Week Task

group assignment:review the safety data sheets for each of your molding and casting materials, then make and compare test casts with each of them
individual assignment: design a mold around the stock and tooling that you'll be using, mill it (rough cut + (at least) three-axis finish cut), and use it to cast parts

Introduction

Pattern is the principal tool during the casting process. It may be defined as a model of anything, so constructed that it may be used for forming an impression called mould in damp sand or other suitable material. When this mould is filled with molten metal, and the metal is allowed to solidify, it forms a reproduction of the pattern and is known as casting. The process of making a pattern is known as pattern making.
The casting have five stages: (1)pattern making (2) moulding and coremaking (3) melting and casting (4) fettling and (5) testing and inspection.

Pattern Material

Following are the some basic pattern material available in market
1. Wood
2. Metal (CI, Brass, Al, White metal )
3.Plastics
4. Rubbers
5. Plasters
6. Waxes

Types of Patterns

Following are the some basic pattern material available in market
1. Single-piece Patteran
2. Split Pattern
3. Match plate Pattern
4. Cope and drag Pattern
5. Gated Pattern
6. Loose-piece Pattern
7. Sweep Pattern
8. Skeleton Pattern
9. Segmental Pattern
10. Shell Pattern
11. Built-up Pattern
12. Boxed-up Pattern
13. Lagged-up Pattern
14. Left and right hand pattern


Pattern Making Allowances

Pattern are not made the exact same size as the desired casting for several reasons. Such a pattern would produce castings which are undersize, allowance must therefore be allowed for shrinkage, draft, finish, distortion and rapping. Following are the allowance need to consider during patterna making
1. Shrinkage Allowance


2. Draft Allowance


3. Distortion or camber Allowance


4. Rapping Allowance

Difference between 3D printing and molding

3D printing is an additive process. It manufactures objects by building them up layer by layer. We can watch this build process as it happens, which is useful when we’re testing a new design.


Injection molding makes use of molds. First, an object’s inverse is carved out of a material that is safe to handle the molten build material (the material the finished object is made of. Then, the molten build material is poured into the mold. Once the material has cooled in the mold, the finished object is ready.


Another difference in them is the way of material is put into the machines, in injection moulding small piece of plastic called “Pellets” are used while in 3D printing “filament” is used.

Individual Assignment

The task for the week is to design a mold around the stock and tooling that we are using, mill it (rough cut + (at least) three-axis finish cut), and use it to cast parts

What i learn?

I am learn about

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