Casting Alternatives

Casting process involves adding pressure to the molten materials to shape it to a mold at under high pressures. In the mold the material is made to cool and later hardens to form the required final product shape. The most common casting materials used is aluminum and steel molten metals.

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The non-metallic materials are like rubber, plastic and spray are some other casting materials. Casting process is not suitable for the ideal process application, which is a popular forming technique.

Casting Advantages:
By using casting process we can create complex shapes.

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Advantages:
Metal liquidity:

Compare with the liquid casting the solid state forming alternative are more time-consuming and involve high labor cost.

Reduced post treatment processes:

Single mold casting makes additional assembly and, where apparatus finishing is unnecessary.

Quick Turnaround:
The casting operation can be performed with minimum maintenance and ideal time. It enables the mass production applications.

Size capabilities:
By using the casting process an effective component is created, both in small and large size. And the weight is nearly 200 tons.

Price per piece:
Compared to the other process we can obtain high amount production and also cheaper than other alternatives.

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Surface textures:
The design of the cast is considered to be smooth, semi-smooth an operation and possess many other qualities.

Metal Forming Operations:
Many types of forming techniques are suitable for the casting process. By using the process once can observe many advantages and also disadvantages.

Alternative type of casting includes:

  • Machining
  • Stamping
  • Forging
  • Rolling
  • Extruding
  • Sintering

Machining:
Machining process is used for different metal shaping methods. Each and every process in machining operation is used in cutting the tools, to drills, twists and to shape the material.

Drilling:

Drilling

Drilling is one of the cutting processes. For cutting process, a drill bit is used to cut or enlarge the hole of the circular cross section in the solid material. The drill bit is a rotary cutting tool and often used for multiple cutting points. The drill bit is arranged above the work piece material and pressed against to the work piece. The drill bit must be made to rotate and remove the material according to the feed rate. The drill bit rotates 100 to 1000 of revolution per minute. After the process one can observe a hole in the work piece material.

Milling:

Milling

In the milling machining process, rotary cutter is used to remove the material from the work piece. Feeding is provided in the direction to the angle with the axis of tool. The tool must be moves in the 3 dimensions to create a shape or circular hole. Milling is the most commonly used processes to manufacture machining parts.

Turning:

Turning

In the turning process, the tool bit is a non-rotary bit or stationary cutting tool. The work piece must be made to rotate with less velocity or in a more linear manner.  The tool movement according to the axis must be a straight line or angle or curve, but they should be linear. In many of the cases the turning operation can be performed on the external surface of the work piece material. By using boring internal surface actions are performed.

Grinding:

Grinding

In the grinding process grinding wheel must be act as tool for the machining process. To the grinding wheel abrasive particles are arranged for the process. Initially, facing operating is performed on the work piece material. Based upon the abrasive size the finishing is obtained.

For this process one requires a labor for inspection, and also during the process. The cost is high for the small productions.

Forging:

Forging

Forging is one of the oldest processes in the manufacturing. During the process compressive forces are involved to shape the metal. Based upon the temperature, forging is classified into several types. They are hot, cold and warm forging. The hot forging process is performed above the room temperature to shape the metals and where malleability is also improves. The cold forgoing process can be performed at nearer to the room temperatures. The forging parts are less in weight that is 1 kilogram to 580 metric tons. Comparing with the casting the forging process delivery’s an end product with high efficiency and also stronger with less porous.

Stamping:

Stamping

Stamping process is also known pressing process. The stamping process that involves high pressure die blows to the metal sheet to obtain a desired shape. Varieties of metal sheet process are manufactured. Mainly this process is performed on the metal sheet and also on the polystyrene.

There are different types of stamping operations that are performed. They are punching, piercing, coining, bending, fine blanking, embossing and flanging.

Punching: This process is used to punch the holes on a metal sheet

Piercing: 

Piercing

This process is also used to machine a small hole on the work piece material. The holes are vary in size of the metal

Coining:

coining

In this process the high pressure must be applied on the die to create an impact on the sheet metal, which looks like a coin.

Bending:
Bending

Brake presses method viewpoints in the product; it is ideal for modest forming submissions such as metal boxes.

Fine blanking

Fine blanking

The metal break on the guide plate, which secures the piece tightly, is known as fine blanking. By using fully automatic stamping machine it can perform the various stamps with different sizes and types to close precision.

Rolling
Rolling
It is a technique used to reduce the thickness of the sheet material. In between the two rolls, the metal sheet must be compressed. By using rolling round rods this is obtained. If the final product is not flat then the process is known as profile rolling.

Extruding:
Extruding
Extrusion processes the components that are done within the fixed cross section. With the help of high pressures forces the base material must be drawn into the die. Extrusion is the closest alternative to the casting process. By using extrusion process complex shapes are performed with different cross sections. The stresses are reduced on the base metal. It is a cheaper process and involves fragile work material.

Sintering:
Sintering

In the casting process molten material is used and in sintering powdered material needs to be used. The mold is fills with the ceramic or bronze. The mold must be heated upto the point where the separation of the grain fuses together. Without deforming the base metal the sintering creates the directional elongation.

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