Industrial Process Description The metal casting process has been divided into the following five major operations:
Obtaining the Casting Geometry : The process is referred as the study of the geometry of parts and plans, so as to improve the life and quality of casting.
Casting Patternmaking : In pattern making, a physical model of casting, i.e. a pattern is used to make the mold. The mold is made by packing some readily formed aggregated materials, like molding sand, around the pattern. After the pattern is withdrawn, its imprint leaves the mold cavity that is ultimately filled with metal to become the casting. n case, the castings is required to be hollow, such as in the case of pipe fittings, additional patterns, known as cores, are used to develop these cavities.
Coremaking & Molding :
In core making, cores are formed, (usually of sand) that are placed into a mold cavity to form the interior surface of the casting. Thus the annul space between the mold-cavity surface and the core is what finally becomes the casting.
Molding is a process that consists of different operations essential to develop a mold for receiving molten metal.
Alloy Melting and Pouring : Melting is a process of preparing the molten material for casting. It is generally done in a specifically designated part of foundry, and the molten metal is transported to the pouring area wherein the molds are filled.
Casting Cleaning : Cleaning is a process that refers to the different activities performed for the removal of sand, scale, and excess metal from the casting. However, all the operations may not apply to each casting method but such processes play an important role to comply with environmental guidelines.