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1. CASTING
Manufacture of a machine part by heating a metal or
alloy above its melting point and pouring the liquid
metal/alloy in a cavity approximately of same shape
and size as the machine part is called casting
process.
The two major classification of casting is as
follows
1. Sand Casting
2. Die Casting
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2. Sand casting
• Pattern Making: The different materials used to make the
pattern are Wood, Metal such as Cast iron, Brass,
Aluminium, Plastics, Rubbers, Plasters, Waxes
• Mould making: Sand is used to make the mould
• Melting the Metal: Metal is melted in the melting furnace
• Casting: Molten metal is poured in the mould
• Fettling: Sand and casting are separated
• Testing & Inspection: Casting is done inspection
Pouring the molten metal into the mold cavity and allowed to
solidify is called Casting.
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3. Sand Casting
 Place a pattern in sand to create a mold.
 Incorporate the pattern and sand in a
gating system.
 Remove the pattern.
 Fill the mold cavity with molten metal.
 Allow the metal to cool.
 Break away the sand mold and remove
the casting.
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4. Mould making
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Sand casting process can be used to make Electric motor bodies, Pump bodies, Machine bodies, Big size gears and Pipes.
Source:http://www.themetalcasting.com/casting-mold-making.html

5. Sand casting process can be used to make Electric
motor bodies, Pump bodies, Machine bodies, Big size
gears and Pipes.
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Source:http://www.finetechnocast.in/casting-product.html

6. Die Casting
1. Close and lock the two halves of a die after coating the mould cavity surfaces
with a mould wash, if specified
2. Inject the molten metal under pressure into the die.
3. Maintain the pressure until metal solidifies.
4. Open die halves.
5. Eject the casting along with runner, riser etc.
6. The above cycle is repeated.
Two pressure die casting methods are used:
1. Hot chamber process
2. Cold chamber process
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7. DIE CASTING METHODS
 This uses pressures
up to 35 MPa and is
used for zinc, tin, lead,
and their alloys. In this
process the chamber,
in which molten metal is
stored before being
pressure injected into
the die, is kept heated.
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Hot chamber process
Source:http://4mechtech.blogspot.com/2014/09/die-casting-process.html

8. Cold chamber process
 Cold chamber process: In
this process, pressures as
high as 150 MPa are used.
The storing chamber is not
heated. This process is used
mainly for metals and alloys
having relatively higher
melting point e.g.,
aluminium, magnesium
and their alloys.
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Source:https://getrevising.co.uk/revision-cards/processing_metals

9. REFERENCES
Manufacturing Technology: Foundry, Forming and Welding, 4e (Volume 1) by PN Rao
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