Die-casting:

Die casting is a metal casting process that involves forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

Die casting is prized for its ability to produce parts with a smooth surface finish and precise dimensions. In addition, this process is relatively fast and cost-effective, making it an attractive option for many applications. 

Centrifugal casting:

 Centrifugal casting is a casting process that uses centrifugal force to distribute the molten metal evenly in the mold cavity. In centrifugal casting, the mold is rotated at high speed while the molten metal is poured into it. The centrifugal force causes the molten metal to flow to the outside of the mold cavity, creating a hollow casting. 

Centrifugal casting is typically used to produce cylindrical or ring-shaped castings, such as pipes, tubes, and bushings. It can also be used to produce other shapes, such as turbine blades and compressor housings. 

Investment casting:

 Investment casting, also known as the lost-wax process, is a manufacturing process for producing high-precision metal parts with complex geometries. The investment casting process begins with the creation of a wax pattern of the desired part. The wax pattern is then coated with refractory material, such as ceramic or plaster, to form a mould. The wax is then melted out of the mould, leaving a cavity in the mould that is the exact shape of the desired part. 

Molten metal is then poured into the mould cavity. The metal solidifies and cools, and the mould is broken away to reveal the finished casting. Investment casting is a versatile process that can be used to produce parts in a wide range of materials, including stainless steel, aluminium, brass, and bronze. It is also capable of producing parts with very complex geometries, which would be difficult or impossible to produce using other manufacturing methods.

Investment casting is used in a wide range of industries, including aerospace, automotive, medical, and dental. Some common applications for investment castings include:

• Turbine blades

• Jet engine components

• Medical implants

• Dental crowns and bridges

• Automotive parts

• Jewelry

Investment casting offers several advantages over other manufacturing methods, including:

• High precision and accuracy

• Ability to produce complex geometries

• Wide range of materials that can be cast

• Good surface finish

• Relatively low cost for mass production

However, investment casting also has some disadvantages, including:

• High cost for one-off or low-volume production

• Long lead times

• Difficulty in producing parts with very large dimensions or weights

Shell Molding:

 Shell moulding is a metal casting process that uses a thin-walled shell made of resin-coated sand to form the mould. The shell is created by applying a sand-resin mixture to a heated pattern. The pattern is then removed, leaving behind a hardened shell. Once the shell is created, it is assembled and clamped together. Molten metal is then poured into the shell cavity. The metal solidifies and cools, and the shell is broken away to reveal the finished casting. 

Shell moulding offers several advantages over traditional sand casting, including:

• Higher precision and accuracy: Shell moulds are more accurate than sand moulds, resulting in cast parts with tighter tolerances.

• Smoother surface finishes: Shell moulds produce cast parts with smoother surface finishes than sand moulds. This eliminates the need for extensive machining or grinding operations.

• Faster production rates: Shell moulding can be automated, which allows for faster production rates than sand casting.

• Reduced labour costs: Shell moulding is less labour-intensive than sand casting, which can lead to reduced labour costs.

Shell moulding is used to produce a wide range of metal parts, including:

• Automotive parts

• Aerospace components

• Industrial parts

• Medical implants

• Jewelry

Continuous Casting:

 Continuous casting is a manufacturing process for producing metal semi-finished products, such as billets, blooms, and slabs, with a continuous cross-section. It is the most widely used method for producing steel and is also used to produce other metals, such as aluminium and copper. The continuous casting process begins with molten metal being poured into a tundish, which acts as a reservoir for the metal. The metal is then fed from the tundish into a mould, which is typically made of copper or steel. The mold has a cross-section that corresponds to the desired shape of the finished product.

 As the metal passes through the mould, it is cooled and solidified by water sprays. The solidified metal is then withdrawn from the mould at a controlled speed. The speed of withdrawal is determined by the desired thickness of the finished product. Once the metal has been withdrawn from the mould, it is cut into lengths using a saw or other cutting device. The finished product is then inspected and packaged for shipment.

 Continuous casting offers several advantages over other casting processes, including:

• High productivity rates

• Good surface finish

• Good dimensional control

• Ability to produce long lengths of material

• Low labor requirements

Continuous casting is a critical part of the steelmaking process, and it has played a major role in the development of modern steelmaking technology.

 Continuous Casting Process

The continuous casting process can be summarized in the following steps:

1. Molten metal preparation: The molten metal is prepared in a furnace or ladle. It is important to ensure that the metal is clean and has the correct temperature and composition.

2. Mold preparation: The mould is prepared by coating it with a lubricant. This helps to prevent the molten metal from sticking to the mould.

3. Pouring: The molten metal is poured into the mould. The metal flows through the mould and solidifies as it cools.

4. Withdrawal: The cast product is withdrawn from the mould at a controlled rate. This ensures that the metal has enough time to solidify before it is removed from the mould.

5. Cutting: The cast product is cut to the desired length. This is typically done using a saw or plasma cutter.

Casting Defects

Lathe Machine:

A lathe machine is a machine tool that rotates a workpiece about an axis of rotation to perform various operations such as cutting, sanding, knurling, drilling, deformation, facing, and turning, with tools that are applied to the workpiece to create an object with symmetry about that axis. 

Lathes are used in woodturning, metalworking, metal spinning, thermal spraying, reclamation, and glass-working. Lathes can be used to shape pottery, the best-known design being the Potter's wheel. Most suitably equipped metalworking lathes can also be used to produce most solids of revolution, plane surfaces and screw threads or helices.

The main components of a lathe machine are:

• Bed: The bed is the main structural support of the lathe machine. It is a long, cast iron frame that supports the other components of the lathe.

• Headstock: The headstock is located at one end of the bed and houses the main drive motor and spindle. The spindle is the shaft that the workpiece is mounted on.

• Tailstock: The tailstock is located at the other end of the bed and houses the tailstock quill. The tailstock quill can be used to support the workpiece or to drive a cutting tool.

• Tool carriage: The tool carriage is mounted on the bed and moves along it. The tool carriage holds the cutting tool and allows it to be fed into the workpiece.

• Leadscrew: The leadscrew is a long screw that runs along the length of the bed. The leadscrew is used to control the feed rate of the tool carriage.

Lathes can be classified into two main types: engine lathes and turret lathes. Engine lathes are the most common type of lathe and are used for a wide variety of tasks. Turret lathes are designed for mass production and can be equipped with multiple cutting tools that can be quickly changed.

Lathes are an essential tool in many industries, including manufacturing, engineering, and construction. They are used to produce a wide variety of products, including shafts, gears, bearings, and other machine components.

Here are some of the most common operations performed on a lathe machine:

• Turning: Turning is the process of removing material from the outside of a workpiece to create a cylindrical shape.

• Facing: Facing is the process of removing material from the end of a workpiece to create a flat surface.

• Boring: Boring is the process of enlarging the diameter of a hole in a workpiece.

• Drilling: Drilling is the process of creating a hole in a workpiece.

• Knurling: Knurling is the process of creating a diamond-patterned finish on the surface of a workpiece.

Shaper Machine :

A shaper machine is a metalworking machine tool that uses a reciprocating cutting motion to produce flat, horizontal, vertical, and angular surfaces on workpieces. It is similar to a planer, but the workpiece is held stationary while the cutting tool moves back and forth. 

Shaper machines are typically used to machine small to medium-sized workpieces, such as gears, keys, and dies. They can also be used to machine more complex shapes, such as cams and spline shafts.

The main components of a shaper machine are:

• Column: The column is the main structural support of the shaper machine. It houses the main drive motor and gearbox.

• Ram: The ram is a reciprocating slide that holds the cutting tool. It is driven by the main drive motor.

• Table: The table is a work-holding device that holds the workpiece in place. It can be moved horizontally and vertically to position the workpiece for machining.

• Crossfeed: The cross feed is a mechanism that allows the table to be moved perpendicular to the direction of the ram travel. This allows the cutting tool to be fed into the workpiece in small increments.

• Down feed: The down feed is a mechanism that allows the table to be moved vertically. This allows the cutting tool to be plunged into the workpiece to a desired depth.

Shaper machines can be classified into two main types: standard shapers and universal shapers. Standard shapers can only machine flat surfaces, while universal shapers can machine flat, horizontal, vertical, and angular surfaces.

Here are some of the most common operations performed on a shaper machine:

• Shaping flat surfaces: This is the most common operation performed on a shaper machine. It is used to produce flat surfaces, such as the top of a block or the face of a gear.

• Shaping slots and grooves: Shaper machines can also be used to machine slots and grooves in workpieces. This is often done to create keyways or to hold other machine components.

• Shaping angular surfaces: Universal shaper machines can be used to machine angular surfaces, such as the chamfer on the edge of a workpiece or the angle on a cutting tool.

Planer Machine

Milling Machine

Drilling Machine

Grinding Machine