Sand Casting 8 ǀ Special casting Processes I ǀ Mechanical Engineering GATE, IES, SSC ǀ PPT Lectu

Sand Casting:

Lecture by Senthil Kumar M
In Gate Exams, Engineering Services and SSC Junior exams in Mechanical Branch, Sand casting is very easy scorable and important topic too. In sand casting we have made ten videos which cover all the topic in sand casting and previous year GATE questions are also discussed in these videos. Lecture will be in PPT Type. Sand casting Videos and their links are given below.
Casting Terminology https://youtu.be/OXHea4KNyGk
• Mold, Pattern, Flask, Cope, Drag, Cheek, Riser, Runner, Gate, Sprue, Pouring Basin, Casting advantages and Disadvantages, Applications
• Previous GATE Questions discussion
Pattern Materials & Types of patterns https://youtu.be/Rw9Tlf36C4s


• Pattern Materials – Wood, Metal, Plastics, Wax & Mercury
• Loose piece Pattern, Match Plate pattern, Skeleton Pattern, sweep pattern, Cope drag Pattern, single piece pattern, Split pattern, Gated pattern, Follow board pattern
Types of Pattern Allowances https://youtu.be/7_sxPYIqz7g
• Shrinkage (or) Contraction Allowances & Pattern allowances Problems
• Draft Allowance, Machining (or Finish) Allowance, Shake Allowance, Distortion Allowance
Moulding sand & Cores https://youtu.be/BP2UqTqJxW4
• Green sand, Dry sand, Loam sand & additives, Sand muller, Sand blaster, Facing sand, packing sand & parting sand
• Moulding sand properties: porosity, Refractoriness, Collapsability, green strength, dry strength, Cores, Buoyant force acting on Core, Core problems – Buoyant Force
Solidification of Casting
• Pouring Temperature, Crystal growth, Solidification of pure metal, skin thickness, Chivorinov’s Rule, Combined Directional and progressive solidification, Chills & Padding
• Solidification problems
Riser Design
• Top riser, blind riser, open riser, riser shape , Riser Problems
Gating Design
• Gating – Runner, gate, Gating ratio, Pressurized Gating & Un- Pressurized Gating, Parting gate, step gating, top gating
• Sprue design Problems
Special Casting Processes-I
• Centrifugal casting, Die casting, Investment casting, CO₂ moulding

Special Casting Processes-II https://youtu.be/Gj8dmgcZh7A
• Shell moulding, Slush casting, Squeeze casting, Plaster casting, Pit moulding, Loam moulding
Casting Defects
• Gas defects – Blow Holes, Pin holes
• Shrinkage cavities
• Moulding material defects- Cuts and washes, Scab, Metal penetration, Fusion, Swell
• Pouring metal defects- Mis-run, Cold shut, Hot tears
• Mould shift - fin or run-out
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