Introduction

• Casting - technological process execution metal objects by filling the molds with molten metal.• Due to the nature of the metal poured into the mold are divided into:- iron casting,- cast molding,- heavy non-ferrous metal casting,- non-ferrous metal casting light.

Basic concepts in casting

• Cast - metal product made through pouring liquid metal foundry.• Mold - the components which make up the deposit slot (cavity) with shapes corresponding to the shape of the casting and gating system.• Model - a device for mapping the external shapes of the mold casting.Core characters - not reproducing elements of the model casting - for making this socket core.• Cores - elements of the mold reproduces the internal shape of the casting.• Core box - device used to perform the core.• Moulding and core - a mixture of primary and secondary materials used to perform foundry molds and cores.

1. Implementation of the drawings casting mold model, based on the design drawing of the finished product.2. Execution models and core boxes (model kit).3. Preparation of molding and core.4. Creation of molds and cores.5. Drying cores, and sometimes forms.6. Submission and preparation forms for pouring.7. Preparation of the liquid metal.8. Flooding of liquid metal forms.9. Breaking out molds and cores from castings.10. Removal of gating systems and cleaning castings.11. Any heat treatment of the re-cast their cleaning.12. Any repair castings.13. Technical control and receipt casts.

The process for casting operations

The stages of the casting

The stages of casting: a) drawing of the finished product, b) drawing the cast, c) the model, d) core box, e) composite mold, f) stamped cast;1 - allowance, 2 - core characters, 3 - half core box, 4 - core, 5 - flasks,6 - core socket, 7 - a form of gating system, 8 - gating system

a) setting model (with no upper subtracted core character) and infusion model subplate supply on the board,

b) imposition bottom flask and cover with icing,c) Sieving through a sieve layer of massd) filling the box using filler,e) churning mass in the box,f) scrape the excess thickened by weight,g) providing channels venting through the puncture,h) reversal of the lower half of the mold made of 180 °, set the upper mark spinal

infusion set models of the refueling boom delivery model (distribution infusion) and model sprue,

i) by setting the upper retainer pins flask and cover the surface of the powder,j) Sieving model mass through a sieve and repeat the previous steps, such as the

performance of the lower part of the mold, the execution of the reservoir cap and remove the model sprue,

k) remove the top half of the mold, turning it 180 °, remove the object model and models of gating system and the control of the mold hardness,

l) inserting the core of the reproduction opening to the bottom of the mold,m) mold assembly and its load bay and spill the liquid alloy,n) Removal the raw casting from the mold.

Hand molding

Mileage craftsmanship forms of the model (the core characters) molding weight: ZW - tank filler, WG – sprue, WR - infusion distribution, WD - infusions feed

Hand molding

Figure cast

In order to introduce the production of a new product, it is necessary to develop technological documentation, which includes:- rysunek konstrukcyjny gotowego wyrobu,- Conceptual drawing of the casting process,- drawing the raw casting,- model assembly design drawings- Figure mold,- special tooling drawings,- card technology,- Instruction card,- imputed card performance cast,- test card,- technical conditions cast.

Figure raw casting

Figure raw casting should contain :- exploratory data,- the surface distribution of the casting mold,- Machining base for starting the machining operation,- oversizes for machining,- technological oversizes,- Pitch and convergence of the walls of the casting in accordance with the mold parting plane,- gating system and bosses,- permissible dimensional surface untreated for those for whom these deviations abnormal,- information concerning special requirements for castings, such as. heat treatment, the requirements for hardness, etc..Exploratory data (item name, no rough casting), material, measure systolic and class of accuracy) is part of the cast plate drawing.

Figure raw castingDocumentation to the cast iron casting coverconstruction drawing

figure model for the formation of a metal hand drawing the metal core box

Figure match plate molding machine bottom Figure a match plate molding machine upper

Figure mold

Figure raw casting

Parting surface is designed to allow removal of the model from the mold during the formation, in the case of large castings parting surface is also used to reduce the burden of large models.The area is divided into parting casting, mold and casting box into two or more parts, and it essentially runs the largest cross-section of the course. In the figure, the raw casting is noted as the axis of the blue and the axis spelled "G" in blue, and the axis of the "D" also in blue or determined as shown in Fig. Example of use and labeling parting surface shown in Fig.

Figure raw casting

• The surfaces of the casting, which in the subsequent course of the technological process will be subjected to machining, oversizes must be of appropriate size. Size allowance machinability is normalized and depend on the accuracy class casting, the size of the area and the type of material cast.• Technological oversizes are those parts, or cast parts that are difficult or impossible to perform by casting in the shape of the illustrated construction of the finished product.

• The most common is the technological oversizes :- filling cavities and holes that are cast as full,- Safety switches cast against warping and cracking during cooling, heat treatment and finishing,- Additional trap used to determine and capture the subject during machining,- oversizes for shrinkage,- oversizes resulting from the inclinations of the walls of the casting is not provided in the drawing object.

Figure raw casting

Figure raw casting

Figure raw casting

Gating system

• Gating system is called a system of channels made in the mold, which should fulfill the following tasks :- bringing liquid metal into the mold cavity defined locations to the desired speed,- stop flowing with metal impurities and slag,- obtain the proper temperature distribution of the filler metal and regulate the form of thermal phenomena during solidification and cooling of the casting,- Power solidifying liquid alloy casting.• The first three tasks can meet the introductory part of the gating system, and the last part of the job meet called lug or ochładzalnikami.

Gating system

Casting gating system and lug: 1 - tank inlet, 2 - sprue,3, 4 and 12 - dispensing infusions, 5 - supplying infusions, 6 - separator,7 - transfer, 8, 9 - top bosses, 10 - lug side, 11 - neck risers

Types of gating systems

Schemes cast position in the mold depending on the level of bringing the metal into the mold cavity

Casting models

• Model casting is an auxiliary device in the shape of an external object cast with some modifications dictated by considerations casting. The dimensions of the model is increased by the amount of shrinkage of metal during solidification.

• In terms of design models can be divided into groups :I- models directly reproducing the shape of the cast: they are

coreless models, ie. natural models,II - indirectly models reproducing the shape of the casting,

requiring the use of boxes coreIII - simplified models.• All models can be made as models of shared and unshared

and detachable parts.• For molding by hand, or for the production of small lot unit,

and is made from wood. Much more durable metal models are made mostly of aluminum, copper and iron.

Natural casting models

Casting models unshared; a) without the removable part,b) a removable part 1 - part subtracted

Casting models unshared

casting models - the core characters - unshared: a) without the removable parts, b) with a subtracted

casting models shared

Natural models shared: a) no part subtracted,b) with a removable, 1 - the division plane

casting models shared

casting models - the core characters - shared:a) without the removable portion, b) a removable portion

Simplified casting models

Types of simplified models: a) a wireframe model and a cross-section of the casting, 1 - Models flanges,2 - core characters, 3 - ribs,4 - longitudinal ribs; b) Pattern about the vertical axis of rotation;c) the pattern of horizontal axis of rotation, d) stencil moved; e) pattern segment1 - pin, 2 - template, 3 - arm; f) the models of pads; g) control gages models

Core boxes box

The box core box: 1 - dowels, 2 - to strengthen, 3 - core

Frame core boxes

Frame core boxes :a) a simple, open,b) with bracket, with one side removed

Armored core box

Armored core box:1 - armor,2 - the inner part of the core box

Moulding materialsMolding materials are used - after proper processing - for making molds and cores. They are divided into major and minor. The foundry sand or a mixture of the core is called the main and auxiliary molding materials with water, selected in suitable proportions and properly prepared. The main molding materials are:- Sand molding - some of the loose and loose sedimentary rock composed mainly of quartz grains of irregular shape, where the matrix grain content is at least 65% by weight. The sands may be the natural mineral binder - in an amount up to 35%. In addition to the sands of the flasks can be used other minerals characterized by high resistance to fire and having a lower thermal expansion like. Natural and Artificial corundum, mullite, grog, magnesite, chromite, and zirconium silimanit.- molding clay containing more than 50% of the binder.     Auxiliary molding material of various kinds are typically organic binders and inorganic acids, for bonding together the loose sand grains, as vegetable oils, rosin, dextrin, molasses, water glass, synthetic resins, and increasingly fast hardening resins cold and hot. For auxiliary materials also include materials that protect against overcooking the weight of the casting surface (graphite, coal dust, charcoal), increasing the permeability of the material (peat, sawdust), powders for molding (lycopodium, talc).

Moulding materials

Moulding materials

• Moulding and core mass can be classified depending on the application and type:- The masses used for the casting of iron, steeland non-ferrous metals,- Mass for foundry forms "on wet" and "dry"- Przymodelowe weight and filling and uniform,- Mass of natural and synthetic,- Molding sand and special core (cement, ceramics etc.).

Moulding materials• Molding sand is prepared with fresh sand and clay with added weight and additives used. The technological process of preparation mixture consists of the following steps:- Preparation of fresh sand with clay content required,- Regeneration of used foundry sand (old)- preparation of admixtures,- preparation of molding the prepared ingredients.

Moulding materials

• Features molding:1. good plasticity - the ability to conform to the shape of the model and the behavior of the same shape,2. large particle cohesion molding provides resistancefor all kinds of hydrostatic pressure shocks and poured metal,3. substantial resistance to high temperature molten metal,4. sufficient permeability to gases and vapors formed during the casting process and during cooling of the metal in the casting mold,5. The ability to maintain full fitness for multiple usein the form of additives to new masses,6. easy separation from the walls of the finished casting during punching.

Molding tools and instruments

For manual application forms are special molding tool, which, depending upon the application can be divided into two groups:- Tools for forming the model in a box or in the substrate foundries- Tools for removing the model of repairing a damaged form and final finishing it.

Basic tools for hand molding:1 - 2 - rammers large,3 - 4 - rammers small,5 - pneumatic rammer,6 - trackpads flat,7 - trackpads edge,8 - lizards, 9 - sieve,10, shovel, 11 - lancet with a hook, 12 - hook to remove the model, 13 - Brush

Molding tools and instruments

Examples of the flasks:a) box manual molding, b) the crane box for manual or automatic molding,c) forming a box automatic lines at high pressures

Methods of forming the manual

• Forming in the ground open,• Forming in the ground of the box,• Forming in two cases,• Forming for forgery,• Formation of peeling,• The formation of three or more boxes,• Forming the core,• Forming in the ground by means of templates,• Forming using models of skeletal,• Forming using gauges control• Forming models using blocks.

Forming in the ground open

Forming in the ground open:1 - ground foundry, 2 - medium soft

Forming in the ground of the box,

Forming the ground of the box: 1 - hard substrate,2 - layer of coke, 3 - air pipes, 4 - puncture vent

Forming in two cases,

Implementation of the mold in two cases unshared wooden model consists of the following treatments.- The model and the inverted box podmodelowej lower on the board,- Imposition of model molding powder to prevent sticking molding,przymodelową mass filling boxes and filling and compaction hernakłuwakiem venting performance,reversal of the lower half of the mold with the model 180 °, set on a model casting gating system model and the upper box,- Fill in the upper box with the sand and kill them her- Slaughtered distribution forms a part, removing the models, repairs and finishing forms - drying cores,- Submission of forms, preparing for flooding and flooding of molten metal.Execution form of a model shared in a similar fashion, but with the difference that after the reversal of the lower flask, which was molded half of the model is placed with its second part, the model of the infusion, and then the upper box, which is filled with molding sand.

Forming in two cases

Example hand molding using a model unshared

Forming in two cases

Example hand molding using a shared model:a) drawing of the venturi tube and the core,b) core box, c) model, d), e), f), g) the formation of the next phase

Forming for forgery

Forming forgery:a) execution of fakes,b) forming bottom the box, c) formingupper box

Formation of peeling

Formation of peeling: a) cast, b) execution of bottom box,c) peeling, d) complex form, 1 - place peeling

The formation of three boxes,

Forming the three cases: 1 - the lower rim portion subtracted, 2 - the top part of the hub part subtracted 3 - central portion of the mold, 4 - the lower mold part 5 - the upper portion of the mold

Forming the core,

Means 6 cylinder block of the internal combustion engine, forming the cores arranged in a metal frame M

Forming template

Example of molding using a template; a) a device for template forming, 1 - placenta, 2 - steel spindle, 3 - arm cast iron, 4 - setting ring; b) forming a patterned cover, 1 - cover, 2 - forming the template upper surface of the lid 3 - forming the upper flask, 4 - forming the lid, 5 - a form prepared for flooding

Machine forming

• Machines for making molds and cores generally call the molding machines.• Moulders mechanized essentially two basic operations:- Concentration by weight in the molding box or core box,- Separating the model from the mold.• Because of the way the masses compaction molding machines are divided into;- Press the molding or pressing,- Shaker,- Shaker with intensification,- Narzucarki,- Shooters and blowers,- Other special molding machine.• Due to the method for separating the model from the mold molding equipment is divided into:a) separating form from his model;- Molding machine spindle or framework- the molding machine of the folding model,b) separating the model up when reversed forms:- the molding machine with a rotating table,- molding machine of przerzucanym table,- molding machine of the rotating column.(This division applies only to the press, shaker and shaker of intensification.

Pressing the molding machine of the upper clamp

Rules compaction molding sands in the form on the upper clamp molding machine: a) molding machine prepared for compacting in the box; b) concentrated massin the box; c) molding machine made arrangements to separate forms of the model:1 - cylinder, 2 - piston, 3 - molding table, 4 - plate model, 5 - flask, 6 - raiser, 7 - block compression, 8 - beam

Pressing the molding machine of the lower clamp

Pressing the molding machine are used almost exclusively for small and medium-sized forms.

The molding machine shaker with clamp

Operations during forming using the molding machine shaker holding:a) setting flask and sprinkle with icing pattern plate,b) the completion of the mass and density of the box pre mechanism,c) the density of the pressing plate, d) venting the mold, e) separating the mold from the model by lifting the pins

Separation of the model forms

Machine types depending on the method of separating the mold from the model:a) raising the mold arbor, 1 - flask, 2 - model 3 - bolts;b) the model dragged, 1 - model 2 - subplate, 4 - the base plate;c) with a swivel table, d) table przerzucanym

Separation of the model forms

Schematic design and operation of the molding machine of the rotating column

Forming at high pressures

Pressing rule under high pressure flexible axial piston head:a) the starting position, b) the beginning of the press, c) the end of the press; 1 - cylinder pressure equalization, 2 - piston head pressing, 3 - squeeze feet, 4 - raiser, 5 - flask, 6 - table machines connected to the match platefrom attacking up the hydraulic cylinder

Forming at high pressures

Scheme work of compression the molding machine at high pressures for a flaskless molding the Disamatic method:a) initial mass density using shooters,b) pressing,c) separating the left the match plate

Specific methods for producing sand cores and molds

• The process of CO2 (the weight of the water glass),• Forming in molds cement• CMS process (liquid mass self-hardening)• Forming in a thermosetting resin masses (hot core box)• Forming in a furan self-hardening masses (cold core box).

Producibility castings

Producibility is based on a comprehensive analysis of the design, material and technology aimed at providing a design adapted to the requirements of the casting process technology and maximum exploit material properties of the casting.Producibility consists of four basic elements:1.Analysis of the conditions of performance requirements as to determine the basic data for the design,2.Analysis of the properties of the casting material to determine its suitability to the operating conditions and technology,3.Analysis technology of casting according to design requirements and material properties,4.Choose the most appropriate variant: construction-material-technology based on cost analysis.

Producibility castings

Analysis of the structure of the casting manufacturability is a key function to create its production. It is based on agreement submitted by the builder concept construction and performance requirements of the casting, with reasonably selected by the technologist foundry way of its implementation. Determining the shape and the technical conditions to be satisfied by casting, it is in principle to the constructor. The final shape of the cast also depends technologist foundry, which determines the amount of allowances for processing, technological allowances and inclinations of the walls of castings, site to bring the liquid metal, the size of risers etc. Often, due to technological reasons or due to the improvement of the quality of the casting, the technologist caster may propose an amendment drafted by the builder how to do casting, for example, instead of sand casting - casting mold. Such a change usually entails a material adjustment to the shape of the casting.

Producibility castings

The most important issues considered during the design of the casting manufacturability analysis include:• ease of mold, including in particular: structural regularity inclinations casting parting surface selection, easy to remove the model from the mold without the use of loose parts, and in the case of metal molds - easy removal of the casting from the mold, and ease of installation and reliability in the form of cores,• correctness and faultless filling the mold with molten metal,• prevent defects systolic• preventing deformation and cracking of the casting during cooling in the mold,• ease and low cost of purification casting• efficiency and low cost of machining of castings,•material savings.

Producibility castings

The structural solutions are only examples illustrating the construction of the cast parts of the analysis. In a closed system which is the system working conditions casting casting design - design foundry equipment - making the raw casting - cleaning and finishing casting, make at any stage of the analysis of changes in the structure of the casting must have an impact on the rest of the system. Hence the change of the structure element to simplify the process of formation or treatment may not always be realized due to the limitations resulting from conditions such as installation or operation of castings.

Producibility castings