Molding Process Selection / Indian Market Trends Opportunities

Weight Range in kg 0.01 0.25 0.50 3.00 10 50 200 500 1000 5000 >5000 Metallurgy
Moulding Process
Investment Casting
Lost Wax
Vacuumassisted Lost
Foam
Replicast (Wax/Foam)
(low carbon steel)
Full Mold Process
V-Process (Vacuum
Process)
Conventional Sand
Moulding
Green Sand moulding
Selection of Moulding Process based on Casting Weight
Remarks
All above
Low C Steel, SS, Al, Mg,
etc
CI, DI, Low C Steel, Mn
Steel, etc
25% savings in coreless and 40% savings castings with core.
25% savings in coreless and
40% savings castings with core.
CI, SGI,High C Steel, SS,
Ni-hard, Hi-Cr Steel, Al,
Cu, Mg etc
CI, SGI,High C Steel, SS,
Ni-hard, Hi-Cr Steel, Al,
Cu, Mg etc
All above
Most versatile moulding process, till quality and surface finish is not the main parameter, but loosing against above due to
environmental considerations and cost.
Very intricate castings, good surface finish. Economics doesn't work out for castings above 3 kg. Castings upto 50 kg can be
done if selling price permits. The casting order should be more than minimum 200 at a time or on regular intervals
Very intricate castings, good surface finish. Very good Economics for castings upto 80 kg. Castings upto 300 kg can be done if
selling price permits. The casting order should be more than minimum 200 at a time or on regular intervals
Very intricate castings, very good quality castings, cost should not be the major parameter.
Select above 4-5ton castings where less numbers of castings needed, and not viable to invest in tooling cost.
Good quality castings, major savings on sand cost and environment. The casting order should be on regular intervals.
Select above 200kg castings where less numbers of castings needed, and not viable to invest in tooling cost.
CI, SGI, Low C Steel, SS,
Ni-hard, Hi-Cr Steel, Al,
Cu, Mg etc
GDMTechnics LLP
Molding Process Selection / Indian Market Trends Opportunities
Process
0 50 100 150 200 250 300 350 400 450 500 550 600
Smooth Rough
Process
0 50 100 150 200 250 300 350 400 450 500 550 600
Least Accurate Most Accurate
A wide range of surface finishes are produced by the various casting methods. Green sand casting is expected to produce the worst surface finish. The V-process typically produces good, consistent results. Resin shell castings are similar in surface finish to sand castings with slightly
less variance, till the pattern is not damaged due-to regular stripping which need regular maintenance. The Lost Foam casting surface is comparable to V-process and the surface finish will be consistent throughout the tool life cycle.
The Lost Foam process will typically yield the best dimensional tolerances with resin shell a close second. Vprocess is comparable to Lost Foam but is subject to pattern wear. Sand castings are expected to yield the least accurate results of the various methods.
Dimensional Tolerance
RELATIVE SURFACE FINISH
Lost Foam
V-Process
Resin Shell Moulding
Sand Moulding
RMS Value
0.17 mm
0.2 mm
0.25 mm
0.76 mm
Dimensional Tolerances / mm
Resin Shell Moulding
Sand Moulding
Lost Foam
V-Process
GDMTechnics LLP
Molding Process Selection / Indian Market Trends Opportunities
Process
0 50 100 150 200 250 300 350 400 450 500 550 600
Porous Solid
V-Process
Resin Shell Moulding
Sand Moulding
Lost Foam
INTERNAL METAL SOUNDNESS
The Lost Foam processes has demonstrated the best internal metal soundness. The process has smooth metal flow characteristics resulting in less gas entrapment during pouring. The lack of cores or sand bonding media in the Lost Foam process eliminates gas absorption from the
mold during solidification. By contrast, the V-process, resin shell and sand processes use cores and bonding material that will contribute to porous metal conditions.
Internal Metal Soundness
SECTOR WISE CONSUMPTION OF CASTINGS AS %AGE OF TOTAL PRODUCTION
32.36%
8.11%
2.07%
4.80%
3.15% 3.16%
8.57%
2.75%
1.93%
7.77%
5.22%
0.55%
4.10%
6.65%
8.81%
0%
5%
10%
15%
20%
25%
30%
35%
Automobile Agriculture Earthmoving Pumps &
Compressors
Valves Diesel Engines Sanitary Electrical Eqp. Machine Tools Pipe & Fittings Railways Defence Power Gen Ind. Machinery Others
%
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GDMTechnics LLP
Molding Process Selection / Indian Market Trends Opportunities
Casting Trends in Auto Sector
India is the fourth largest producer of metal castings worldwide, and has increased its casting production by more than 100% since 2002. manufacturers with latest technology of equipments and raw materials will have a bright opportunity in India.
GDMTechnics LLP