Introduction to Metal Casting | Manufacturing Processes |
Channel: Mechpro classes
Date: 2020-07-08

In this video we have discussed the basic introductory part of metal casting process starting from basic concepts of casting, its background, its origin, advantages, limitations, basic casting terms by a suitable diagram.

#metalcasting#manufacturingsciences#manufacturing#casting#mould

Metal casting is a modern process with ancient roots. In the metal casting process, metal shapes are formed by pouring molten metal into a mold cavity, where it is cooled and later extracted from the mold. Metal casting is arguably the earliest and most influential industrial process in history. It’s used to make many of the metal objects used in our daily lives as in automotive parts, train wheels, lamp posts, school bus pedals, and much more. Apart from that metal casting, foundries rely on metal recycling as a cost-efficient source of raw material, significantly reducing wasted scrap metal that might end up in landfills.

The History of Metal Casting

The oldest known metal casting is that of a copper frog, believed to have been produced in 3200 B.C. in Mesopotamia when copper was a popularly used material. Later, around 2000 B.C., iron was discovered. But it was not until around 700 B.C. that the first production of cast iron was developed in China. Interestingly enough, the sand molding process of casting metals was also invented in China in 645 B.C.

Basic Steps in Casting Process

Patternmaking.
Coremaking.
Molding.
Melting and pouring.
Finishing.

Advantages of Sand casting

Large parts can be produced
Complex shapes can be casted easily
Large selection of metal to choose from
Tooling and equipment cost is low compared to some other metal forming processes
Scrap metal can be recycled
Short lead compared to other similar processes

Disadvantages of Sand casting

Low material strength
Low dimensional accuracy
Poor surface finish
High porosity
Secondary machining operation often required
Processing cost is high compared to tooling and material cost
Safety hazards to humans and environmental problems
Removal of pattern of the thin and small parts is very difficult

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