金工实习英文讲义-铸造

Mechanical Engineering Training
Sand Casting
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1. Introduction to Casting
Casting is a manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or various cold setting materials that cure after mixing two or more components together; examples are epoxy, concrete, plaster and clay. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods. Casting is a 6000 year old process. The oldest surviving casting is a copper frog from 3200 BC.
In this training course, considering the availability of required equipment in the training center, we will focus on the training of metal casting methods.
2. Metal Casting and Its Common Methods
Metal casting is one of the most common casting processes. Metal patterns are more expensive but are more dimensionally stable and durable. Metallic patterns are used where repetitive production of castings is required in large quantities. Common metal casting methods include Sand Casting, Die Casting and Evaporative-pattern Casting.
Sand Casting
Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand as the mold material. The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. Over 70% of all metal castings are produced via a sand casting process. As the most widely used metal casting methods, it is the main focus of this training course and will be talked about in detail in the following sections.
Figure 1 Sand Casting
Sand casting is relatively cheap and sufficiently refractory even for steel foundry use. In addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is moistened, typically with water, but sometimes with other substances, to develop strength and plasticity of the clay and to make the aggregate suitable for molding. The sand is typically contained in a system of frames or mold boxes known as a flask. The
mold cavities and gate system are created by compacting the sand around models, or patterns, or carved directly into the sand. A demonstration of sand casting is shown in Figure 1.
Die Casting
Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminum, magnesium, lead, pewter and tin based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
The casting equipment and the metal dies represent large capital costs and this tends to limit the process to high volume production. Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is especially suited for a large quantity of small to medium sized castings, which is why die casting produces more castings than any other casting process. Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.
Figure 2 shows a die casting machine. In later sessions of the training course, you will have the chance to see the die casting process and make an aluminum model of a fighter yourself with the machine.
Figure 2 Die Casting Machine
Evaporative-pattern Casting
Evaporative-pattern casting is a type of casting process that uses a pattern made from a material that will evaporate when the molten metal is poured into the molding cavity. The most common evaporative-pattern material used is polystyrene foam.
The two major evaporative-pattern casting processes are:
(1) Lost-foam casting
(2) Full-mold casting
The main difference is that lost-foam casting uses an unbonded sand and full-mold casting uses a bonded sand (or green sand). Figure 3 shows patterns and according products made from the patterns in evaporative-pattern casting. Please pay attention to
the materials of the pattern and product.
Figure 3 Pattern and Product of Evaporative-pattern casting
3. Components of Sand Casting
Figure 4 Structure of Sand Casting Process
Figure 4 shows the structure of a sand casting process, from which we can see that the structure is mainly composed of the flasks, a mold cavity, a core, the ventilation system and the gating system.
Patterns
From the design, provided by an engineer or designer, a skilled pattern maker builds a pattern of the object to be produced, using wood, metal, or a plastic such as expanded polystyrene. Sand can be ground, swept or strickled into shape. The metal to be cast will contract during solidification, and this may be non-uniform due to uneven cooling. Therefore, the pattern must be slightly larger than the finished product, a difference known as contraction allowance. Patterns also have core prints that create registers within the molds into which are placed sand cores. Such cores, sometimes reinforced by wires, are used to create under-cut profiles and cavities which cannot be molded with the cope and drag, such as the interior passages of valves or cooling passages in engine blocks.
Paths for the entrance of metal into the mold cavity constitute the runner system and include the sprue, various feeders which maintain a good metal 'feed', and in-gates which attach the runner system to the casting cavity. Gas and steam generated during casting exit through the permeable sand or via risers, which are added either in the pattern itself, or as separate pieces.
Molding Box and Materials
A multi-part molding box (known as a casting flask, the top and bottom halves of which are known respectively as the cope and drag) is prepared to receive the pattern. Molding boxes are made in segments that may be latched to each other and to end closures. For a simple object—flat on one side—the lower portion of the box, closed at the bottom, will be filled with a molding sand. The sand is packed in through a vibratory process called ramming, and in this case, periodically screeded level. The surface of the sand may then be stabilized with a sizing compound. The pattern is placed on the sand and another molding box segment is added. Additional sand is rammed over and around the pattern. Finally a cover is placed on the box and it is turned and unlatched, so that the halves of the mold may be parted and the pattern with its sprue and vent patterns removed. Additional sizing may be added and any defects introduced by the removal of the pattern are corrected. The box is closed again. This forms a "green" mold which must be dried to receive the hot metal. If the mold is not sufficiently dried a steam explosion can occur that can throw molten metal about. In some cases, the sand may be oiled instead of moistened, which makes possible casting without waiting for the sand to dry. Sand may also be bonded by chemical binders, such as furane resins or amine-hardened resins.
Cores
To produce cavities within the casting—such as for liquid cooling in engine blocks and cylinder heads—negative forms are used to produce cores. Usually sand-molded, cores are inserted into the casting box after removal of the pattern. Whenever possible, designs are made that avoid the use of cores, due to the additional set-up time and thus greater cost.
With a completed mold at the appropriate moisture content, the box containing the sand mold is then positioned for filling with molten metal—typically iron, steel, bronze, brass, aluminum, magnesium alloys, or various pot metal alloys, which often include lead, tin, and zinc. After filling with liquid metal the box is set aside until the metal is sufficiently cool to be strong. The sand is then removed revealing a rough casting that, in the case of iron or steel, may still be glowing red. When casting with metals like iron or lead, which are significantly heavier than the casting sand, the casting flask is often covered with a heavy
plate to prevent a problem known as floating the mold. Floating the mold occurs when the pressure of the metal pushes the sand above the mold cavity out of shape, causing the casting to fail.
After casting, the cores are broken up by rods or shot and removed from the casting. The metal from the sprue and risers is cut from the rough casting. Various heat treatments may be applied to relieve stresses from the initial cooling and to add hardness—in the case of steel or iron, by quenching in water or oil. The casting may be further strengthened by surface compression treatment—like shot peening—that adds resistance to tensile cracking and smooths the rough surface.
4. Basic Process of Sand Casting
Figure 5 Sand Casting Process
As can be seen in Figure 5, the process can be summarized into 6 steps:
(1) Place a pattern in sand to create a mold.
In this step, first of all, put the pattern in the center of the flask. Two locators are needed here for you to identify the relative position and orientation of the pattern after it is covered by sand. Then fill the flask with sand, the sand should be filled over and around the pattern and the locators. After certain amount of sand is filled in, a procedure called ramming should be done, during which the sand is tightened under the continuous ramming of a hammer, until the tightened sand reaches the top of the flask. Note that in this procedure, please pay attention to the locations of the pattern and the locators so that you can avoid changing their location when ramming the sand.
(2) Incorporate the pattern and sand in a gating system.
The gating system is used to guide the molten metal into the mold cavity. So in the creation of the mold, the gating system should be considered. The gating system can be divided into sprue gate, cross gate and ingate according to their position in the system. The sprue gate guides the molten metal vertically down from the casting head, while the
cross gate spreads the metal so that it can fully cover the space to be filled and the ingate guides the metal into the cavity.
(3) Remove the pattern.
Remember to be very careful when removing the pattern, any movement in the wrong direction may damage the mold cavity. When doing so, first use a brush dipped with water to moisten the joints of the pattern with the sand, so that the sand may not easily collapse. Then, slightly knock the pattern so that clearances occur between the pattern and the cavity to facilitate removal. Finally, carefully remove the pattern in the vertical direction. If damages do happen during the removal, you should try to restore its original shape. (4) Fill the mold cavity with molten metal.
The molten metal comes from a furnace that melts the metal in very high temperature. You can use a casting ladle to transfer the molten metal, in which the metal shouldn’t occupy over 80% of the full capacity of the ladle. You should be very careful when transferring the metal because any drop of the molten metal can cause permanent damage to human skin if it accidentally splash on the body.
(5) Allow the metal to cool.
In this step, wait patiently for the metal to cool down and solidify and never touch the metal with bare hand.
(6) Break away the sand mold and remove the casting.
When the metal cools down, break the sand mold and get the casting out with a clamp, then dip the casting in water for more than 10 seconds before you can touch it with your hands.
5. Safety Rules
(1) Place the tools you use in order and remember to clean your position before you
leave.
(2) Do not make loud noise or quarrel during the training.
(3) Remember to wear protection suits to protect yourself from injury when you are
trying to get the molten metal out of the furnace.
(4) Do not use your hands to touch the casting before it cools down. When cleaning
the casting, remember to take care of the people around in case the tools you use hurt them.。