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IENG 303 Manufacturing Processes Laboratory Report Casting

IENG 303 Manufacturing Processes Laboratory Report
Casting

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Lab Group Locker # Section
(A) (5) (002)

Table of Contents
List of Figures ii
List of Tables ii
1 Executive Summary 1
2 Laboratory C1 1
3 Laboratory C2 1
3.1 Sand Permeability 1
3.2 Sand Strength 3
4 Process Comparison 5
5 Casting Process Selection Discussion 7
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List of Figures
Figure 1: Permeability vs. Rams for Dry Sample 2
Figure 2: Permeability vs. Rams for Green Sample 3
Figure 3: Strength vs. Rams for Dry Sample 4
Figure 4: Strength vs. Rams for Green Sample 5

List of Tables
Table 1: Permeability test data for Dry Sample 1
Table 2: Permeability test data for Green Sample 2
Table 3: Strength Test for Dry Sample 3
Table 4: Strength test data for Green Sample 4

 

Executive Summary
From this lab information about metal casting in which geometrically complex parts are shaped by melting metal and pouring it into a mold made of sand which is C-1, additionally in that segment we did hardness tests to the mold subsequent to filling it with sand then we did finally the solidification test and porosity test. On the second segment C-2 we had the opportunity to do the permeability test, strength test, compact ability test, and the Moisture test. Besides, we were requested that pick 2-3 experiments from what we did in C-1 and C-2 to analyze and discuss the findings in this report, I chose sand permeability and strength test.
Laboratory C1
In the C-1 section, two shapes were filled with sand to make them ready for pouring of hot molten metal into them. Several properties of the metal were measured including hardness and dimensions of sprue, runners, and gates. The time for damping the hot molten metal after it had been poured into iron and sand molds was measured too. These were used to determine the results of the solidification and porosity tests for metal casting.
Laboratory C2
This section presents several tests that we conducted on sand casting, for example, permeability and strength test, shape and fitness test, solidification test and porosity test for this method of casting, compactability test, and moisture test. The data and figures for the permeability and strength are presented test below.
Sand Permeability
In this test, six samples were initially made for green and dry sand. The process begins by first filling the tube with sand and then using rammer to ram the sand. Electric permeability meter was then used to record the readings for the six samples in each sand trait when different amounts of ram were applied.
Table 1: Results for the permeability test for the dry Sample
Dry Sample Weight of Specimen (gm) Permeability
Before After
1ram 1 110 106 290
2 136 130 260
Total 246 236 550
Average 123 118 275
3rams 1 130 126 190
2 126 122 200
Total 256 248 390
Average 128 124 195
5rams 1 154 148 130
2 140 134 110
Total 294 282 240
Average 147 141 135

Each number of rams has two samples. Averages were taken for both samples to get an accurate measurement for permeability. Weight was taken before and after heating the samples.

Figure 1: Graph of permeability versus Rams for the dry Sample
As a consequence of this test for dry samples, permeability decreases when number of rams of the sample increases.
Below is the data for the green sample for permeability test:
Table 2: Results for permeability test data for the green Sample
Green Sample Weight of Specimen (gm) Permeability

1 ram 1 134 280
2 112 320
Total 246 600
Average 123 300
3 rams 1 130 200
2 126 210
Total 256 410
Average 128 205
5 rams 1 154 150
2 128 140
Total 282 290
Average 141 145

Each number of rams has two samples so average was taken for both samples to get an accurate measurement for permeability.

Figure 2: Permeability vs. Rams for Green Sample
We make the same conclusions on the results for the green sample as dry sample. For both sample-types, permeability decreases when number of ram’s increases.
Sand Strength
The same samples used for permeability test were also used in this section for sand strength test. Half of each sample under a specified number of ram was used for measuring the shear strength while the remaining half for sample was used for measuring compression strength urgent paper writing help. The sand strength machine was very useful in calculating all the strength values for the two samples.
Table 3: Results for the strength Test for Dry Sample
Dry Sample Weight of Specimen (gm) Dry Compression (Psi) Dry Shear (Psi)
Before After
1 ram 1 110 106 – 3.1
2 136 130 18.6 –
Total 246 236 – –
Average 123 118 – –
3 rams 1 130 126 – 4.7
2 126 122 22 –
Total 256 248 – –
Average 128 124 – –
5 rams 1 154 148 – 6.2
2 140 134 54 –
Total 294 282 – –
Average 147 141 – –

Compression was measured for second sample of each ram while shear was measured for first sample of each ram.

Figure 3: Graph of Strength versus Rams for the dry Sample
As a result of the data calculated above we conclude that strength of dry sample increases proportionally when number of rams increases.
Below is the data and figure for the Green sample conducted by strength test:
Table 4: Results for strength test data for Green Sample
Green Sample Weight of Specimen (gm) Green Compression (Psi) Green Shear (Psi)

1 ram 1 134 – 2.1
2 112 10.6 –
Total 246 – –
Average 123 – –
3 rams 1 130 – 2.9
2 126 13 –
Total 256 – –
Average 128 – –
5 rams 1 154 – 7.5
2 128 27 –
Total 282 – –
Average 141 – –

Shear was measured for first sample of each ram while compression was measured for second sample of each ram.

Figure 4: Graph of strength versus Rams for Green Sample
The strength of the green sample is similar to that of the dry sample. For both samples, strength increases as number of rams increases. But the values for the compression and shear for green samples were less than the values for dry samples.
Process Comparison
Briefly (bulleted lists are acceptable) fill out the following table discussing several different casting methods.
Casting Process Description Advantages Disadvantages Most Efficient Use Ref.
Sand Form geometrically complex parts by melting metal and poured it into a mold made of sand. Low capital investment, cast complex shapes, producing large component, and suitable for small production rates. High cost, bad surface finish, thin sections can’t be made, not suitable for large production rates. Crankshafts, brake drums, engine blocks, and gear blanks [1]
Centrifugal The molten metal is poured into a rotating and permanent mold. Centripetal and gravitational forces are necessary in the casting process.
The method can utilize both expendable and permanent molds, which can be produced though the lost-wax method.
Centrifugal forces are crucial in overcoming viscosity, thus, allowing the production of fine details from the mold. Very High quality and precise measurements.
Produces high volumes of castings.
Does not require gates and risers.
It simplifies the production of thin-walled cylinders.
Can be used to cast a wide variety of metals. Only works with specific metal alloys.
Shape limitations since only cylindrical objects can be produced. Production of jewelry, pipes, gears, freewheels, and bushing, spherical objects including metallic balls, machine fittings, railway carriage wheels, [3]
Plaster Mold Similar to sand casting but uses the plaster of paris in molds.
The mold improves the environmental friendliness, drying ability and permeability of the molds. Relatively cheap due to the low cost of casting inputs such as plaster.
Produces near-net shapes.
It cools slowly and thus results to the production of fine near net shape products.
Can produce a variety of shapes. Only applicable with lowering melting temperature of non-ferrous materials [5].
The slow cooling process may limit the number of products produced.
Plaster requires close supervision since it weaker than sand. Ornaments, tools, fittings, lock components, gears, and valves. [4]
Investment Wax pattern is coated with ceramic material. After the ceramic material solidifies, the wax is melted and the molten metal poured into the cavity.
Injection molds having the same shape and geometry are very common.
A gating system helps in pouring the molten liquid into the multiple molds. High quality products precisely due to accuracy, integrity, reproduction, and versatility.
The wax is reusable.
Products can incorporate intricate contours.
Produces shaped difficult to produce through other methods.
Can cast many varieties of metals. Casting requires intensive care and careful handling.
It is a very expensive process.
The size of castings is limited.
A few defects in the shape. Turbine blades, jewelry, dental fixtures and ratchets, golf clubs, motor vehicle parts [2]
Die “Molten metal, usually zinc or aluminium is forced under high pressure into closed metallic dies”
Can use both nonferrous and ferrous metals.
Excellent dimensional accuracy.
Very quick production based on automated systems.
It is easy to produce very small thicknesses.
It is economical.
Can cast low viscous metals. Requires large scale production to take advantage of production costs.
Large capital investment.
The size of products is limited.
Uses low melting point metals. Door knobs, printing accessories, geometrical shapes for engines/motors [5]
Lost Foam Uses the low boiling point of wax to simplify the investment process; eliminates the need to melt the ice.
Some process use substances that can easily evaporate instead of wax. Excellent surface finishes without using drafts, flash or parting lines.
Production does not require cores. Very economical and requires less capital investment.
Does not require skilled labor. Expensive for low volume production because patterns can be easily damaged.
Time consuming
Requires supervision and control to avoid the damage of the molds. Differential carriers, engine blocks, transmission cases, [6]
Discussion of the process of casting
Die casting is a strategy utilized by different companies to develop mold cavities. It involves forcing molten metal to cool under great pressure into a mold hole. The companies that are involved in such operations use different metals including magnesium, lead, copper and tin-based alloys. Companies that produce molds in large masses have adopted this strategy based on its various advantages. One of the key upsides of this instrument is the expanded rate of generation. This is on account of the procedure can deliver complex shapes contrasted with different processes, with almost no machine by any means. It can likewise deliver a huge number of comparable castings before any extra tool is required. This is leverage to XYZ since it will save money on time and assets. What’s more, the procedure has a Dimensional Accuracy and Stability. This implies die castings can deliver dimensionally stable parts, which are likewise warm safe. This switch will, consequently, enhance part quality.
Nonetheless, the Company is liable to confront various hindrances from the procedure. These incorporate High Investment Budget. The Casting mechanical assembly required and other related contraptions are expensive. The organization will, in this manner, spend a lot of capital for the procedure to be successful on the association. To make the procedure more sparing, the organization ought to create in expansive scale. The other impediment is that the procedure must be connected in zones where delicate parts are required. This will restrain the organization since Parts requiring Hardening won’t be made utilizing the procedure. Regardless of the above weaknesses, it will be more practical for XYZ Company to move to Die-Casting. This is on the grounds that it will deliver substantial volumes of Parts and in the meantime builds its creation rate to take care of the demand of the organization.
 
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[1] “Sand Casting Advantages vs Disadvantage,sand Casting Sourcing Service.”Sand Casting Advantages vs Disadvantage,sand Casting Sourcing Service. Ningbo Castwell Industrial Co., Ltd. Web. 7 Oct. 2015 – Research Paper Writing Help Service. .
[2] Ammen, Wilson. Metalcasting. New York: McGraw-Hill, 2000. Print.
[3] Campbell, John. Complete Casting Handbook: Metal Casting Processes, Metallurgy, Techniques and Design. Oxford: Elsevier Butterworth-Heinemann, 2011. Print.
[4] Kaufman, John, and Elwin, Rooy. Aluminum Alloy Castings: Properties, Processes, and Applications. Schaumburg: American Foundry Soc, 2007. Print.
[5] Wuest, Dr. Thorsten. “IE 302: Manufacturing Process (Lecture Slides).” West Virginia University. Web. 7 Oct. 2015 – Research Paper Writing Help Service. .
[6] “Lost-foam casting”. Web. 7 Oct. 2015 – Research Paper Writing Help Service.< https://en.wikipedia.org/wiki/Lost-foam_casting#Advantages_and_disadvantages>.

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