Manufacturing Processes 11

8/3/2019 Manufacturing Processes 11

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Casting Products


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PRESENTED BY

ARMAAN KHAN

(2010-ME-61)


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CastingThe process of making an object by pouring

some material in a mold.


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Types of castingBased on the type of mold used, casting is divided

into two categories

y Expandable Mold casting

Mold is destroyed in order to get the casted part.

y

Permanent mold castingMold can be used over and over to produce many

castings.


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Casting productsyV-8Engine blockIntegrated structure comprising of the cylinders of aVtypeengine.


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Materials

ySand

yWood

y

Aluminum

y Binders


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Production of V-8 engine blockyCreation of patternA replica of theengine block is made using wood.


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Production of V-8 engine blockyCreation of moldA mold is created using sand and binders.


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Production of V-8 engine blockyMelting and pouring of metal

Aluminum metal is melted and then poured into the

mold for solidification.


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Production of V-8 engine blockySolidificationThe molten metal solidifies i n the cavities and takes

the shape of the engine block after which it isremoved from the mold for further cleaning andmachining operations to produce the net shape.


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Production of V-8 engine blockThe final shape of theengine block is


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ApplicationsV-8engines are most commonly used in

y Muscle cars

y Pony carsy Sports cars

y Luxury cars

y Trucks

y SUVs *

* Sports utility vehicle


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Casting productsyWash basin(sink)

A sink (also basin, hand basin and wash basin) is abowl-shaped plumbing fixture used forwashing hands, for dishwashing or otherpurposes.


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MaterialsySand

yBinders

y

Ceramic materials

yColors


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Manufacturing of sinkyMold preparationThe first step is thepreparation of mold of the

desired product.


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Manufacturing of sinkySlippreparation

The liquid slurryproduced by mixing variousceramic materials is called slip. The mainmaterials used in this process are Feldspar,quartz, talc, china clay, soda and silicate.


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Manufacturing of sinkyCastingIn this process, the slip is introduced in the molds.


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Manufacturing of sinkySurface finishing

After casting process, the surface of the sink issmoothen with thehelp of dusters.

yGlazing

In this process, the sink is colored accordingto the market needs.


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Manufacturing of sinkyFiring

The sink is then baked in a furnace tostrengthen it. After baking the sink is readyto be sent to the market.

ApplicationsMainly used in homes and offices for

personal hygiene and cleanliness.


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Casting productsySlabsSlab is a length of material( metal or ceramic),

rectangular in cross section.


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Materialsy Quartz

y Pigments

y Polymer resins

y Sand

y Binders


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Preparation of slabySlippreparation

Liquid slurry is prepared by mixing quartz powder,

polymer resins and pigments.

yMold preparation

A mold of the form of slab is produced using sand

and binders.yCasting

The liquid slurry is then pored into the mold.


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Preparation of slabyPressingThe slab is then compacted by a vacuum at a very

highpressure.yFiringthe slabs are then baked in a furnace for increase

strength and solidity.

yPolishingSlabs are then polished to end up the finishing

process as well as the manufacturing process.


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Applications

Used for

y kitchen countertops

y Constructing floors and ceilings

y Distributing heavy wall loads across any building.


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Casting productsy Pipe fittings (elbow, tee, plug)

Fittings are used in pipes to connect various pipe

sections to form different sizes or shapes.


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Materialsy Sand

y Binders

y Refractory material (silica, alumina, zircon)

y Polystyrene

y Metal (copper/aluminum)


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Manufacturing ofpipe fittings

yPattern makingIn the first step, a pattern of the fitting is made by using

polystyrene.


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Manufacturing ofpipe fittingsyRefractory coating

Thepattern ofpolystyrene is coated with the

refractory material.

yMold preparation

Foam pattern is placed in mold box and sand iscompacted around thepattern.


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Manufacturing ofpipe fittingsyPouring of metal

Molten metal is poured into theportion of mold

having polystyrenepattern.Thepattern vaporizes ahead of the advancingliquid, thus allowing the resulting mold cavity tobe filled.

After filling, the metal cools to give theelbow ofdesired shape.


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Manufacturing ofpipe fittings


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ApplicationsPipe fittings are used to

y Extend or terminate a pipe

y Change a pipes direction

y Connect two or morepipes

Manufacturing Processes 11

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