variation. Casting. Principle of the process Structure Process modeling Defects Design and DFM Process variation.

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Casting process (continued)

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  1. Casting process (continued) Module 4b

  2. Casting Principle of the process Structure Process modeling Defects Design and DFM Process variation Module 4b

  3. Casting Principle of the process Structure Process modeling Defects Design and DFM Process variation Process design: how to determine the process parameters so that the desired product can be manufactured and defects are eliminated as much as possible Module 4a

  4. Design of a casting process is to determine: • pattern, mold, sprue, gating system, mold cavity, riser parting line • pour temperature • Process goal: Mold cavity is completely filled without defect • Process constraints: casting material, casting geometry, cost, time, quality Module 4a

  5. Design and DFM Design for locating parting line – determine parting line or surface Parting line or parting surface is the interface that separates the cope and draghalves of a mold, flask, or pattern and also the halves of a core in some core-making processes. Module 4b

  6. Design and DFM The main functional requirement for determining the parting line is: the pattern can be drawn out from the mold to leave a cavity. Besides, this basic function, the selection of parting line can affect Cores (as little as possible) Draft (as little as possible) The core and draft cause material waste and extra steps in the casting process, which means cost increase. (a) (b) (b) Is better as there is no need to have core and no need of draft; but (a) needs them. Module 4b

  7. Design and DFM Original design Modified design Module 4b

  8. Design and DFM Parting line or surface determination Three Options Parting line Design features, such as round, may also put restriction to the location of parting line in the above cases Module 4b

  9. Design and DFM Design for Controlling the process Module 4b

  10. Design and DFM Two sections intersection causes: hot spots (gap) and stress concentration Stress concentration shrinkage Fillets Hot spots Module 4b

  11. Design and DFM Fillet Holes Module 4b

  12. Design and DFM Additional Riser To control the shrinkage cavity to the riser Module 4b

  13. Design and DFM Avoid hot spots Module 4b

  14. Design and DFM Pattern shrinkage allowance Large casting, special rule: 1% - 5% Solution to Cavity caused due to Shrinkage Module 4b

  15. Design and DFM Riser External and Internal Chills Directional Solidification – Forced Solidification Location of riser (V/A)2 > (V/A)1 Module 4b

  16. Mold How Pattern is made Mold Materials Summary Constituents of Casting Process How Mold is made Module 4b

  17. One mold multiple casting One casting one mold Summary Permanent casting Casting Expandable casting Module 4b

  18. Summary Type of casting: expandable or permanent Surface quality Way to make mold Way to make pattern What We are Going to Look at Given a Casting Process Quality Requirement Function Requirement Volume of Production Module 4b

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