06ME838-Foundry Technology |
PART – A |
UNIT I: |
FOUNDRY METALLURGY: Oxidation of liquid metals, gas dissolution in
liquid metals, methods of degassing, fluidity, factors affecting fluidity,
fluidity tests, hot tearing, shrinkage of liquid metals.
|
UNIT II: |
CASTING DESIGN: Introduction to casting design, redesign
considerations, design for minimum casting stresses, design for directional
solidification, design for metal flow, safety factors, design for low pattern
cost and model making as an aid in design.
|
UNIT III: |
SOLIDIFICATION OF CASTINGS: Crystallization and development of
cast structure - nucleation, growth and dendritic growth. Structure of castings
- significance and practical control of cast structure, grain shape and
orientation, grain size, refinement and modification of cast structure. Concept
of progressive and directional solidification, solidification time and
derivation of Chvorinov’s equation, influence on mold characteristics and
cast metal.
|
UNIT IV: |
RISERING AND GATING: Need for risering, general considerations of
risering, riser shapes, riser size, and location. Requirements of a riser. Sand,
insulating, and exothermic materials used for risers. Riser feeding distance
and theory of risering. Internal chills, external chills, use of mould materials
of different chill capacities, padding for directional solidification. Open type
and blind risers. Riser treatment using exothermic and insulating compounds.
Gating system – theoretical consideration of gating, laws of fluid flow,
turbulence in gating system, use of ceramic foam filters in gating, need for
tapered sprue, gating ratio, simple problems.
|
PART – B |
UNIT V: |
SPECIAL MOULDING TECHNIQUES: Principles, materials used,
process details and application of no-bake sand systems, vacuum moulding,
flaskless moulding, and high pressure moulding.
CUPOLA MELTING: Developments in cupola melting – hot blast cupola,
water cooled cupola, balanced blast cupola, cokeless cupola, cupola charge
calculations.
|
UNIT VI: |
FERROUS FOUNDRY: Melting procedures, casting characteristics,
production, specification, and properties of some typical steels, grey cast
iron, malleable iron, and spheroidal graphite cast iron castings.
|
UNIT VII: |
NON-FERROUS FOUNDRY: Melting procedures, casting characteristics,
production, specification, and properties of some typical aluminum, copper,
and magnesium based alloy castings.
|
UNIT VIII: |
MODERNIZATION AND MECHANIZATION OF FOUNDRY: Need
for modernization, and mechanization, moulding and core making, melting,
pouring, shake out equipment and fettling, dust and fume control, material
handling equipments for sand moulds and cores, molten metal and castings,
reclamation of sands. Pollution control – norms, and agencies.
|
REFERENCE |
TEXT BOOKS: |
1. Principles of metal casting, Heine Loper & Rosenthal TMH - 2005
2. Principle of Foundry Technology, P. L. Jain, TMH – 2006.
|
Reference Books |
1. Castings, John Campbell, Second edition, Elseivier
2. Foundry Technology, P. N. Rao
3. Manufacturing Process, I, Dr. K. Radha Krishna 5th Edn. Sapna
Book House, Bangalore
|
|