Technological methods of workpieces manufacturing. Metal Casting: Manual

Manual «Technological methods of workpieces manufacturing. Castings» provides the knowledge regarding different foundry processes and their industrial importance. It is considered the modern techniques of processing raw materials by casting as an important stage of solving the tasks of designing technological processes of manufacturing the parts. Manual includes fundamentals of metal casting, the evolution of foundry industry, basic casting techniques, the metal casting operations, methods of manufacturing the cast blanks; the most rational variants of their manufacturing; equipment, tools and machining attachments for making workpieces of machine elements and parts in different process specifications and conditions. Also focused on efficient design of casting runner, riser, gating system with minimal casting defects and solidification process. Recommended for students of first (Bachelor of Science) level of higher education, 13 «Mechanical Engineering» major, 131 «Applied Mechanics» specialism, and can also be useful for engineering and technical specialists of foundry technologies in the mechanical engineering industry.INTRODUCTION...5 1. EVOLUTION OF METAL CASTING INDUSTRY...6 2. METAL CASTING AS A MANUFACTURING PROCESS...16 3. METALS AND ALLOYS USED IN METAL CASTING 4. FUNDAMENTALS OF METAL CASTING...25 4.1. Metal casting basics: molds, patterns, pattern material, cores, gating and elements of a gating system...27 4.2. The metal casting operation. Pouring, fluidity, risers, shrinkage and other defects...36 4.3. Gases in metal casting. Gases during the manufacture of a casting...43 4.4. Metal casting design. Mold and gating system design, directional solidification, and troubleshooting...45 5. EXPENDABLE MOLD CASTING 5.1. Sand casting...53 5.2. Plaster mold ...62 5.3. Ceramic mold casting...64 5.4. Shell molding...66 5.5. Vacuum casting...70 5.6. Expanded polystyrene casting...74 5.7. Investment casting...77 6. PERMANENT MOLD CASTING 6.1. Basic permanent mold casting...82 6.2. Slush casting...87 6.3. Pressure casting...92 6.4. Vacuum permanent mold casting...95 6.5. Die casting...97 6.6. Hot chamber die casting...101 6.7. Cold chamber die casting...104 6.8. True centrifugal casting...108 6.9. Semicentrifugal casting...112 6.10. Centrifuge casting...117 6.11. Ingot manufacture...122 6.12. Continuous casting...127 7. CASTING DEFECTS 7.1. Casting microstructure and defects...132 7.2. Casting defects and remedies...135 8. COMPUTER SYSTEMS FOR CASTING PROCESSES SIMULATION...149 GLOSSARY...163 REFERENCES...19