Metal Casting Process

Al-Si Alloys ◽  
2017 ◽  
pp. 49-81
Author(s):  
Francisco C. Robles Hernandez ◽  
Jose Martin Herrera Ramírez ◽  
Robert Mackay
Keyword(s):  
Casting Process ◽  
Metal Casting

REDESIGN N METAL CASTING TOOLS USING ANTHROPOMETRY AND QFD

2019 ◽  
Vol 1 (2) ◽  
pp. 16-23
Author(s):  
Andung Jati Nugroho ◽  
Erma Kusumaningsih ◽  
Ferida Yuamita ◽  
Aldi Yoga Pradana
Keyword(s):  
Liquid Metal ◽  
Quality Function Deployment ◽  
Combustion Process ◽  
Casting Process ◽  
Metal Casting ◽  
White Cement ◽  
Casting Tool ◽  
Design Idea ◽  
Body Map ◽  
Design Ideas

The case in the metal casting process is when the metal is melted and then poured into a liquid metal reservoir and then poured into a pouring tool and then poured into a mold. In the process of pouring into the mold is still using manual equipment, namely by using wood which ends have a container such as a bucket ( bucket)) made of a mixture of white cement, brick fire sand and clay and the metal liquid pouring tool has a length of 1.5 cm, a weight of 5 kg with a diameter of 15 cm and a height of a container for liquid metal 20 cm does not include the load. If the pouring device filling with liquid metal, then the weight reaches ± 20 kg, with a weight of ± 20 kg the worker must pour the liquid continuously into the mold and at least each worker must go back and forth 6 times pouring metal liquid into a mold in a single combustion process. Based on the nordic body map questionnaire data as many as 8 workers felt pain in the shoulder and arm because the burden was born, resulting in workers often feel pain in the muscles of the arms and back. Because the wooden handle used to pour metal liquid is too slippery (exposed to sweat), so there is a need for improvement in activities. From the results of the above observations, it is necessary to design ideas for new work facilities. It expects to affect the improvements related to the position of the hand in the process of pouring liquid into the mold. Then the design idea needs to be done in the form of a casting tool that has been modified and can be used according to user needs and can be said to be ergonomic, safe, and comfortable. The method used in designing castings is quality function deployment and anthropometric techniques.

scholarly journals THE CHARACTERISTICS OF LAMPUNG LOCAL SAND AS CASTING SAND IN THE METAL CASTING PROCESS

2019 ◽  
Vol 30 (1) ◽  
pp. 10
Author(s):  
Yusup Hendronursito ◽  
David Candra Birawidha ◽  
Kusno Isnugroho ◽  
Fathan Bahfie ◽  
Wulanda Yurista Persatika ◽  
...  
Keyword(s):  
Casting Process ◽  
Metal Casting ◽  
Casting Sand

scholarly journals Strength Properties of Concrete with Aggregates from Alternate Sources

2019 ◽  
Vol 9 (1) ◽  
pp. 4066-4069
Keyword(s):  
Compressive Strength ◽  
Glass Powder ◽  
Coarse Aggregate ◽  
Environmental Issues ◽  
Casting Process ◽  
Strength Properties ◽  
Metal Casting ◽  
Fine Aggregate ◽  
Foundry Sand ◽  
Compressive Strength Of Concrete

Aggregates used in concrete are fast depleting natural resource and the quarrying of which is causing environmental issues. Hence, the use of aggregate from alternate sources such as from waste discarded glass, from foundry sand discarded after metal casting process and sea shells is investigated. Compressive strength of concrete with glass powder, foundry sand and sea shell is studied individually. Concrete is cast with glass powder and foundry sand as 5%, 10%, 15% and 20% replacement of fine aggregate and with sea shell as 5%, 10%, 15% and 20% replacement of coarse aggregate individually. It is observed that compressive strength of concrete decreases with glass powder, foundry sand, and sea shell. Fine aggregate replaced by 10% glass powder, 10%, foundry sand and coarse aggregate replaced by 10% sea shell have the least decrease in strength when compared to control concrete mix.

scholarly journals CFD Optimization Method to Design Foam Residue Traps for Full Mold Casting

2021 ◽  
Author(s):  
Yuto Takagi ◽  
Masahiro Inagaki ◽  
Ken’ichi Yano
Keyword(s):  
Molten Metal ◽  
Casting Process ◽  
Optimization Method ◽  
Post Treatment ◽  
Metal Casting ◽  
Mold Casting ◽  
Casting Design ◽  
Cfd Optimization ◽  
Product Part

Full mold casting is a casting process in which a mold made of wood or metal is substituted for a styrofoam model. This metal casting process is advantageous for the production of large-sized castings because it uses a foamed model. However, this unique process of melting a foamed model causes a problem which is the foamed model remains dissolved in the casting. This is called foam residue defect and is specific to full mold casting. In this study, we propose a new casting design called a residue trap to reduce these residue defects. This residue trap collects the residue of foam models included in the molten metal, which tends to be generated when the temperature of the molten metal becomes low by being attached to the product part in the same way to overflows. We also optimized the shape of the residue trap in terms of easing of post-treatment and increasing efficiency of collecting foam residue. Eventually, the effectiveness of the residue trap was verified by actual full mold casting experiments.

scholarly journals Experimental Study on Mold-Lay Filament instead of Wax in Investment Casting Process

2020 ◽  
Vol 5 (1) ◽  
pp. 39
Author(s):  
Imam Kusyairi
Keyword(s):  
Investment Casting ◽  
Casting Process ◽  
Metal Casting ◽  
Result Show ◽  
Long Time ◽  
Technological Developments ◽  
Investment Casting Process ◽  
To Come ◽  
Main Components ◽  
Plastic Mold

Metal casting with investment casting method is metal casting which has the ability to produce accurate parts and has a controlled fineness. Current technological developments are very influential in the development of investment casting. One of them has been found mold-lay filament as a substitute for wax, which is now wax is one of the main components in investment casting process. Mold-lay filament is printed using a 3D Printer machine. In this study, the wax in the investment casting process was replaced by a mold-lay filament with the specifications 0.75kg / 0.55 lb of 1.75mm MOLDLAY filament, prints at temperatures of 170-180 ° C. The result show that  mold-lay flutes are also able to come out well from slurry molds, but require more time than wax, this is because one of the plastic mold-lay compositions, which takes a long time for the moldlay fillment to come out of the mold. Further research suggestions are needed further testing in terms of roughness of the product with moldlay filament and compared with wax. This will also see if there are any remaining moldlay filaments from the mold.

Interactive Scenario-Based Teaching of Metal Casting Processes

2011 ◽  
Author(s):  
Zahed Siddique ◽  
Mrinal Saha ◽  
Firas Akasheh ◽  
Shaiful Arif ◽  
Bipul Barua
Keyword(s):  
Active Learning ◽  
Learning Experience ◽  
Casting Process ◽  
Metal Casting ◽  
University Of Oklahoma ◽  
Post Test ◽  
Manufacturing Engineering ◽  
Novel Concept ◽  
The University ◽  
The Impact

It is well documented that students learn more effectively when they are actively involved in the learning process. Interactive scenario-based education is a novel concept expected to stimulate active learning and provide an engaging learning experience. Recently we have developed a Create your Scenario Interactively (CSI) module to teach metal casting and have implemented it in manufacturing engineering courses at the University of Oklahoma. In this paper, we discuss the impact of the CSI on students’ learning in manufacturing engineering education. The pedagogical effectiveness of the CSI instruction has been evaluated in several areas such as students’ engaging and active learning through pre-test and post-test format and survey questionnaires. Our preliminary results suggest that a majority of the students feels that the CSI module is very effective in keeping them engaged. Results also indicate that the CSI instructions help improve their understanding of the metal casting process. The details of the CSI module, implementation details, and assessment results are discussed.

scholarly journals An analysis of brass casting parameter process using sand casting mold

2019 ◽  
Author(s):  
M Nasrul Kamal
Keyword(s):  
Liquid Metal ◽  
Molten Metal ◽  
Casting Process ◽  
Sand Casting ◽  
Metal Casting ◽  
Liquid Pressure ◽  
Casting Mold ◽  
Casting Parameter

This research tried to analyze the existing casting process ofganto recycled brass by varying the liquid pressure parameters ofdifferent induction metals, followed by the pouring of liquid metal intothe mold. The method used in this research was descriptive qualitativewith aesthetic analysis. As a result, metal casting can be defined as theprocess of molten metal, poured into a mold, then allowed to be cooland freeze. In conclusion, Ganto is one of the objects of brass castingthat continues to produce the brass handicrafts in Jorong Kapalo Koto,especially the production center of Zikri ganto.

scholarly journals Virtual Casting: State of the Art in Metal Casting Simulation Tools

2018 ◽  
Vol 15 (2) ◽  
pp. 142
Author(s):  
Muhammad A.A. Khan ◽  
Anwar K Sheikh
Keyword(s):  
Mechanical Performance ◽  
State Of The Art ◽  
Mechanical Load ◽  
Casting Process ◽  
Holistic Approach ◽  
Metal Casting ◽  
Ongoing Research ◽  
Cast Part ◽  
Simulation Tools ◽  
Simulation Based

The demands on the productivity and robustness of metal casting processes for high quality components are continuously increasing. Moreover, the financial considerations necessitate    meticulous and reliable planning of the entire casting process before it is actually put into practice. A holistic approach to perform cradle to grave analysis of cast products is simulation-based metal casting.  This method allows engineers to model, verify, and validate the process followed by its optimization and performance prediction in virtual reality. This paper provides insights on state of the art in simulation-based metal casting with reference to some case studies. Casting simulations software, mathematical models and solution methods, and casting process simulation together with the results obtained are clearly explained. The current practices revealed extensive utilization of simulation packages for defect minimization, yield maximization, and improved quality. The ongoing research on integration of casting simulations with mechanical performance simulations makes it possible to analyze the serviceability of cast parts. The reliability of cast part in service with dynamic loading of varying thermal and mechanical load cycles can be predicted through this integration. However, more rigorous work is needed in this area, particularly by developing the reliability prediction modules embedded in advanced simulation tools. 

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