C- Shell Molding and Die Casting Flashcards
What is the casting process of developing a mold cavity surrounded only by a very thin layer of refractory material to then fill with molten metal?
SHELL MOLDING
What must the PATTERNS used in SHELL MOLDING be made of?
METAL, only used if large numbers of the part are to be produced.
How are the METAL PATTERNS made?
SAND CASTING
What is a box containing the sand and resin mixture, which is attached to the METAL PATTERN?
DUMP BOX
What are the pins on the pattern plate are used to remove the shell from the plate?
EJECTOR PINS
What are the ADVANTAGES of SHELL MOLDING (over sand casting)?
Thin shells (fast cooling, flexible, good gas permeability), low sand volume (compared to sand casting), surface finish, lightweight, fewer flaws.
An EXPENDABLE MOLD process that involves wax. Investment means to “DIP”.
INVESTMENT/LOST WAX CASTING
What is a process to make wax patterns. Usually for making items such as rings and jewelry with organic shapes.?
WAX CARVING
What is a method of creating plastic parts and wax patterns in very large numbers?
INJECTION MOLDING
What is an assembly of wax elements including the patterns, which will eventually become an entire casting system with a pouring basin, sprue, runners, and mold cavities.?
TREE
What are the TREES dipped into?
STUCCO or CERAMIC SLURRY
What is the process of removing the wax from their surrounding ceramic shells?
MELT OUT
What is a method of separating the ceramic shell and the metal tree?
SHAKE OUT
What is a process similar to lost wax/ investment casting, but with STYROFOAM.
LOST FOAM CASTING/ EVAPORATIVE FOAM CASTING/ EXPANDED POLYESTERENE PROCESS
What is one of the best aspects of LOST FOAM CASTING?
Hollow parts can be made WITHOUT CORES.
What are casting processes where the mold can be utilized over and over again?
PERMANENT MOLD CASTING (usually made of tool steel or graphite)
What is the process of using metal molds for permanent mold casting?
DIE CASTING
What is a metal mold used in CASTING?
A DIE
What are retractable metal CORES that are pushed into the die cavity to inject out the metal parts?
CORE PULLS
What are mechanical plungers used to pop out the walls of the die cavity and kick out the part?
EJECTOR PINS
What is used in conjunction with the hydraulically actuated CLAMPING SYSTEM required to keep the two die halves closed?
TOGGLE LOCK
Which method requires the metal CHARGE to be placed in the SHOT TUBE (chamber) ahead of the piston?
COLD CHAMBER
Which die casting method maintains a reservoir of molten metal as part of the machine?
HOT CHAMBER
How is the PRESSURIZED INPUT of metal achieved?
By using a PISTON (straight cylinder) or PLUNGER (gooseneck system)
What are the six attributes required for successful DIE CASTING?
PRESSURIZED METAL INPUT (shot charge)
VENTING/VALVE SYSTEM
CLAMPING/LOCKING SYSTEM
EJECTOR PIN SYSTEM
CORE PULLS
COOLING SYSTEM
