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Permanent Casting Molds
Permanent Casting Molds
Permanent molds, also known as permanent metal molds or reusable molds, are molds made from materials like metal or refractory ceramics that can be used repeatedly for metal casting. Unlike expendable molds that are destroyed after each casting, permanent molds are designed to withstand multiple casting cycles without significant wear or deformation. Permanent molds are typically used in processes such as permanent mold casting or die casting.
Advantages of Permanent Molds over other mold types include:
Durability and Reusability: Permanent molds are designed to be durable and withstand repeated casting cycles, making them highly cost-effective over time. They can be used for a large number of castings, reducing the need for frequent mold replacement and associated costs.
Improved Surface Finish: Permanent molds often result in better surface finish and dimensional accuracy compared to expendable molds. The smooth and consistent mold surface helps produce castings with minimal surface defects, requiring less post-casting surface finishing operations.
Dimensional Stability: Permanent molds maintain their shape and dimensional stability throughout multiple casting cycles. This results in consistent and repeatable part dimensions, making them suitable for applications that require tight tolerances and precise specifications.
Faster Production Rates: Permanent molds enable faster production rates compared to some other casting methods. Once the mold is prepared and set up, it can be used for multiple castings without the need for mold creation or preparation for each cycle. This efficiency can lead to higher productivity and shorter lead times.
Cost Savings: While permanent molds may have a higher initial cost compared to expendable molds, their reusability and longevity offer significant cost savings in the long run. The reduction in mold replacement and associated tooling costs, as well as the potential for improved process efficiency, can make permanent molds a cost-effective option for high-volume or repeated casting production.
Process Control: Permanent molds provide better process control and consistency due to their inherent stability and repeatability. This helps achieve consistent casting quality, reduce variability, and minimize the risk of defects compared to some other casting methods.
Permanent-Pattern Molds
Permanent-Pattern Molds
Permanent-Pattern Molds reuse non-expendable patterns with custom-made, expendable molds. The most common variation of this is molds made with sand packed tightly around the permanent pattern, which is removed before casting.
Advantages of Permanent-Pattern Molds include:
Cost-Effectiveness: Permanent pattern molds can be cost-effective for producing low to medium volumes of castings. The initial cost of creating the pattern may be higher, but the pattern can be reused for multiple casting cycles, reducing the need for costly pattern remanufacturing.
Reduced Waste: Permanent pattern molds generate less waste compared to expendable patterns, as the pattern is reused instead of being consumed or melted away during the casting process. This can lead to reduced material waste and associated costs.
Versatility: Sand molds allow for a wide range of part versatility, so long as the part(s) fit within the molding frame. Additionally, the sand is affordable and reusable.
Expendable Pattern Molds
Expendable Pattern Molds
Expendable pattern molds, also known as disposable pattern molds, are molds in which the pattern used for casting is consumed or destroyed during the casting process. These patterns are typically made from materials such as wax, foam, or plastic, and they are not reused for subsequent castings. Expendable pattern molds are commonly used in processes like investment casting.
Cost-Effectiveness: Expendable pattern molds are often more cost-effective than non-expendable pattern molds. Since the patterns are not reusable, there is no need for pattern maintenance, storage, or refurbishment costs. This makes expendable pattern molds particularly advantageous for low to medium production volumes or one-off casting requirements.
Design Flexibility: Expendable pattern molds offer design flexibility as they allow for the creation of intricate and complex part geometries. The expendable patterns can be easily formed or molded into various shapes and sizes, accommodating intricate details, undercuts, and internal features.
Easy Pattern Creation: Expendable pattern molds can be created relatively quickly and easily compared to non-expendable pattern molds. Patterns can be formed using various techniques like injection molding, 3D printing, or hand sculpting. This allows for rapid iteration and modifications during the design and prototyping stages.
Variety of Mold Materials: Expendable pattern molds can be used with a wide range of mold materials, such as sand, plaster, ceramic, or refractory materials. This versatility enables the selection of the most appropriate mold material based on factors like the complexity of the part, desired surface finish, and casting process requirements.
Size and Weight Considerations: Expendable pattern molds are suitable for casting both small and large parts. They can be easily scaled up or down depending on the size and weight of the desired casting, allowing for versatility in casting applications.
7.4✔ CHECKPOINT
7.4✔ CHECKPOINT
Machinist Hammer Casting Mold
Machinist Hammer Casting Mold
For this checkpoint, you will create the mold for casting your machinist hammer, based on the pattern you made in the previous module
Following the workflow in the video shown for "Expendable Pattern Molds" section above, create a ceramic mold around your casting pattern using Suspendaslurry
Once all the layers of your mold are built up, coordinate with your instructor to remove the 3D printed pattern from the mold and to cure the mold in preparation for casting
Once done, upload documentation of your progress (text/pictures/gifs/videos) to your previously-created "Machinist Hammer" project page on your portfolio website, including:
Your mold & the process(es) you followed to make it
Descriptions/summaries of what you did/learned
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