As you know, the Casting process is the oldest manufacturing method and hence the mainstream of mechanical industries. It is used to manufacture various casting in desired shape and size using various moulds.
But, most of the casting processes are their own advantages and disadvantages. Here, This article will elaborate on the Advantages and Disadvantages of the casting process in a detailed manner.
So, sit back and relax while I will take you on the knowledgeable journey with Engineers Rail.
So, without further delays, Let’s jump straight to the topic.
Advantages of casting process-
Here are some major advantages of the casting process-
The flexibility of size & weight-
Any size big or small can be manufactured with casting which made the casting method so flexible. The size of an object doesn’t matter for casting. Practically possible to make a casting of any size even up to 200 tons of weight.
Formation of complex shape-
The complex shapes can be manufactured with the casting method which can be very difficult for other manufacturing processes.
In this process, molten metal can flow into small sections of the mould cavity easily. This makes it very easy to form a complex casting shape.
Simple & inexpensive tools-
Tooling and equipment costs are low compared to other metal manufacturing processes. Tools required for casting processes are generally inexpensive. This process doesn’t require costly equipment. The process is also very simple in general.
Flexibility in materials choices-
Almost every material in the world can be used for casting. No restriction for types of materials. Mostly all types of engineering Such as aluminium, magnesium, copper alloys, tin, zinc, lead alloys, iron & steel materials can be cast through this process
Low wastage of material and cost-
As extra materials can be reused for further casting requirements, hence Wastage of materials is very less and further the parts made by the casting process has the lowest possible cost compared to other manufacturing processes.
Wide range of materials-
There are certain materials that cannot be used in any other manufacturing process. But it can be successfully used for the casting process.
Short production lead time-
o consideration in the production, the casting process has a short lead time for complex parts when compared to other manufacturing processes and hence this process is ideal for short production runs especially while manufacturing complex parts like automobile cylinders, machining tools. crankshaft, camshafts, IC engines parts etc.
High production rate-
The production rate of this process depends on various factors, usually, it is from 5-200 parts per hour, this depends on factors like the size and complexity of the part.
Disadvantages of casting process-
Here are some limitations of the casting process–
This process requires a lot of labour work with skilled manpower and here, Sand casting requires higher levels of handcrafting and is more labour intensive than other casting methods. Hence this process comes under labour intensive process.
Poor Dimensional Accuracy-
Because of shrinkage in the casting, the dimensional accuracy might be at risk. proper care must be taken and suitable allowance must be provided. In this process, there needs to do machining & finishing operations to get the required dimension. So, this can become poor dimensional accuracy and this is the biggest limitation of this process.
Poor surface finish-
Most of the time casting suffers from a poor surface finish. However, this was the problem in the older days. Nowadays, Methods are developed such as investment casting, shell moulding casting, vacuum-sealed moulding process has got the excellent surface finish.
Just casting a part is not enough. It requires secondary machining operations in order to improve the surface finish and this needs to follow the sequence of machining operations to make the final part.
Modern casting processes can be automated to some extent but automation can be considered when production is medium to large.
Low in strength-
The parts made by the casting process have low strength when compared to machined parts or forged parts. This is due to the high porosity in parts made by the casting process.
The forged parts are more reliable and stronger than casting due to the better grain structure.
Cooling of casting is generally uniform from all directions, hence it generally doesn’t have directional properties.
These were the Advantages and Disadvantages of the casting process in a detailed manner. I hope you liked the way it was presented to you. If so, consider sharing with your friends and colleagues.
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Abhishek Tiwary is a blogger by passion and a Quality Engineer by profession. He has completed his B.Tech degree in the year of 2017. Now working in a reputed firm and He loves to share his knowledge with others.