ABSTRACT
Hooks are one of the repeatable components with mass production in lifting of
loads. For overhanging load pulley mechanisms are optimize to get maximum
lifting loads with less effort. Casting is a predominant and reliable process of
manufacturing components with low cost. For production purpose, better quality
of samples has to prepare by using CNC machining techniques. Hooks are
prepared by CNC machining Techniques and casting process. In this we increase
the performance of the load.
In the present project we are designing a hook, manufacture the masters
with CNC milling and casting masters will be submitted.
CONTENTS
Page No.
Title Page
Certificate i
Declaration ii
Acknowledgment iii
Abstract iv
Contents v-vi
List of Figures vii-viii
List of Tables ix
Chapter 1 Introduction 1
1.1 Sand Casting 1
1.2 Basic Steps In Making Sand Castings 2
Chapter 2 Literature Survey 4
2.1 About Casting 4
2.2 Types of Castings 5
2.3 Sand Casting 6
2.4 Important Considerations for Casting 7
Chapter 3 Types of Metals Used for Casting Production 14
3.1 Different Metals Used for Casting Production 14
3.2 Pattern Material Properties of Aluminium (AL) 15
3.3 Cast Iron Properties 18
3.4 Types of Cast Irons 18
Chapter 4 Introduction To CAD 22
Chapter 5 Introduction To Unigraphics 24
5.1 Scientific Computing 24
5.2 Design Considerations of Roller Hook Pattern 25
Chapter 6 Introduction To Manufacturing 29
6.1 Introduction to CAM 29
6.2 Introduction to CNC Machining 30
6.3 Some of the CNC machines 31
6.4 Electric Discharge Machining 32
6.5 CNC Machine Programming 33
Chapter 7 Introduction To Program 34
7.1 G-codes 34
7.2 M-codes 36
7.3 Computer Numerical Control Machine 37
7.4 Tooling 38
Chapter 8 Introduction To DELCAM 40
8.1 Raw Material Specifications 40
8.2 Pattern Manufacturing Process 41
8.3 Generation of CNC Program for Tool Paths 45
8.4 Finishing Tool Path 48
8.5 Results 50
Conclusion 53
References 54
LIST OF FIGURES
Fig. No. Particulars Page No
1.1 schematic showing steps of the sand casting process 3
2.1 work flow in typical sand-casting foundries 6
2.2 taper in design 7
2.3 design components of a mould showing chaplets 8
2.4 Shell mould casting 9
2.5 hot and cold chamber die casting 12
2.6 centrifugal casting schematic 13
5.1 2D drawing in sketcher 25
5.2 3D development by extruding 25
5.3 2d-layout 26
5.4 3d-layout 26
5.5 direction of usage 27
5.6 pattern layout 28
7.1 five-axis machining center with rotating table and
computer interface 37
7.2 high speed steel with cobalt end mills used for cutting
operations in a milling machine 38
7.3 a CAT-40 tool holder 39
7.4 a boring head on a Morse taper shank 39
8.1 raw material actors 41
8.2 DELCAM starting 41
8.3 file importing 41
8.4 work plane and raw material block creation 42
8.5 tool path generation 42
8.6 creating tool path for finishing 43
8.7 surfacing tool path 43
8.8 tool path simulations 44
8.9 master print machining 51
8.10 assembly of hook with masters 51
8.11 core box assembly components 52
LIST OF TABLES
Table No. Page No
2.1 Types of casting, advantages, disadvantages and examples 5
3.1 Different metals used for casting production 15
3.2 Various shapes and sizes of Aluminium 16
CHAPTER-1
INTRODUCTION
Housing is one of the accurate components to keep the bearing reliability and safety.
A new generation of bearing protectors is now available that can help maintain lubricant
cleanliness, prevent loss of lubricants, and prolong the life of your rotating equipment.
Depending upon the design of a shaft or housing, the shaft may be influenced by an unbalanced
load or other factors which can then cause large fluctuations in bearing efficiency. For this
reason, it is necessary to pay attention to the following when designing shaft and housing:
Bearing arrangement selection; most effective fixing method for bearing arrangement
Selection of shoulder height and fillet radius of housing and shaft.
Shape precision and dimensions of fitting; area run out tolerance of shoulder.
Machining precision and mounting error of housing and shaft suitable for allowable alignment
angle and inclination of bearing.
1.1 Sand Casting
Sand casting, also known as sand moulded casting, is a metal casting process characterized by
using sand as the mould material. It is relatively cheap and sufficiently refractory even for steel
foundry use. A suitable bonding agent (usually clay) is mixed or occurs with the sand. The
mixture is moistened with water to develop strength and plasticity of the clay and to make the
aggregate suitable for moulding. The term "sand casting" can also refer to a casting produced via
the sand casting process. Sand castings are produced in specialized factories called foundries.
Over 70% of all metal castings are produced via a sand casting process.
Molds made of sand are relatively cheap, and sufficiently refractory even for steel
foundry use. In addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs
with the sand.
The mixture is moistened, typically with water, but sometimes with other substances, to
develop the strength and plasticity of the clay and to make the aggregate suitable for molding.
The sand is typically contained in a system of frames or mold boxes known as a flask.
The mold cavities and gate system are created by compacting the sand around models,
or patterns, or carved directly into the sand.
1.2 Basic Steps In Making Sand Castings
The basic steps involved in making sand castings are:
1. Patternmaking: Patterns are required to make moulds. The mould is made by packing
moulding sand around the pattern. The mould is usually made in two parts so that the pattern
can be withdrawn.
In horizontal moulding, the top half is called the cope, and the bottom half is called the
drag.
In vertical moulding, the leading half of the mould is called the swing, and the back half
is called the ram.
When the patterns withdrawn from the moulding material (sand or other), the imprint of
the pattern provides the cavity when the mould parts are brought together. The mould
cavity, together with any internal cores as required, is ultimately filled with molten metal
to form the casting.
2. If the casting is to be hollow, additional patterns, referred to as core boxes, are needed to
shape the sand forms, or cores, that are placed in the mould cavity to form the interior surfaces
and sometimes the external surfaces as well of the casting. Thus the void between the mould and
core eventually becomes the casting.
3. Moulding: is the operation necessary to prepare a mould for receiving the metal. It consists of
ramming sand around the pattern placed in support, or flask, removing the pattern, setting cores
in place, and creating the gating/feeding system to direct the metal into the mould cavity created
by the pattern, either by cutting it into the mould by hand or by including it on the pattern, which
is most commonly used.
4. Melting and pouring are the processes of preparing molten metal of the proper composition
and temperature and pouring this into the mould from transfer ladles.
5. Cleaning includes all the operations required to remove the gates and risers that constitute the
gating/feeding system and to remove the adhering sand, scale, parting fins, and other foreign
material that must be removed before the casting is ready for shipment or other processing.
Paths for the entrance of metal into the mold cavity constitute the runner system and
include the sprue, various feeders which maintain a good metal 'feed', and in-gates which attach
the runner system to the casting cavity.
Gas and steam generated during casting exit through the permeable sand or
via risers, which are added either in the pattern itself, or as separate pieces.
CHAPTER-2
LITERATURE SURVEY
2.1 About Casting
2.1.1 Casting methods
Metal casting process begins by creating a mould, which is the ‘reverse’ shape of the part we
need. The mould is made from a refractory material, for example, sand. The metal is heated in an
oven until it melts, and the molten metal is poured into the mould cavity.
The liquid takes the shape of cavity, which is the shape of the part. It is cooled until it
solidifies. Finally, the solidified metal part is removed from the mould.
A large number of metal components in designs we use every day are made by casting. The
reasons for this include:
(a) Casting can produce very complex geometry parts with internal cavities and hollow sections.
(b) It can be used to make small to very large size parts
(c) It is economical, with very little wastage: the extra metal in each casting is re-melted and re
used
(d) Cast metal is isotropic – it has the same physical/mechanical properties along a ny direction.
2.1.2 Common Examples
The solidified part is also known as a casting, which is ejected or broken out of the mold to
complete the process. Casting materials are usually metals or various cold setting materials that
cure after mixing two or more components together; examples are epoxy, concrete, plaster and
clay.
Door Handles, Locks, The outer casing or housing for motors, pumps, etc., wheels of
many cars. Casting is also heavily used in the toy industry to make parts, e.g. toy cars, planes, etchttps://drive.google.com/file/d/0B8R6tfk14y2QU3hSTHFPWFBMTXM/view?usp=drivesdkhttps://drive.google.com/file/d/0B8R6tfk14y2QU3hSTHFPWFBMTXM/view?usp=drivesdk
Hooks are one of the repeatable components with mass production in lifting of
loads. For overhanging load pulley mechanisms are optimize to get maximum
lifting loads with less effort. Casting is a predominant and reliable process of
manufacturing components with low cost. For production purpose, better quality
of samples has to prepare by using CNC machining techniques. Hooks are
prepared by CNC machining Techniques and casting process. In this we increase
the performance of the load.
In the present project we are designing a hook, manufacture the masters
with CNC milling and casting masters will be submitted.
CONTENTS
Page No.
Title Page
Certificate i
Declaration ii
Acknowledgment iii
Abstract iv
Contents v-vi
List of Figures vii-viii
List of Tables ix
Chapter 1 Introduction 1
1.1 Sand Casting 1
1.2 Basic Steps In Making Sand Castings 2
Chapter 2 Literature Survey 4
2.1 About Casting 4
2.2 Types of Castings 5
2.3 Sand Casting 6
2.4 Important Considerations for Casting 7
Chapter 3 Types of Metals Used for Casting Production 14
3.1 Different Metals Used for Casting Production 14
3.2 Pattern Material Properties of Aluminium (AL) 15
3.3 Cast Iron Properties 18
3.4 Types of Cast Irons 18
Chapter 4 Introduction To CAD 22
Chapter 5 Introduction To Unigraphics 24
5.1 Scientific Computing 24
5.2 Design Considerations of Roller Hook Pattern 25
Chapter 6 Introduction To Manufacturing 29
6.1 Introduction to CAM 29
6.2 Introduction to CNC Machining 30
6.3 Some of the CNC machines 31
6.4 Electric Discharge Machining 32
6.5 CNC Machine Programming 33
Chapter 7 Introduction To Program 34
7.1 G-codes 34
7.2 M-codes 36
7.3 Computer Numerical Control Machine 37
7.4 Tooling 38
Chapter 8 Introduction To DELCAM 40
8.1 Raw Material Specifications 40
8.2 Pattern Manufacturing Process 41
8.3 Generation of CNC Program for Tool Paths 45
8.4 Finishing Tool Path 48
8.5 Results 50
Conclusion 53
References 54
LIST OF FIGURES
Fig. No. Particulars Page No
1.1 schematic showing steps of the sand casting process 3
2.1 work flow in typical sand-casting foundries 6
2.2 taper in design 7
2.3 design components of a mould showing chaplets 8
2.4 Shell mould casting 9
2.5 hot and cold chamber die casting 12
2.6 centrifugal casting schematic 13
5.1 2D drawing in sketcher 25
5.2 3D development by extruding 25
5.3 2d-layout 26
5.4 3d-layout 26
5.5 direction of usage 27
5.6 pattern layout 28
7.1 five-axis machining center with rotating table and
computer interface 37
7.2 high speed steel with cobalt end mills used for cutting
operations in a milling machine 38
7.3 a CAT-40 tool holder 39
7.4 a boring head on a Morse taper shank 39
8.1 raw material actors 41
8.2 DELCAM starting 41
8.3 file importing 41
8.4 work plane and raw material block creation 42
8.5 tool path generation 42
8.6 creating tool path for finishing 43
8.7 surfacing tool path 43
8.8 tool path simulations 44
8.9 master print machining 51
8.10 assembly of hook with masters 51
8.11 core box assembly components 52
LIST OF TABLES
Table No. Page No
2.1 Types of casting, advantages, disadvantages and examples 5
3.1 Different metals used for casting production 15
3.2 Various shapes and sizes of Aluminium 16
CHAPTER-1
INTRODUCTION
Housing is one of the accurate components to keep the bearing reliability and safety.
A new generation of bearing protectors is now available that can help maintain lubricant
cleanliness, prevent loss of lubricants, and prolong the life of your rotating equipment.
Depending upon the design of a shaft or housing, the shaft may be influenced by an unbalanced
load or other factors which can then cause large fluctuations in bearing efficiency. For this
reason, it is necessary to pay attention to the following when designing shaft and housing:
Bearing arrangement selection; most effective fixing method for bearing arrangement
Selection of shoulder height and fillet radius of housing and shaft.
Shape precision and dimensions of fitting; area run out tolerance of shoulder.
Machining precision and mounting error of housing and shaft suitable for allowable alignment
angle and inclination of bearing.
1.1 Sand Casting
Sand casting, also known as sand moulded casting, is a metal casting process characterized by
using sand as the mould material. It is relatively cheap and sufficiently refractory even for steel
foundry use. A suitable bonding agent (usually clay) is mixed or occurs with the sand. The
mixture is moistened with water to develop strength and plasticity of the clay and to make the
aggregate suitable for moulding. The term "sand casting" can also refer to a casting produced via
the sand casting process. Sand castings are produced in specialized factories called foundries.
Over 70% of all metal castings are produced via a sand casting process.
Molds made of sand are relatively cheap, and sufficiently refractory even for steel
foundry use. In addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs
with the sand.
The mixture is moistened, typically with water, but sometimes with other substances, to
develop the strength and plasticity of the clay and to make the aggregate suitable for molding.
The sand is typically contained in a system of frames or mold boxes known as a flask.
The mold cavities and gate system are created by compacting the sand around models,
or patterns, or carved directly into the sand.
1.2 Basic Steps In Making Sand Castings
The basic steps involved in making sand castings are:
1. Patternmaking: Patterns are required to make moulds. The mould is made by packing
moulding sand around the pattern. The mould is usually made in two parts so that the pattern
can be withdrawn.
In horizontal moulding, the top half is called the cope, and the bottom half is called the
drag.
In vertical moulding, the leading half of the mould is called the swing, and the back half
is called the ram.
When the patterns withdrawn from the moulding material (sand or other), the imprint of
the pattern provides the cavity when the mould parts are brought together. The mould
cavity, together with any internal cores as required, is ultimately filled with molten metal
to form the casting.
2. If the casting is to be hollow, additional patterns, referred to as core boxes, are needed to
shape the sand forms, or cores, that are placed in the mould cavity to form the interior surfaces
and sometimes the external surfaces as well of the casting. Thus the void between the mould and
core eventually becomes the casting.
3. Moulding: is the operation necessary to prepare a mould for receiving the metal. It consists of
ramming sand around the pattern placed in support, or flask, removing the pattern, setting cores
in place, and creating the gating/feeding system to direct the metal into the mould cavity created
by the pattern, either by cutting it into the mould by hand or by including it on the pattern, which
is most commonly used.
4. Melting and pouring are the processes of preparing molten metal of the proper composition
and temperature and pouring this into the mould from transfer ladles.
5. Cleaning includes all the operations required to remove the gates and risers that constitute the
gating/feeding system and to remove the adhering sand, scale, parting fins, and other foreign
material that must be removed before the casting is ready for shipment or other processing.
Paths for the entrance of metal into the mold cavity constitute the runner system and
include the sprue, various feeders which maintain a good metal 'feed', and in-gates which attach
the runner system to the casting cavity.
Gas and steam generated during casting exit through the permeable sand or
via risers, which are added either in the pattern itself, or as separate pieces.
CHAPTER-2
LITERATURE SURVEY
2.1 About Casting
2.1.1 Casting methods
Metal casting process begins by creating a mould, which is the ‘reverse’ shape of the part we
need. The mould is made from a refractory material, for example, sand. The metal is heated in an
oven until it melts, and the molten metal is poured into the mould cavity.
The liquid takes the shape of cavity, which is the shape of the part. It is cooled until it
solidifies. Finally, the solidified metal part is removed from the mould.
A large number of metal components in designs we use every day are made by casting. The
reasons for this include:
(a) Casting can produce very complex geometry parts with internal cavities and hollow sections.
(b) It can be used to make small to very large size parts
(c) It is economical, with very little wastage: the extra metal in each casting is re-melted and re
used
(d) Cast metal is isotropic – it has the same physical/mechanical properties along a ny direction.
2.1.2 Common Examples
The solidified part is also known as a casting, which is ejected or broken out of the mold to
complete the process. Casting materials are usually metals or various cold setting materials that
cure after mixing two or more components together; examples are epoxy, concrete, plaster and
clay.
Door Handles, Locks, The outer casing or housing for motors, pumps, etc., wheels of
many cars. Casting is also heavily used in the toy industry to make parts, e.g. toy cars, planes, etchttps://drive.google.com/file/d/0B8R6tfk14y2QU3hSTHFPWFBMTXM/view?usp=drivesdkhttps://drive.google.com/file/d/0B8R6tfk14y2QU3hSTHFPWFBMTXM/view?usp=drivesdk
Great Read! CNC machining is a manufacturing process in which pre-programmed computer software dictates the movement of factory tools and machinery.
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