What Are The Common Types Of Metal Casting Process In Engineering and Industry?
Summary
TLDREl proceso de fundición de metales es una técnica antigua que se utiliza para crear piezas a partir de metales derretidos vertidos en moldes. Se divide en dos grupos principales: moldes desechables y moldes no desechables. Se discuten varios tipos de fundición, como la fundición de arena, molde de mortero, molde de capa y fundición por centrifugación, cada uno con sus ventajas y desventajas en términos de calidad, costo y complejidad de las piezas.
Takeaways
- ⚒️ El proceso de fundición de metal es una técnica antigua utilizada para crear piezas a partir de metales fundidos que se enfrían en un molde de la forma deseada.
- 🐸 El primer objeto fundido conocido es una rana de cobre del año 3200 a.C. encontrado en Mesopotamia, en la actual Iraq.
- 🏺 Durante la Edad del Bronce, la fundición de metal se hizo muy popular, utilizando bronce, una aleación más fuerte y fácil de trabajar que el oro.
- 🔩 La fundición de metal se divide en dos grupos principales: moldes desechables y moldes no desechables o permanentes.
- 🏜️ La fundición de arena es un método de fundición de metal que utiliza arena para crear el molde en el que se verterá el metal fundido.
- 🗿 La fundición de moldes desechables puede producir piezas complejas y sofisticadas, utilizando materiales como arena, cerámica y yeso.
- 📈 La fundición de plaster mold ofrece una buena terminación superficial y reduce los costos de machado, adecuada para metales no ferrosos.
- 🐚 La fundición de moldes de capa utiliza arena recubierta de resina para formar el molde, ideal para piezas pequeñas a medianas de alta precisión.
- 🌪️ La fundición por perdida de polvo (lost foam casting) es un método que utiliza un patrón de polistireno que se vaporiza cuando se verter el metal fundido.
- 🗝️ La fundición de inversión (investment casting) es un proceso que utiliza un patrón de cera recubierto de material refractario para formar el molde.
- 🏭 La fundición en moldes no desechables o permanentes utiliza moldes que se pueden reutilizar, adecuados para producir piezas repetibles y simples.
Q & A
¿Qué es el proceso de fundición de metal?
-El proceso de fundición de metal es el proceso en el cual el metal derretido se verter en un molde que contiene una cavidad hueca de una forma geométrica deseada y se deja enfriar para formar una pieza solidificada.
¿Cuál es la antigüedad del proceso de fundición de metal?
-Los procesos de fundición de metal se han conocido por miles de años y han sido ampliamente utilizados para crear esculturas, joyas, armas y herramientas.
¿Cuál fue el primer objeto fundido conocido?
-El primer objeto fundido conocido es una rana de cobre que data de 3200 a.C., encontrada en Mesopotamia, actualmente Irak.
¿Cuál fue el material más utilizado durante la Edad del Bronce para la fundición de metal?
-Durante la Edad del Bronce, el bronce fue un aleado mucho más fácil y fuerte de trabajar en comparación con el oro y se fundió en herramientas y armas utilizando moldes de piedra.
¿Cuáles son los dos grupos principales de procesos de fundición de metal según el diseño del molde?
-Los procesos de fundición de metal se pueden dividir en dos grupos principales según la naturaleza del diseño del molde: el molde desechable y el molde no desechable o permanente.
¿Qué es el molde desechable en la fundición de metal?
-El molde desechable es un método que utiliza moldes de un solo uso o temporales para producir la fundición final, ya que el molde se romperá para sacar la fundición.
¿Cuáles son los tipos de molde desechable en la fundición de metal?
-El molde desechable se divide en dos: el patrón permanente y el patrón evaporativo. El patrón permanente utiliza un modelo permanente para crear el patrón del molde, mientras que el patrón evaporativo utiliza un modelo temporal que se evaporará para crear el patrón del molde.
¿Qué es la fundición de arena y cómo funciona?
-La fundición de arena es un proceso de fundición en el que se utiliza arena para crear un molde, en el cual se verter el metal líquido para crear una pieza. Este proceso implica fabricar un patrón, hacer el molde de arena a partir de este patrón y luego crear canales y conexiones conocidas como puertas y corredizo.
¿Cuáles son las ventajas de la fundición de arena?
-Las ventajas incluyen un bajo costo de establecimiento, adecuado para series pequeñas de producción, bajo valor del equipo y capacidad para crear piezas muy complejas si se utilizan las cores y el sistema de entrada correctos.
¿Qué es la fundición de molde de yeso y cómo se diferencia de la fundición de arena?
-La fundición de molde de yeso es un proceso similar a la fundición de arena, pero utiliza yeso de París en lugar de arena como material de molde. Generalmente se usa para fundir metales no ferrosos.
¿Cuáles son las desventajas de la fundición de molde de yeso?
-Las desventajas incluyen la incapacidad de manejar temperaturas más altas que 1200 grados Celsius, el tiempo de preparación y configuración del yeso consume más tiempo y si hay más contenido de humedad en el molde, puede causar defectos en la fundición.
¿Qué es la fundición por centrifugación y cómo funciona?
-La fundición por centrifugación es un proceso de molde permanente que utiliza la fuerza centrífuga para llenar un molde con material derretido. El molde gira alrededor de un eje y el metal derretido se vierte en la copa de vertido desde donde es empujado en el molde por la fuerza centrífuga.
¿Cuáles son las ventajas de la fundición por centrifugación?
-Las ventajas incluyen la adquisición de alta densidad, alta resistencia mecánica y estructura de grano fino en la fundición, la ausencia de compuertas y levantamientos y una alta producción.
¿Qué es la fundición continua y cómo se diferencia de otros procesos de fundición?
-La fundición continua es un proceso de fabricación que permite que los metales y aleaciones de metal se formen y solidifiquen sin interrupción. El metal derretido se alimenta en un molde de la forma requerida, se extrae el calor del metal utilizando agua enfriada alrededor del molde y el metal se estira para alcanzar el grosor requerido.
Outlines
🔩 Proceso de Fundición de Metales
El proceso de fundición de metales es una técnica en la que el metal derretido se verter en un molde con una cavidad de forma geométrica deseada y se deja enfriar para solidificar en una pieza. Este método se ha utilizado durante miles de años para crear esculturas, joyas, armas y herramientas. Durante la Edad de Bronce, la fundición de metal se volvió muy popular, especialmente con bronce, que es más fácil de trabajar que el oro. En este vídeo, se exploran diferentes tipos de procesos de fundición de metal, divididos en dos categorías principales: moldes desechables y moldes no desechables o permanentes. Se describen métodos como la fundición de arena, molde de mortero, molde de capa y fundición de polímero perdido, cada uno con sus ventajas y desventajas específicas.
🗜 Fundición de Moldes No Desechables
La fundición de moldes no desechables utiliza moldes permanentes que se pueden reutilizar después de cada ciclo de producción. Aunque permite la producción de piezas repetibles, se limitan a formas simples debido a que el molde debe abrirse para sacar la pieza. Se mencionan varios métodos como la fundición de presión en molde, fundición por gravedad en molde, fundición centrifuga y fundición continua. Cada uno de estos procesos tiene sus propias ventajas y desventajas, como la alta producción de piezas idénticas, el control de dimensiones cerrado y una buena terminación superficial, o el alto costo inicial del molde y la limitación para fundir metales con puntos de fusión altos.
🌀 Fundición Centrífuga y Fundición Continua
La fundición centrifuga es un proceso de molde permanente que utiliza la fuerza centrífuga para llenar el molde con material derretido. Existen tres tipos de este proceso: centrífugo, semicentrífugo y verdadero centrífugo. La fundición continua es un método de fabricación que permite que los metales y aleaciones se formen y solidifiquen sin interrupción, lo que resulta en una menor pérdida de material y menos necesidad de maquinado. Sin embargo, este proceso tiene un alto costo de establecimiento y no es práctico para pequeñas cantidades o formas especiales de productos.
Mindmap
Keywords
💡Fundición de metal
💡Molde desechable
💡Molde no desechable
💡Fundición de arena
💡Patrón permanente
💡Patrón evaporativo
💡Fundición de yeso
💡Fundición de molde de capa
💡Fundición de inversión
💡Fundición por presión
💡Fundición por gravedad
Highlights
Metal casting process involves pouring molten metal into a mold to form solidified parts.
Casting processes have been used for thousands of years for creating sculptures, jewelries, weapons, and tools.
The first known cast object is a copper frog from 3200 BC.
During the Bronze Age, metal casting became popular for creating tools and weapons.
Metal casting can be divided into expendable mold casting and non-expendable mold casting.
Expendable mold casting uses single-use molds that are broken to remove the casting.
Non-expendable mold casting uses permanent molds that can be reused.
Sand casting is a common expendable mold casting method using sand molds.
Plaster mold casting uses plaster of Paris instead of sand for the mold.
Shell mold casting uses resin-covered sand for molds, suitable for high precision parts.
Ceramic mold casting uses refractory ceramic material for high-temperature casting.
Lost foam casting is an evaporative pattern casting method using a polystyrene foam pattern.
Investment casting, also known as lost wax casting, uses a wax pattern for creating complex shapes.
Pressure die casting involves forcing molten metal under pressure into a metal die.
Gravity die casting uses gravity to fill the mold cavity with molten metal.
Centrifugal casting uses centrifugal force to fill the mold with molten material.
Continuous casting shapes and solidifies metals without interruption.
Transcripts
metal casting process is defined as the
process in which molten metal is poured
into a mold that contains a hollow
cavity of a desired geometrical shape
and allowed to cool down to form a
solidified part
metal casting processes have been known
for thousands of years and have been
widely used for creating sculptures
jewelries weapons and tools the first
known caste object is a copper frog that
dates back to 3200 bc found in
mesopotamia present-day
during the bronze age metal casting
exploded in popularity bronze was a much
easier and stronger alloy to work with
compared to gold and was cast into tools
and weapons using stone molds
welcome to james sword research channel
in this video we shall be discussing the
different types of metal casting process
in engineering and industries
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types of metal casting metal casting can
be divided into two major groups by the
basic nature of the mold design
they are one expendable mold casting 2
non-expendable or permanent mold casting
expendable mold casting expendable mold
casting is a method that utilizes single
use or temporary molds to produce the
final casting as the mold will be broken
to get the casting out
sand ceramics and plaster are common
materials used to make these molds
they are generally bounded using binders
to improve the qualities of disposable
molds
expendable mold casting can be used to
cast complex sophisticated shapes
types of expendable mold casting the
expendable mold casting is divided into
two the permanent pattern and the
evaporative pattern the permanent
pattern uses a permanent model to create
the mold pattern
examples includes sand casting plaster
mold casting shell mold casting and
ceramic mold casting while evaporative
pattern uses temporary model which will
evaporate to create the mold pattern
example includes lost foam casting and
investment casting
sand casting this is a casting process
by which sand is used to create a mold
after which liquid metal is poured into
this mold to create a part
the first step in the sand casting
process involves fabricating the pattern
the replica of the exterior of the
casting for the mold these patterns are
often made from materials such as wood
plastics etc
and are oversized to allow the cast
metal to shrink when cooling
cores are internal mold insert that can
also be used if interior contours are
needed
the second step
is the process of making the sand mold
from this pattern the sand mold is
usually done in two halves where one
side of the mold is made with one
pattern and another side is made using
the other pattern
the top part of the mould is known as
the cope and the bottom half is the drag
and both are made by packing sand into a
container around the pattern and rammed
after ramming the pattern are removed
and leave their exterior contours in the
sand where manufacturers can then create
channels and connections known as gates
runners into the drag and a funnel in
the coke known as sprue
this gate runners and sprue are
necessary for an accurate casting as the
runner and gate allows the metal to
enter every part of the mold the sprue
allow for easy pouring into the mold
advantages of sand casting it has a low
set up cost and is cost effective ideal
for short production runs as the lead
time to make the mold is short the value
of the equipment is low as it regularly
includes simply sand and reusable
pattern sand casting can create very
complex parts if the right cores and
gating system are used
disadvantages of sand casting creates a
high degree of porosity in the metal
causing a low final part strength the
surface finish out of the mold is poor
and must be cleaned low dimensional
accuracy defects are unavoidable in sand
casting secondary machining operations
is often required if tighter tolerance
is needed
plaster mold casting plaster mold
casting is a metal casting process which
is similar to the sand casting process
except that the molding material is
plaster of paris instead of sand
it is generally used for casting
non-ferrous metals
steps in plaster mold casting the
powdered plaster of paris is mixed with
water to form plaster additives like
talc and silica flour is added to the
plaster of paris and water mixture the
mixture is then poured over the casting
pattern the slurry is kept for around 20
to 25 minutes so that it sets properly
before removing the
pattern the pattern used for the plaster
molding process is either made of
plastic or metal
wood patterns are not preferred as wood
shows tendency to warp when it remains
in contact with the moist plaster for a
longer time
after this the mold is separated from
the pattern and it is baked to
temperature between 120 to 260 degrees
celsius
the baking is done to remove the
moisture content from the mold and gives
it strength finally the molten metal can
be poured in the mold cavity
advantages of plaster mold casting very
good surface finish is obtained and
machining cost is reduced slow and
uniform rate of cooling of the cast is
achieved manufacturing of complex shapes
is possible at less cost good geometric
accuracy can be obtained
disadvantages of plaster mold casting
cannot handle temperature higher than
1200 degrees celsius the mold
preparation and setting of plaster
consumes more time if the moisture
content is more in the mold then it will
cause casting defects the production
rate is low due to the longer time for
solidification
shell mold casting shell mold casting
process uses resin covered sand to form
the mold
it is used for small to medium parts
that require high precision
steps in shell mold casting a heated
match plate or cope and drag pattern is
placed over a sandbox mixed with a
thermosetting resins the box is then
turned upside down to allow the sand and
resin to fall onto the hot pattern
this creates a partially cured mixture
to form a hard steel on the surface of
the pattern the sand shell is cured by
heating in an oven for several minutes
the shell mold is then removed from the
pattern the shell molds two halves are
assembled and pouring and casting is
completed
advantages of shell mold casting good
surface quality high dimensional
accuracy for complex casting less than
five millimeters wall thickness is
obtainable in shell casting in
comparison to sand casting less manpower
and molding skill requirements
disadvantages of shell mold casting high
production cost high pattern cost size
and weight limitations
ceramics mold casting ceramics mold
casting is very similar to sand or
plaster mold casting except that the
mold is made of refractory ceramic
material the ceramic material can
withstand high temperature compared to
plaster mold hence it is used to cast
materials such as cast steels cast iron
and other high temperature alloys
advantages of ceramics mold casting
excellent surface finish closed
dimensional tolerance thin cross section
and intricate shapes can be cast
disadvantages of ceramic small casting
difficulty in controlling dimensional
tolerance across the parting lines it is
expensive as it has more equipment cost
production rate is slow because the mold
preparation is time consuming
lost foam casting lost foam casting is a
type of evaporative pattern casting this
method is quite similar to investment
casting which uses wax instead of foam
in the pattern-making process
the lost foam casting uses a polystyrene
foam pattern to create a sand mold
the pattern then vaporizes when the
molten metal is poured into the mold
it is sometimes referred to as expanded
polystyrene casting lost pattern process
or evaporative foam casting
lost foam casting process steps the
polystyrene pattern is coated with a
refractory compound the foam pattern is
then placed in the mold box and sand is
compacted around it the pouring carp and
sprue are formed by pouring molten metal
into the portion of the pattern that
forms the pouring cup and sprue poured
molten metal vaporizes the polystyrene
pattern as the metal enters the mold
filling the resulting mold cavity
advantages of lost foam casting
guarantee high precision and smooth
surface finish guarantee nearly no error
or defects in casting more economical
than investment casting casting of very
complicated parts is possible
disadvantages of lost foam casting the
pattern cost is high for low volume
applications it can easily get damaged
or distorted because of its low strength
investment casting process in investment
casting a wax pattern is coated with a
refractory material to make a mold which
is then melted away before pouring
molten metal into the cavity to solidify
investment casting is also known as lost
wax casting advantages of investment
casting parts with extremely complex
shapes and intricate feature can be
casted as a single piece short length or
shallow depth features can be casted
without cold shut defects has excellent
dimensional accuracy and tighter
tolerance are easily achievable can
achieve an excellent surface finish
without any post processing
disadvantages of investment casting
parts are difficult to cast if they
require core limited to large production
qualities due to high cost of dyes to
make patterns it involves many complex
steps making the process relatively
expensive
non-expendable or permanent mold casting
non-expendable mold casting uses
permanent molds which can be reused
after each production cycle although
permanent mold casting produces
repeatable parts due to the repeated use
of the same mold
it can only produce simple casting as
the mold needs to be open to remove the
cast
examples of permanent mold casting
includes pressure die casting gravity
die casting centrifugal casting and
continuous casting
pressure die casting pressure die
casting is a process in which molten
metal is forced under pressure into a
securely locked metal dye cavity where
it is held by a powerful press until the
metal solidifies
after solidification of the metal the
dye is unlocked opened and the casting
ejected
after removal of the casting the die is
closed and locked again for the next
cycle two types of system are used for
injecting the molten metal into the die
the hot chamber system and the cold
chamber system
advantages of pressure die casting
ability to produce high volumes of
identical metal components with high
level of accuracy cost effective
solution for the mass production of
castings can produce thousands of
component before needing to be replaced
closed dimensional control and good
surface finish
disadvantages of pressure die casting
requires complex and expensive equipment
a large capital investment is required
for the setup relatively inflexible when
compared to gravity die casting
possibility of porosity in the cast due
to air pockets
gravity die casting gravity die casting
is one of the oldest methods for metal
or metal alloy casting
here the metal is poured inside the
cavity in liquid form using a ladle or a
vessel
the cavity hole has to be on the top
surface
there is no external force the gravity
that fills the cavity after pouring the
molten metal the metal is transferred
manually or automatically into the mold
sometimes it is necessary to tilt the
dye to control the pouring
manufacturers use sand cores to keep
holes or pores in the casting part if
necessary
advantages of gravity die casting good
surface finish tight dimensional
tolerance thin casting can be produced
easily ideal for mass production take
small floor space
disadvantages of gravity die casting
high initial cost of the mold not
suitable for casting metals with a high
melting point
centrifugal casting centrifugal casting
is a permanent molding process which
makes use of centrifugal force to fill a
mold with molten material
there are three types of this process
centrifugal casting semicentrifugal
casting and true centrifugal casting the
principle is the same for all the three
types the mold is rotated around an axis
and molten metal is poured into the
pouring cup from where it is forced into
the mold by centrifugal force
advantages of centrifugal casting
casting acquire high density high
mechanical strength and fine grain
structure inclusion and impurities are
lighter gates and rises are not needed
high output formation of hollow
interiors without cause
disadvantages of centrifugal casting
inaccurate diameter of the inner surface
of the casting not all alloys can be
casted in this way
continuous casting is a manufacturing
process that allows metals and metal
alloys to be shaped then solidifies
without interruption
the molten metal is fed into a mold of
the required shape heat is extracted
from the metal by placing cooled water
around the mold
the metal is given its base shape and
its partially solidifieds
the semi-solid metal is then sent
through a guide that will stretch the
material to the required thickness
the metal continues cooling in this
stage and the fully solidified metal is
set through straighteners to achieve the
final dimensions advantages of
continuous casting perfect for pressure
applications less material is wasted
than some other casting method less
machining is needed same product can be
gotten every time
disadvantages of continuous casting high
cost of setup not practical to use this
method for small quantities or for
special shapes of a product limited to
more simple shapes that have a stable
cross-section
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