Classification of solidification processes

2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Casting Principle of the process

Configuration / Structure

Process modeling

Defects

Design For Manufacturing (DFM)

Process variation
Module 4a 2
Principle of the Casting
Process

Module 4a
 Casting Principle and process

Casting is a process in which the molten metal

flows by gravity or other force into a mold and
solidifies in the shape of the mold cavity.

Physics: 1. Fluid flow and interaction with solid

2. Thermal dynamics

Any material can be cast, as any material

undergoes the liquid state and solid state.

Module 4a 4
Basic casting steps (very simplified):

1. Melt metal Furnace

2. Pour it into mold Casting

system
3. Let it freeze
Casting Principle of the process

Configuration / Structure

Process modeling

Defects

Design For Manufacturing (DFM)

Process variation
Module 4a 6
Casting system

Module 4a
Casting System (Generic) structure
Basic components
and their connections

Make a
cavity

Module 4a 8
Casting Principle of the process

Configuration / Structure

Process modeling

Defects

Design For Manufacturing (DFM)

Process variation
Module 4a 9
 Process modeling

1. Heat up metal to a certain temperature

2. Pour molten metal into mold cavity
3. Solidify molten metal

Module 4a
 Heat up metal

-Heat metal above the melting point

-Pour it into the mold cavity

Heat energy required for

(1) heat for raising the temperature to the melting point,

(2) heat of fusion to convert the solid to the liquid,

(3) heat for raising the molten metal to the metal at the
desired temperature ready to pour it into a cavity.
Module 4a 11
 Heat up metal (2) heat of fusion to convert
the solid to the liquid
3.1 Heating Period Thermal Analysis

H V {Cs (Tm T0 ) H f Cl (Tp Tm )}

(1) heat for raising the temperature

to the melting point

(3) heat for raising the molten metal to

the metal at the desired temperature ready
to pour it into a cavity.

Given T0, determine the total energyModule

H, and4a then set up the furnace property
12
 Pour molten metal into mold cavity

Flow rate at the base of a sprue (energy balance:

P1v12 P2 v22
h1 F1 h2 F2
2g 2g

v 2 gh

Module 4a
 Pour molten metal into mold cavity
Mass balance
Mass in = mass out

Q=v1 A1 = V2 A2

Assumption: Fluid is incompressible.

Module 4a 14
 Pour molten metal into mold cavity

Time to fully fill the model cavity

V
MFT
Q

Assumption: not consider the transient process of

molten metal in the cavity.

MFT is shorter than the actual time needed to fill up

the mold cavity.
Module 4a 15
 Process modeling

1. Heat up metal to a certain temperature

2. Pour molten metal into mold cavity
3. Solidify molten metal

Module 4a
 Solidify molten metal
Chvorinovs rule: the time needed for the molten metal to
completely solidify in the mold cavity

V n
TST C m ( )
A

TST: total solidification time, min

V: volume of the casting, in.3 (cm3)
A: surface area of the casting, in.2 (cm2)
N: exponent, 2
Cm: mold constant, min.in.2 (min/cm2)
Module 4a 17
Cm is a function of
mold material
thermal properties of the cast metal
pouring temperature relative to the melting
point of the metal.

Determination of Cm can be done through experiment.

The principle of such an experiment is to have a

scenario that is the same as the casting and a known
cavity geometry, to operate the process, and to record the
Time TST.

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Implication of Chvorinovs Rule:

A casting with a higher volume-to-surface area ratio will

cool and solidify more slowly than one with a lower ratio.

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Casting Principle of the process

Configuration / Structure

Process modeling

Defects/quality control

Design For Manufacturing (DFM)

Process variation
Module 4a 20
Defects

Basic Problems in Casting Processes

- Incomplete filling of cavity

- Gaps in casting

Incomplete filling is caused by too fast solidification and flow

blockage. Solutions: multiple pouring cups, riser, etc.

Gaps in casting is caused by a phenomenon called

shrinkage. Solutions: riser, pattern allowance, etc.

21
Module 4a
Liquid
Contraction
0.5%

Further
Contraction
Lack of molten
metal

Different metal
thermal
expansion
coefficients

Shrinkage handouts 3 22
Riser: conducive to overcoming defects 1 and 2

Riser
Casting

Cup and Sprue to pour Riser = Reservoir

the molten metal
Module 4a 23
Summary of discussions so far

Principle of casting process (casting is liquid to fill up cavity)

Casting can be applied to any material
Three processes: heat up, pour, solidify
Defects (incomplete filling, )

Module 4a 24