In this article, we will discuss the flow of the metal casting process. Before we begin, you should understand what a process flow is. So, the process flow is the flow of work or, more broadly, the stages that are taken to create a product. So, what stages are involved in the manufacture of a product using metal casting techniques? Take a look at the metal casting process flow chart and explanation below.
1. Casting Design
The first step in the metal casting process is design casting. The engineer will design product images from customers in order to produce quality products with lower production costs. There are several steps involved in casting design:
Design
The initial process that influences the final quality of the resulting product is casting design. Casting design must also consider the subsequent processes to be carried out in order to make the next process easier and avoid problems.
Calculations are performed in the casting design to determine the size of the pouring channel, such as in the gate, runner, sprue, and riser. Also included is an efficient pour channel layout to ensure that the freezing of metal liquids runs smoothly.
Casting design should be used because it can minimize defects, turbulence, mold and core erosion, regular thermal gradients, and efficient production costs.
Material
Following the completion of the casting design, the next step is the selection of pattern materials, products, and molding sand. Material selection is beneficial when it comes to casting material, mold material, and pattern material. The selection is based on the product’s personality, quality, product designation, and quantity of orders.
Simulation
The final step in the casting design stage is a simulation, which occurs after all previous stages have been completed. Depending on the software used, simulations are run to see the results of the casting design, such as product defects, fluid flow, freezing, and so on. The simulation can be used as a guide for the next step, ensuring that the final product is of high quality. If the simulation results are not satisfactory, re-create the casting design until the desired simulation results are obtained.
2. Trial
When the casting design stage is finished, the trial is performed. The trial phase is used to create product samples. The trial stage is the stage in which the product is determined according to the specifications desired by the customer. If the sample product is approved by the customer, the manufacturing process continues.
3. Manufacturing
The production phase begins after the trial phase is completed. Several processes are being carried out at this stage, as explained below.
Patterns
Pattern-making is the first step in the manufacturing process. The following are the provisions for creating the pattern.
- Slope: The slope is designed to make it easier to pick up the pattern in the mold while also preventing damage to the pattern or mold profile.
- Parting line: Depending on the complexity of the pattern, the cleavage is divided into two or more parts. Complex patterns usually require a parting line, but simple objects can be made without one.
- Additional work: an additional size or thickness of about 3 mm on the part to be machined.
- Shrinkage: When the casting product is frozen, it will shrink due to temperature changes from the pouring temperature to room temperature. Shrinkage must be used to increase the size of the pattern so that the size of the casting product does not decrease.
Mold
The molding process creates a cavity that will later be cast into the shape of a casting product. Mold sand is classified into two types: wet sand and dry sand. Wet sands, including green sand and red sand. Meanwhile, dry molding sands are available in the Co2 Process, cement process, no-bake process, and resin-coated sand (RCS). The grain size of the sand used ranges from 0.06 to 2 mm, depending on the application.
Smelting
Smelting is the process of melting metal material before pouring it into a mold to form a casting product.
4. Quality Control
Quality control is the final stage. At this stage, the product is chosen based on the specifications specified by the customer, and it is then delivered to the customer. In the meantime, products that do not meet specifications will be recycled.