Learn about Varioud Casting Groups and Associations

Casting

Casting has endured through the ages since the time of Ancient Egypt, possibly longer. Since then small foundries have developed to meet the needs of the individual caster. There are several reasons that people choose to create their own home grown foundries. A top reason is the need to create parts and pieces that are no longer available on the market or that are just too expensive to purchase. Those who get into Metal Casting for this reason are usually interested in restoration projects, home improvement projects, or hobby building like model planes and trains. Artists are the other group that see metal casting as a cheap and easy way to create sculptures from small to large. Jewelers even use metal casting to create complex pieces that would just otherwise be impossible to create.

Given the wide scope of metal casting there are several methods and techniques that have developed. For those new to metal casting or for those wanting to try some of these other methods may find it difficult to find information on your own. Luckily, there are several metal casting associations and groups that are more then willing to share information and exchange ideas, projects, and pictures of the goings on in the their home foundries.

On the internet, Casting associations and groups are either message boards full of casters where they can ask questions, post ideas, and pictures or are websites that are maintained by a set group of people offering general information and educational resources.

Both of these types of websites are incredibly helpful to metal casters who can benefit from the educational purposes of some of the sites tempered with the real life applications and experiences of the message boards.

The majority of the information that will be easy to find will be geared at industrial and manufacturing foundries versus the small home foundry. Industrial metal casting sites can be wonderful sources of information so do not skip by these. Use both small metal casting sites and industrial sites to your advantage.

One of the most popular message board type sites for information is the Casting Hobby Group found through Yahoo Groups. This casting group was developed and maintained by experienced metal casters and enjoys a high amount of activity. You will find lots of quick information here as well as tons of idea's, photo's and possible some plans on building various furnace types.

The Casting Hobby Group can be found at http://groups.yahoo.com/group/castinghobby/

The Association of Backyard Metal Casters is located at http://www.abymc.com/.  This online metal casting association has an extensive membership complete with informative articles, forums, and even live chat. Of course, pictures are posted on the site to give visitors ideas about what other furnaces and foundries look like. Don't worry if you're foundry isn't pretty, there actually doesn't seem to be very many of them that are.

Now, The American Foundry Society is mainly for the industrial metal casters and companies but they also promote information and education to consumers. The information provided on the site is great for anyone wishing to follow advancements in metal casting technology. There is even an online store.

http://www.afsinc.org/ is the online home for the American Foundry Society.

For the most part metal casting associations and groups exist on the local level more than a unifying force on the web. What does exist on the web is a great source of information, ideas, and insight. It is a great idea to join any of the groups you can in order to share and find knowledge.
 
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Bronze Metal and Bronze Casting Described

Metal Casting

Metal Casting has been practiced for centuries. Many civilizations have used this alloy for weapons, sculptures, and general pieces of hardware. The popular way to cast bronze is the Lost Wax Casting process which was first used sometime in the 3000 BC near ancient Sumeria. The Lost Wax process is still used to this day and its modern equivalent Investment Casting is very popular with jewelry makers.

Bronze is the preferred alloy for metal working artists as it's relatively easy to work with and resistant to corrosion. The properties of bronze tend to be stronger than most other alloys, except of course for steel, and lends itself easily to the molding and casting process. Many small foundries like the kind that can be found in a backyard or workshop find that bronze is a great material to work with and with a melting point of 1,700 Fahrenheit or about 925 Celsius many homemade furnaces are able to melt down the bronze quickly and efficiently.

Many modern day artists create their own furnaces with the metal casting in mind. These metal casters employ the Lost Wax Casting method which proves to be the best when dealing with the alloy. The Lost Wax Casting is making an original of the sculpture from wax and then creating a mold using this original. Often times the original is lost during the mold making process so keep that in mind if you want to hang on to the original for whatever reason. Molten wax is poured into the mold which is chased or smoothed of imperfections. During this point, any other pieces are attached and small wax tubes are placed into the piece. These tubes will be how the molten bronze is going to travel into the piece replacing wax with the alloy.  When this is complete the artist will create a ceramic shell around the wax model. The real benefit of the shell is that it will help form the melted bronze which will in turn help to melt the wax. When the molten bronze is poured the bronze takes place of the wax. Afterwards, the artist will crack the shell and reveal the bronze piece. This method allows the transfer of very exact detail from the wax to the bronze.

Some artists really enjoy addint Patina to the sculpture but its really to each his own. The Patina is a chemical that when applied to bronze creates colors and makes the bronze take an aged look. The Patrina compounds used depends on the type of color desired. Ferric Nitrate will make the bronze take on a red or brown color while Sulphurated Potash will make black and Cupric Nitrate will create blue and green. Modern day artists choose to go with a very high polished bronze instead of using these compounds. This step depends solely on the artist’s taste and the look they are going for.

Metal Casting will remain a popular medium until another alloy is developed that exhibits properties that are easier to manage and are more resistant to corrosion. Casting the alloy is easily done so metal casters that want to experiment are encouraged to do so. Making anything from small figurines, large sculptures, and even cabinet handles can be accomplished with the use of bronze. The only limitations in Metal Casting are with the caster himself.
 
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Brass Casting TIps

Casting

Brass is a great metal to cast with as it can provide some really great looking results.  Many believe that brass, an alloy of zinc and copper, has been around since our prehistoric ancestors. You will find brass today is a lot of musical instruments including trumpets and of course the penny's in your pocket are made of brass.

The low melting point makes brass a really great material for metal casting since even the smaller home grown furnaces can be used. By adding and subtracting alloys from bronze one can successfully make hard or soft bronzes. Aluminum and tin are sometimes added to bronze to create a layer that is not corrosive and very durable. People using these types of foundries at home will find that you don't have to be a scientist to find casting material as scrap will work just fine. Locating scrap pieces of brass should be sufficient enough for whatever project you have in mind. Due to brass' gleam and yellow shine, many artists will use the alloy for sculptures, jewelry, and other decorative items. Other metal casters may choose to use brass for general hardware needs or vintage car restoration, and of course, whatever else they may choose.

Generally there are three casting methods that prove to be suitable for Brass Casting . Its good that casters of metal branch out and try to cast with other alloys and other techniques.

Metal Casting casting is usually associated with bronze casting but can also be used for brass and for really any other metal. By using a wax model and covering it with a ceramic shell, artisans are able to inject the molten alloy which replaces the wax. When you start to chip away the shell, you will see that the brass piece is revealed. Lost wax casting is used when a high attention to detail is needed. Artists or metal casters looking to create decorative brass pieces or sculptures will find that the lost wax casting technique will meet their needs far better than other techniques and methods.

Die casting is yet another method used for Metal Casting . Die casting is normally used in commercial foundries since the initial start up cost is undesirable for the smaller home foundries. By using a reusable mold created from steel, the caster will be able to create scores of identical products. Die casting with brass should be used if the caster or artists is planning to make multiples of one product and can find a viable market for those pieces.

Sand casting is probably the oldest type of casting and is still a popular method especially for small foundries. The brass is poured into sand molds and can create a unique look which may be preferred for the artisans. Sand casting tends to be the most economically sensible for small foundries and if the casting does not have to be incredibly attractive then this method is preferable for many.

Whichever casting method is used for casting the brass really depends on the individual. Many find that casting brass to be fun and easy since it does melt rather easily. Brass casting is one of the best alloys to start casting with if you have little to no budget as it does not require a large furnace for this alloy to melt. Many have even been able to melt brass in small ceramic pots using charcoal!

Some ideas of what to make with brass include candle holders, plumbing fixtures, and even musical instruments
 
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Information on Casting Patterns and the Creation of Metal Casting Patterns

Metal Casting

A casting pattern is basically a shaped form of either metal or wood where sand is packed around it in the mold. When this pattern is removed, the resulting cavity would be exactly the shape of the pattern object that was to be cast. The casting pattern should however be designed in order to be easily removed without any damage done to the mold. The pattern should be also be perfectly dimensioned and should be very durable for the intended use. The patterns that are used in sand casting can be made of plastic, metal, wood or any other material. The casting patterns are made to the right standards of construction this is basically because they can last for a reasonable time. The quality of the grade in the casting pattern is really what determines the durability of the pattern for the long term. If the pattern is made of right quality then they would be constantly providing dimensionally perfect casting patterns.

The process: The process of making Metal Casting is actually called as pattern making which is in fact a skilled trade which is related to the trades of die and tool making and mold making. However this also sometimes incorporates the elements of fine wood making. The makers of casting patterns basically learn their pattern making skills through trade schools and apprenticeships over a number of years of experience. Engineers and Pattern Makers are the ones who carry out the design but really its the pattern maker who carries out this process more often than the engineer.

Design: The Casting Patterns incorporate proper allowances for the shrinkage and this process is called as contraction allowance. Their accurate values however depend on the alloys that are being used and the accurate sand casting methods that is used. There are a few alloys that have the overall linear shrinkage of nearly 2.5 percent as other alloys might actually experience 0 percent shrinkage or even a light positive shrinkage or it might also increase the size in the casting process. The amount of the shrinkage is also dependant on the sand casting process that is employed for instance chemical bonded sands, clay bonded sands or other bonding materials.

The casting patterns should also include proper allowance for the draft. This means that the sides would be tapered so that when it would be taken out from the sand it will not tend to drag out sand of place along with it. This process is also called as taper that is normally done in the range of one to three degrees. The foundry engineers or the pattern maker of the casting patterns actually decide where the gating systems, risers and the sprues are places in terms of casting patterns. In this pattern a hole is desired in the Metal Casting that uses a core which defines the location and volume of in the casting where the metal would not flow into. Chills are also used sometimes located on the casting patterns surface and these are then formed into sand molds. These casting patterns however continue to be a vital requirement for sand casting of metal.
 
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Information on Art Casting

Metal Casting

Art Casting is one form of excellence, put with diverse craft skills. It should be perfect and graceful at the same time. One should have unique craft skills which can produce a perfect art casting. There are several websites which can provide a person with information on art casting technique, their sculptors and the craft skills which are required to be a sculptor.

The websites that showcases the Art founders combines to provide advanced foundry techniques and similar superb craft skills. One can thus understand the sculptor’s needs and vision after viewing the art form. Previously, such sculptors were used in museums, galleries and exhibitions. Even today, at large the sculptors are used in public places, galleries and such art casting are made out of modern equipments and casting techniques.

Types of art casting: There are many types and kinds of art casting. Wax art casting, sand art casting, lost wax casting and many more. These websites that offer a client the art casting images and its services, offers concept design, Marquette works and enlargement of certain sculptors. The creative department has created new work for their clients and have provided enlargement of the miniature sculptures.

Typically, an assignment would begin with the concept stage and wherein the creative department makes drawings for approval. After this, a Marquette is done and the scaling procedure is done to work up the required size and alignment of the sculpture. Such work undertaken is done under one roof with involvement of clients who accompany in decision making of the design, creating stage and also through out the casting and finishing of the sculpture. Some of these websites are full service in the fact that they help their customers will complete installation and a delivery of the sculpture to anywhere in the world.

Lost Wax process: Most of the art casting of lost wax is processed by use of lost wax ceramic method of casting. This can make it a possibility of reproduction of maximum detail from original concept. Such facilities can make the sculptors to keep the original core in mold and allow the production of the largest wax in the country. A perfect cast is very much demanded by the clients. Smaller works like the abstract works, animal figures and many more are designed on such department. These wax shops are bright with daylight bulb.

Sand casting art form: The Art Casting shops which focus on making sand sculptures use sand pieces and they make sure that there are deep undercuts on the making process. The team which undertakes the process are experienced and they strive to create some of the magnificent works that ranges from life size horses to full sized boats and such letter signs. A lot of the works with right to sand casting provide great dimensional stability and less reduction of metal.

Strengths of the art casting work shops: One of the key strength of the Metal Casting shop is the depth of skill set and experience in the department. The Bronze one's are collected and finished by master craftsmen. The final touch to the sculpture is of coloring it and patination of the work which is important part of the whole art casting process. These workshops provide lots of patinas and colors which a client may require right from traditional browns and green to blue, white, black and red color.
  
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DIY Casting Information

Metal Casting

People who like to make their own artifacts and are enchanted with the idea of building new and useful things from scratch are sure to enjoy ‘do it yourself casting’ that can be done at home using simple methods and techniques. A Metal Foundry is just the start of your home made process of creating and designing casting materials. A good understanding of some basic foundry knowledge and few simple tools can help you make metal casting at home possible. Many people find it difficult to get special parts for their cars or bikes or even find it very costly to modify their cars, house or even bikes. If you develop your hobby of Metal Casting , then you can easily make special parts for your cars and bikes and also will find it easy and save a lot of money. Casting can be used to make many things like, simple ornaments knobs and even handles. Hand wheels and small machinery or tools can also be made. Small articles like brass name plates, statues, vintage motorcycle and car parts, etc can also be made at home.

Furnace Designs that can be made at home:

Coffee Can Casting Furnace : This is very easy to build and even a large coffee-can will serve the purpose. This can be used to build a simple gas fired furnace.

The “2 bucks” furnace: Is not as the name suggests, the furnace can’t be built in two bucks.This is really a two bucket design that we are referring to. It is very useful and a good experienced person can build it with a budget that is below 10 bucks. What you are getting here is that it effectively burns propane which is a plus.

Flowerpot crucible furnace: This furnace can also be built very easily and most importantly, it can be built using the waste material from your back yard. All you need is an old flower pot and a few metal cans. Melt the metal cans and coat the inside of the flower pot with the melted metal and you furnace is ready.

Brick Furnaces, Chimney Pipe Furnaces, Dirt and Brick Furnaces and Breaking Metal in Barbecue are just a few other type of furnaces that can be build at home.

Tools and material needed:

Home made Aluminum pulleys: Pulleys of different size and shapes can be made by bending aluminum rods or plates. Really, once you make a few of these you will realize how simple and easy they are and it may even become fun.

Building steel crucibles: Steel crucibles are a bit difficult to make. You need to cut the steel and weld it using a welder, so it is a bit risky job and can cause injuries. It needs to be done with utmost care and precaution.

Home made ladle: A ladle can be made at home using a small portion of a steel water pipe; you can select the water pipe according to your needs and then cut it in the desired dimensions to create your home made ladle.

After doing all this basic work and gathering all the required information, you can now start your own Metal Casting and make desired articles. You need t be thinking about the shape and size of the materials you want to make so you can move forward in the process of making molds. All types of metals and alloys can be used and melted for home casting, only their degree of heat required varies.

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Learn about Cupola Casting and the process of Cupola Casting

Metal Casting

A Cupola is a type of furnace that is very much alike to blast furnace. The Cupola furnace is refractory lined, stack of steel that is around 20 to 35 feet high. It rests on a base plate that is made of cast iron and has four legs. The casting that is obtained from the cupola furnace is known as a cupola casting.

Cupola Furnace: The Cupola Casting furnace is one of the oldest forms of furnace that have been used by the iron and metal foundries. The Cupola furnace is well known throughout the casting industry as it is the simplest and easiest furnace to make and utilize. However, the cupola’s use is declining and the furnace is fast being extinct.

Merits of the Cupola Casting Furnace: Though the electric or the blast furnace has started replacing the Cupola Furnace, it has some special benefits of its own. Whats nice about the Cupola furnace is that is usually can be running continuously. The furnace also offers a very high melting rate. The most important merit of the furnace is that it has relatively very low melting cost. The furnace has also permits a lot of ease of operation.

However, due to the invention and development of the electric furnace, the use of Cupola furnaces has substantially declined. The electric furnace melts a much larger amount of metal. The operation cost of the electric furnace is also very low. The electric furnace also emits a much smaller level of smoke heat and also pollutants.

Construction of the Cupola furnace: The Cupola furnace is constructed in a crude and simple manner. The Cupola Metal Casting furnace is a vertical structure like a steel shell. The steel is lined with refractory bricks from the inside. The furnace has an opening half way in the vertical shaft. The charge is introduced through the opening. The charge is divided into different layers. This is the place where the metal is contained that is inline to be melted. The metal is mixed with coke, fuel, and lime stone flux. The fuel is burnt directly into the air and is introduced in to the furnace through the tuyeres which are positioned above the hearth. The hot gases that have been produced ascend and pre heat the charge.

The cupolas in majority of the cases have drop down doors. The bottoms can be dropped down to facilitate the cleaning and the repairs. At bottom in front of the furnace is a tap hole. The molten metal is removed from the tap hole. Sometimes at the botton or rear there is another hole for slag to escape. A fume arrester or what is known as a spark is on top of the stag.

Usually the cupola has a diameter of 405 to 2000 mm. It is operated on varying fuels for different metal ratios. The molten metal that can be produced in the copula of this size at a speed of 1 to 30 tones per hour.

Its once the process of melting has finished when the charging is halted and this is called continuity of process. However, the blast of hot air is always maintained till all the metal has been melted and has been taken out from the tap hole. After a period of time and the air cools down, there are doors at the bottom that are then opened so the residue can be removed that has been left behind.           

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Learn about Resin Casting

Metal Casting

Resin Casting is a system of technical installation that is used in the process of casting resin. The process of Resin Casting is a complex process that is used in a variety of fields. The resin casting giver a high quality and precision to the product that is casted.

Need for Resin Metal Casting : Resin casting is used to obtain a high level of quality and also precision in the dimensions of the product. Resin casting is basically used in the process of miniaturization i.e. the process of making things small. The process of Resin Casting is also used extensively the field of electronics. The electronics industries today resort to the resin castings to achieve the norms of total quality management.

The process of resin metal casting earned success and also gained popularity in the field of electronics because it facilitated the acute miniaturization process and also at the same time maintained a high level of quality. The electronics industry is a very demanding field in terms of quality and cost. Experts recommend that the process of resin casting is an ideal way to achieve the required quality and it also helps cut down the cost of production. The process is also highly productive and also reliable with respect to speed.          

Industrial Applications of Resin Casting: The process of resin casting is basically used in the electronics industry. Resin Casting is used in the production of transformers, Liquid Crystals Displays more commonly known as the LCD’s. It also used in the manufacture of heavy electronic systems.

Important steps in Resin Metal Casting : The process of resin casting is completed in basically five important steps. The first step is to condition the resin, and then the material is transported. After the transportation of the material the three most important steps are executed. First the material is metered, then the material is mixed and then finally it is dispensed.

Conditioning process: The process of conditioning in the resin casting evenly distributes the fillers ion the mixture. The conditioning also eliminates the moisture and air. It also makes the mixture constant, and also elevates the temperature of the mixture. The process of conditioning also maintains a low viscosity in the mixture. This process is very important for complex combinations as it intensifies the quality of the product.

Process of Material Transportation: In the process of transportation of the materials, the piston pumps, screw pumps, and the gear pumps are used. For the highly viscous substances, instead of gear pumps, follower plate pumps are used.

Mixing Process: This process is very important as it is mean to be used to obtain an equal and stabilized reaction through all the materials. The most commonly used methods in the mixing are the static mixing tube, the dynamic blender, and the dynamic static mixing tube.

Dispensing process: The process of dispensing is the most important process in the Resin Metal Casting . The dispensing Unit and the movement of the part are actually relative to one another in the dispensing process.

Resin is casted through various dispensing processes like the metering systems, or sometimes the dispensing is done in a vacuum. In the industrial to cut costs and also time multiple dispensing units are used.          

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Learn about the basics of Casting Sand

Metal Casting

Green Sand: Green sand is also called as foundry sand or molding sand. This is utilized for sand Casting . When this sand is oiled or moistened, it has a tendency to pack well and retain the shape. Green Sand is made up of three things: Pulverized Coal, Water, and Bentonite Clay and Sand. Out of these four components, the biggest part is that of the sand.  There are several proportions of these four components. The different ratios are used to adjust the surface finish, moldability and capacity of the hot molten metal to degas. The prime use of this sand is in the Casting . The coal is usually called as sea coal in foundries. The amount of sea coal is less than 5 percent. It undergoes partial combustion when there is molten metal present and this causes offgassing of organic vapors.

Green sand is stored in flasks (as the casters call the container). These are boxes that do not have a bottom or lid. This box is divided into two half parts and these are connected together. These halves are called as the top or cope and bottom or drag flask.

As per its name, green sand is not green in color. The word “green” is used as it is used in the wet state.

Casting Sand: Some Casting sands are oil bonded and foundry mix sand. This is a mixing of oil, resin and sharp fine silica sand. Such a mix can be utilized in sand casting of all varieties of metals. Some casting sands consist of 20 percent more oil and resin as compared to other brands. The objective is to ascertain the best mix for maximum green power and the best finish for the surface, that is possible.

The oil bonded sand is a substitute for water bonded green sands to be used for casting sand. The advantage over traditional, older sands is that as water is absent, the sand does not steam like the traditional sands. What is good about this sand is that it is more secure than green sand. The reason is that potentially explosive quantities of steam are not generated. Due to this dearth of steam generation and the smooth texture of the sand, the oil bonded sand results in a smoother surface finish. The novice can use these sands and get professional results.

Use of casting sand: The same techniques, patterns and tools that are used for water bonded sands can be used for oil bonded casting sands. As the sand has better adhesive properties, there are fewer hassles with loose sand in the impression. The difference is that water cannot be used to manage loose sections. However, as the self adhesion is better, there are fewer problems of crumbling.

When the oil comes in contact with molten metal, it does not burn. When the castings are being shaken out, it is advisable to take off the sand that is burned. This sand that is burned can then be mixed again in the pile of fresh sand. It reabsorbs oil and works very well. After repeated use of this sand, the oil gets depleted. In this case, around 30W of non-detergent motor oil can be used to reload the sand with oil.

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The definition of Metal Casting Crucibles

Metal Casting

A pot in which metal is held, while melting in a furnace is called as a “Crucible.” It is made of silicon carbide and clay graphite.

Shapes of crucibles: A bilge shaped crucible has the shape of a barrel. The part of the crucible in the middle region is called as a bilge. This is the widest part of the crucible and has the maximum diameter. The top of the Casting crucible has lesser diameter than the bilge. The base of the crucible has lesser diameter than the top. As per a thumb rule, the # of a bilge crucible is the number of pounds of aluminum that it would hold. For bronze and brass, thrice the # can be held. For instance, a #5 bilge crucible can hold almost 5 pounds of aluminum and 15 pounds of brass. This thumb rule is applicable for bilge shape only.

An “A” shaped crucible has a narrow bottom and a wider top. There are straight sides that are bent outwards. The diameter continuously increases from the base to the top. As it is simpler to manufacture this shape than the bilge one, the A shaped crucible has a lesser cost. When compared with the equivalent bilge style, the capacity of the A shaped crucible is lesser.

Both the above mentioned shapes can be manufactured in Clay graphite and silicon carbide.

Properties of crucibles: A crucible must be able to bear the extremely high temperatures of the molten metal. For this, the melting point of the material used to create the crucible must be more than the melting point of the metal that in placed in the crucible. Also, the crucible material must have excellent strength even in the white hot state.

For melting metals like aluminum and zinc, a steel crucible made at home can be used. The reason is that the melting point of aluminum and steel is lesser than steel. In this case, the interior surface of the steel Casting crucible undergoes flaking or scaling. Due to this scale, the molten metal is polluted. The thickness of the crucible walls decreases fast. Hence, a coating of marcote-7 is applied to the inner surface of the steel crucible. The use of steel crucibles is okay if the contamination due to the scales is not regarded serious.

Materials used: To construct a Metal Casting crucible, the usual refractory materials (i.e. carbon bonded silicon carbide and clay graphite) can survive the extremely high temperatures of work of a foundry. In addition, silicon carbide is a very durable material.

Some of the clay graphite crucibles can be used up to 2750 degrees Fahrenheit. Some A shaped crucibles are used up to 2000 degrees Fahrenheit. These crucibles can be used to handle gold, silver, bronze, brass, aluminum and zinc alloys.

The A shaped crucibles have a rough surface finish and there are dents along the rims. However, this roughness does not interfere with the performance by any means.

It is important that when you handle crucibles you need to use tongs that are correctly fitted. In correct tongs can lead to damage or total failure of the crucible. When you look at the base of the furnace and crucible, its very important that there is a disk of cardboard or some other coating that is between.

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Metal Casting Associations and Metal Casting Groups

Metal Casting

Metal Casting is one of the most widely used processes that is used in the production and process industry. In the metal industry the process of Casting is the basic and he most essential step in the process of production. At the dawn of the industrial revolution, casting was a very crude process that had not undergone development.

Need for associations and institutes: Though the process of Casting is an important step in  production, it remained underdeveloped for a very long period of time. The basic need for the formation of metal casting related associations was to develop the process of casting. Whats important is that these various metal casting associations are working together so they can share ideas and improve the mteal casting process. Associations and the groups that have been formed by the companies are constantly experimenting with the proposed reforms in the casting process. Many of them have also come up with sound technical rectifications and an amazing number of proposals.

Aims and Objective of Metal Casting Associations and groups: The basic objective of all the Meat casting Groups and associations that have been working for a few decades remains unchanged. The associations strive to develop the process of casting to the pinnacle. The global market has become demanding and competitive than ever. The associations helps the member companies in maximizing their quality standards. These associations also work for the spread of appropriate technology. Many innovations and inventions are proposed and executed for the technological benefit of the member companies. This kind if technical support helps the company to cut the cost of production. It also helps the companies to increase the quality and also ht performance of their production units.
                       
Work against pollution: Metal Casting companies are often pressurized and also accused of polluting the environment. Many of the associations provide technical knowledge to the companies about the disposal of pollutants. A lot of times, companies work together in their respective area's to dispose of waste at the same location. Many of the associations have set up their own norms for the member companies.

Man power safety: Some of the associations also keep a tab on the safety of the workers. A metal casting industry is a very dangerous place to work in. the associations hence have prescribed many safety norms to the member companies.

The norms regarding safety of the environment and the safety of the workers if not followed always invite trouble from the government. If the safety norms of the associations are followed then the intervention of the government reduces considerably.

Spread of Knowledge: To make the people in the industry aware of the ongoing commercial development and technical research the associations arrange international expos and also many exhibitions. The associations also represent their member companies in many seminars organized on the international level.

Commercial Aspects: The metal casting associations work as exchange houses for commercial meetings. Many associations give sound financial information and also explains the market conditions to the member companies.

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Learn about the basics of Metal Casting Tools

Metal Casting

There are various types of Metal Casting tools. Provided below are details of some of the casting tools.

Esmarch plaster scissors: These are German stainless steel cast scissors of high quality. The entire length is 20 centimeters or 8 inches. There is a 6 centimeters slanted blade for safety of the patient. The handle for leverage is of 15 centimeters. This is perfect to cut the inner layers of synthetic cast materials or plaster.

Good stainless steel scissors are really what you want for casting and the best ones are Lister Bandage Scissors. The size of the blade is 5.5 centimeters. It resists rust and corrosion. This scissors are perfect to remove QuickCast splints and casts.

Cast scissors for serial finger casts: These are manufactured from German stainless steel of highest quality. Nine Centimeters ends up being tht total length. There is a 1.3 centimeters slant design on the cutting surface. During cast removal, there is good patient safety and the scissors offer excellent force.

Metal Casting spreader: This has a stainless steel construction. There is a spring loaded handle to facilitate use.

Metal Casting breaker: The length of the cast breaker is seven inches. This is an O.R. quality German instrument. This is used for lightweight cast breaking and trimming. This has deep serrated tips and is free of latex. The cast breaker is available in sizes of 9.5 inches also.

Plaster and Utility shears: The length of this instrument is 8 inches. This is a German instrument of O.R. quality. There is a spring loaded handle design that decreases the hand fatigue. This is very efficient in case of cotton or cloth wadding. It is free of latex.

Wire suture scissors: This is a stainless steel scissors of high quality. This is a perfect device to remove finger serial casts and to make tight corner cuts.

Fiskars all purpose snips: This instrument has a positive safety latch, a stainless steel spring and a comfort grip. The design is such that there is maximum power and handling ease. The stainless steel blades of high quality are used to cut a wide range of materials. Low temperature thermoplastics can be cut at room temperature by this device.

Aviation snips: These snips are of industry quality. Non-heated splinting material can be cut with efficiency. It can be used to cut straight lines as well as wide curves. The handles are coated with plastic to increase the comfort. This device can be used in the left hand as well as right hand.

Softouch spring action scissors: Those who have weak hands can also operate these by employing half the effort. There is a gray cushion grip. This is used to provide relief to the finger and thumb discomfort. It also absorbs squeezing pressure. The handle can be easily gripped and used in the left hand or right hand. There is a gentle spring action to open blades at the end of each cut. This offers relief to the hand and joints. There is a large slide lock for single handed operation. This also maintains the blades closed for portability and safe storage. It is free of latex.

Cast stand: The height can be adjusted. This comprises of a drip bucket. While the limb is being casted, it provides support to the arm or leg of the patient.

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Iron Casting: How does Iron Casting Work?

Metal Casting

Iron Metal Casting can be referred to as products made out of melted iron molecules. These molecules are, first, poured into mold and allowed to cool. They are then extracted. The casting properties depend a great deal on the foundry practice. They also depend on the cooling rate. Iron contains huge carbon concentrations. This content facilitates melting, simplicity of casting, and machining. Iron casting designs have a great variation owing to the property of iron to resist shrinkage during the process of cooling. The end product attains a great reputation for its strength and durability. Tensile strength ranges between 20,000 psi and over 60,000 psi. The values of hardness (without heat treatment) range between 100 and 300 BHN.

Some factors need to be considered while buying iron Metal Casting . On the long list of things to check, the quality of the foundry that is to be used in products and procedures should be at the top of the list. This should be done because foundry practices determine the casting properties. The consumer might have a tough time in finding the apt one. Secondly, the concentration of carbon should be looked into. The percentage of carbon commonly ranges between 2.5 and 4%. An addition of even 0.Even the small amount of 1% would cause the strength to decrease by the large number of 2700 psi. Every foundry has different ways of doing things which means their casting procedures will be different from each other.

Green sand molding is the most commonly used type of Casting . Normally, small and medium sized products are produced using this type of casting. Shell molding is preferred for bigger applications. Shell molding is great in the fact that its really good for helping with the cooling of the heated metal in the mold. This process gives a better finishing to the final product as compared to all the other processes. Centrifugal casting is used for producing big cylinders and pipes. Both, producer and consumer would get highly satisfied if a proper blend of correct casting process and reputed foundry is made.

Iron castings are utilized extensively in machinery, automotive, and agricultural industry. Parts such as turbine and pump housings, dynamometer bases, compressors are made out of iron castings. Majority of manufacturers have the caliber to go for high and low production outputs. They are also entitled to go for short order runs. There are standard prototypes ensuring customer satisfaction and accuracy. Some manufacturers provide finishing services like galvanizing, painting, and machining as well. In general, iron castings include alloy casting, ductile castings, and malleable castings. There are some terms relating to iron castings. They need to be known in order to get a fair idea of iron.

Brinell Hardness Number (BHN): It can be defined as the method used for measuring the hardness of iron. For iron castings, a metal ball of 3000Kg is put on a flat iron piece. After the removal of ball, indentation observed is recorded. This measurement indicates the value of hardness.

Tensile Strength: Tensile strength can be defined as the quantity of bending and stretching undergone by a material before tearing or breaking. Here the metal is iron.

Modulus of Elasticity: It can be defined as the ratio of stress to strain. This value determines the elasticity as well as the stiffness of the concerned material.

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Aluminum Casting and the Types of Aluminum Casting

Metal Casting

Aluminum is amongst those metals which can be ‘cast’ by every process used in metal casting. These processes, in descending order of quantity of aluminum  casting are: die casting, permanent mold Casting , sand casting, plaster casting, investment casting, and continuous casting. The Metal Casting process is selected on the basis of factors such as cost, feasibility, quality, etc.

Feasibility is not a problem, as all the above methods are quite practicable. However, the most suitable casting method can be decided according to the design features or dimensions.  For instance-Large products are made using sand casting. The quality factor is also important in selecting the casting process. Quality refers to both, mechanical properties (ductility and strength) and soundness (surface imperfections, cracking, and porosity freedom).

The methods most commonly used can be described as follows:

Die Metal Casting : As per the statistics, around $2.5m worth of die-castings of aluminum  alloys are produced in the US alone every year. The process of die casting utilizes almost two times the tonnage of aluminum  alloys as the combination of other casting processes. Die casting is best suited for large quantity production of relatively tiny parts. Aluminum die castings upto 50 Kg of weight can be produced if casting-machine costs and high tooling are justified.

Some common applications of die cast aluminum  alloys are inclusive of alloy 380.0 for Lawnmower housings, Alloy A380.0 for streetlamps housings, dental equipment, typewriter frames, Alloy 360.0 for frying skillets, instrument cases, cover plates, parts needing corrosion resistance, Alloy 413.0 for outboard parts of motor like connecting rods, pistons, housing, and Alloy 518.1 for conveyor components, escalator parts, aircraft, marine hardware.

Die castings cannot be easily heated or welded due to entrapped gases. Efforts are being on the war footing to overcome this obstacle. The die castings of aluminum  alloys are generally produced using aluminum -silicon-copper alloys. This alloy family gives an excellent combination of corrosion resistance, strength, and cost, along with respite from ‘hot shortness’ and high fluidity which are mandatory for easy casting. If one desires a better resistance to corrosion, he should make use of alloys having a lower copper content.

‘Permanent Mold’ casting: ‘Permanent mold’ casting is best suited for high-volume production. Their size is larger than ‘die castings’. These castings have a very low pouring rate. They are gravity-fed. Outstanding mechanical properties are exhibited by ‘permanent mold’ castings. There is a lot of scope for further improvement if they are given heat treatment.

Alloy 366 is one of the most widely used allows of aluminum permanent mold casting.0 for automotive pistons, Alloys 355.0, A357.0, C355.0  for impellers, timing gears, compressors, missile and aircraft components, Alloys A356.0, 356.0 for aircraft wheels, parts of machine tools, pump parts, valve bodies, marine hardware, and 296.0, 333.0, 319.0.

Sand casting: This type of casting involves formation of casting mold (with sand). It is inclusive of conservative sand casting & lost-foam casting. The first one involves forming a pattern of sand, pouring the molten metal into it and breaking it once the product is formed. Lost-foam pattern involves putting a dispensable pattern of polystyrene in the mold. The rest of the procedure is the same as conservative sand casting.

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Die Casting Process, Cold Chamber Process, Hot Chamber Process

Metal Casting

Die casting is the method used for forcing molten metal into mold cavities under high pressure. Casting is very versatile and hence, is the widest used method for casting a metal. Die casting is same as permanent mold casting the only difference is that the metal is injected into the mould at very high pressure of 10-210 Mpa. This results in a more uniform part, usually good dimensional accuracy and also good surface finish.

The different metals and alloys that can be used in die casting are zinc, aluminum, copper, magnesium, tin and lead. Ferrous metals can also be used for die casting, die casting method is generally used for applications in which a large quantity is medium or small sized parts are required with detail, good dimension and fine surface finish.

There are namely two equipments used for die casting cold chamber and hot chamber process.

Lets take a look at the cold Chamber Process because within the cold chamber process, you get to fill a cold chamger of each module with molten metal. The time exposure provided for the molten metal to plunge the walls of the mold is less. This clod chamber process method is very useful for metals like aluminum, copper and metals that easily alloy with iron at high temperatures.

Hot Chamber process: In the hot chamber process method of Metal Casting , the pressure that is connected to the die cavity is forever and permanently in molten metal. As the plunger moves towards the open position that is towards the non - pressurized area, the inlet port connected to the pressurizing cylinder is uncovered.

The die casting molds which are used in this method are expensive and take usually take long production time. These die casting modules are also called as “dies’

Advantages of Die Casting: The method of die casting gives excellent dimensional accuracy. The dimensional accuracy is as good as 0.1mm for the first 2.5cms and 0.005 for the first inch. The thing about Die Casting is that is can also provide very smooth cast surfaces. Small and thin walls and can be made using the method of die casting walls as tiny as 0.75mm approximately can be casted. Inserts like thread insert, high strength bearing surfaces and heating elements can also be inserted using the Die Casting method. Casting also helps in reducing or even completely eliminating the use of secondary machining operations. The use of Die Casting method also helps to reduce the production time and a huge number of articles can be produced in a very short time. Die casting method also helps to retain as well as increase the tensile strength of the metal. You can get great strength that is about as high as 415 MPa and that is about 60ksi.
 
Disadvantages of Die Casting: The casting weight is very less hardly between 30 grams and 10 kgs. Also the size of the material that needs to be casted using the Die Casting method needs to small say around 600mm. the high initial cost of Die Casting sometimes has people shying away because there is such a large investment to get started. Die Casting method makes the metal porous up to some extent. In the Die Casting method the thickest section needs to be less than 13mm or 0.5 inches.

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CRT Monitors

A CRT Monitor is one of the most common types of computer monitors used today. The other most common monitor being the more recent invent, the LCD monitor. But what are the differences between the two models? How can you be sure that a CRT monitor is right for you? The main step is understanding the difference and the benefits of each type.

 

What is a CRT?

 

CRT is an abbreviation of cathode-ray tube. A CRT works by moving an electron beam back and forth across the back of the screen. Each time the beam makes a pass, it lights the phosphor dots on the inside of the glass tube. This illuminates the active portions of the screen, and by drawing many of these lines from the top to bottom of the screen, it creates the image or images you see on your computer screen.

 

Comparing CRT and LCD

 

Size-wise, the CRT monitor is much larger than the newer LCDs that are more compacted and lightweight. Due to the presence of the cathode-ray tube unit inside, adequate desk space must be allowed for CRT monitor that offers an added advantage of a larger viewing display size. LCDs, however, are becoming increasingly comparable in size to CRT monitors.

 

Many CRT monitors are able to display unlimited colors as well as multiple video resolutions. Both of these factors give CRT a leg up on LCD monitors that are limited in color capability and resolution. The CRT monitors can display multiple resolutions at the same quality while LCDs are limited to what is known as a Native resolution (the best display resolution).

 

CRT monitors generally do not have an issue with brightness due to the construction of the unit itself. The CRT also has the benefit of being able to be viewed from a very wide angle and from just about ever side.

 

While CRT monitors are generally cheaper than their LCD counterparts, the long-term costs of the CRT over the LCD are higher. CRTs consume much more energy than LCD monitors.

 

CRT Monitors in the Workplace

 

While LCDs have decreased in prices over the years, CRT monitors still have their fans in industry. The printing and broadcasting industry as well as other graphic fields (where higher resolution and viewing capabilities are needed) still use, almost exclusively, CRT monitors. Professional video and photography businesses are also still using CRTs because of the better color and contrast abilities.

 

Finding CRT Monitors

 

Deciding what type of monitor you purchase depends on your individual needs. Many major manufacturers of CRT monitors have discontinued or plan to discontinue production of these monitors. So, if you wish to purchase a CRT model, you may find yourself having to search harder than originally hoped.  However, be diligent, even with the newer models of LCD monitors becoming available with new capabilities, CRT monitors still have them beat in many important areas.

DIY Gravity Casting and How to Gravity Cast

Metal Casting

Research and development in Metal Casting has taken an important step in making metal products a part of our day to day lives. The products used in homes, aircrafts, artifacts, automobiles have become more durable and less expensive. Cast alloy parts are formed by melting the alloy and then pouring it in a mold under heavy pressure or vacuum. Casting is also known as vacuum casting. It is a technique in which large diameter filaments are used with adequate separation. This ensures that no clusters are formed and also good metal wetting of the fiber is guaranteed. This technique was first used in 1970. The gravity casting method has advantages like cost effective, good quality, and process control over other casting techniques.

Gravity casting is done in ceramic molds, sand, permanent casting and also in investment or lost wax casting. The Metal Casting process was started with common steel after successful implementation it was further tried on heat resistance super alloys. With recent development and with more refined methods today even titanium alloys are being cast using the gravity casting method and using ceramic crucibles. The use of desired mold designs and also specially made unique designs enable a reduction in the metal cast to yield the given part. This also helps in reducing the amount of energy that is used in making such casting articles.

With new developments, today even computerized control of the vacuum pressure and rate is possible. The rate of fill can now be controlled by the user because of this. This makes casting of high quality metals like and viscous metals like metal matrix and composites of aluminum casting possible. This gravity casting method is used to produce casting worth of more than $200 million. The industry is expected to grow rapidly in the coming years due to the increase in production of automotive exhaust manifolds in stainless steel.

Howmet Industries was the first company to use this technology commercially. This technology was used when one would want to design turbine blades for aircrafts because they had to be precisly made. This technology is also being used by Ford Motors to develop and improve the casting process of light truck and automobile engine blocks.

Today, metal parts fabricated using gravity casting method is being used in 90 per – cent of all durable goods. Goods like stoves, washing machine, automobiles, refrigerators, lawn mowers, cars and even boats. Many other articles like badminton rackets, tennis rackets, and even football studs are made by using light weight metals which are gravity casting method. This gravity casting method has been used to develop metal alloy parts, which are used for the auto and airline industries, which is said to make vehicles lighter though much stronger and extremely efficient.

Casting grade iron and casting grade steel are some of the typical metals that may be used when one is gravity casting. Also die cast grade zinc can be cast using gravity casting method. Also other raw materials like sand, spin or plaster are used. Aluminum is also used, but it is very difficult to gravity cast aluminum a lot of care needs to be taken and proper pressure should be applied to obtain the desired shape and effect. 

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Learn about Spin Casting, Sand Casting, and other Metal Casting Processes

Metal Casting

There are various casting processes being implemented now days. The oldest amongst them is sand casting. Metal Casting is also widely used. They can be described as follows:

Sand Casting: Metal Casting involves formation of mold from a mixture of sand and to pour a casting liquid, most probably, a molten metal into mold. Then, you wait a while and let the metal harden up so then you can remove the mold. The Green Sand Method and the Air Set Method are the two types of Sand Casting that make up Sand Molding. The first one consists of mixture of clay, moisture, silica, and many other additives. The second one consists of mixture of dry sand and other materials, not moist clay. They are mixed with the help of a quick curing adhesive. The collective use of these materials is called ‘air set’.

At times, there is temporary plug placed to pour the fluid which is to be molded. Air-set molds usually form molds consisting of two parts-the bottom and the top. After the mix of sand gets added, it also gets tamped down. It does not generate any by-product. After the solidification and cooling of metal, the mold gets usually destroyed. This is because its removal involves a lot of breaking and cracking. The casting accuracy depends a great deal on the sand and the process of molding used. Castings composed of green sand result into formation of rough texture on casting surface, and this characteristic makes them easily recognizable. In reality, studies show that molds that are air-set produce the smoothest castings.

Many a times, the casting process results in losing of components of sand mixture. It is possible to reuse green sand by the way of adjusting the composition to get the lost additives and moisture replenished. The entire pattern itself is eligible to be reused for producing novel sand molds. The method of reuse can be continued for an indefinite period. In 1950, casting process got automated partially. They have been in great demand for developing production lines since then. 

Spin Casting: Sand Casting is better known as Centrifugal Rubber Mold Casting (CRMC). It implies utilization of centrifugal force for producing castings out of rubber mold. As a customary practice, a mold having shape of a disc gets spun through its ‘central axis’ at a pre-decided speed. The material used for casting is usually thermoset plastic in the liquid form or a molten metal. It gets poured into the mold through the opening at its centre. Corresponding to the solidification of metal, or the setting of thermoset plastic, the spinning of the filled mold takes place.

Normally, organic rubber or vulcanized silicone is used as a mold-making substrate in spin casting. Vulcanization takes place in the middle of process of mold-making. After the successful completion of vulcanization process, venting and gating must be undergone by the mold. This implies carving of channels for ensuring proper material flow and air during the course of casting. Your best bet for preforming the proccessed is to either use a scalpel or knife. The mold complexity is directly proportional to the time required in implementation of venting and gating.  

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We can learn about G-Code in an example

cnc programming

Next, we are going to go through an example of cutting out a 2” square with a CNC Plasma.  Then we will look at the G-Code to see what is happening.

2” Square G-Code:
The numbers on the left of the G-Code are the sequence numbers of the code and the order it will be executed in.  I have added notes after different actions to let you know what that line of code means.  My note starts with a “-“ then continues.  A “-“ means nothing in gcode.

N0000 (Filename: 2INSquare.txt) – Name of File
N0010 (Post processor: Plasma.post) – Name of Post Processor Used
N0020 (Date: 8/1/2007) - Date G-Code was generated
N0030 G20 (Units: Inches) – Measurement Units Used
N0040 G53 - Machine co-ordinate system
N0050 G90 – Absolute Programming
N0060 G40 – Tool radius compensation off
N0070 F1 – Feedrate of 1” per min
N0090 (Part: Square) – name of the part
N0100 (Process: Plasma,  DEFAULT, Plasma, 0.01 in kerf) – Tool to be used
N0110 G00 – Go to Home
N0120 X0.1113 Y-0.0904 – Move to this exact X, Y position
N0130 G04 P2000 – Pause for 2 seconds, this is in milliseconds
N0140 M03 – Fire the plasma torch
N0150 G04 P500 - Pause for .5 seconds, this is in milliseconds
N0160 G03 X0.0000 Y-0.0050 I-0.1113 J-0.0298 F40.0 – move to this X, Y position in an arcing movement at a feedrate of 40 inches per min
N0180 G01 Y2.0000 – Travel in the Y+ direction for 2 inches to X0, Y2
N0200 G01 X2.0000 – Travel in the X+ direction for 2 inches to X2, Y2
N0220 G01 Y0.0000 – Travel in the Y- direction for 2 inches to X2, Y0
N0240 G01 X0.0000 – Travel in the X- direction for 2 inches to X0, Y0
N0250 G03 X-0.1113 Y-0.0904 I0.0000 J-0.1152 – move to this X, Y position in an arcing movement
N0260 M05 – Turn off the plasma torch
N0270 G04 P2000 – Pause for 2 seconds, this is in milliseconds
N0280 G00 – Move to Home
N0300 M30 – End Program

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Why would I ever want to know about G-Code?

cnc tutorial

G-Code is the common name for the programming language of CNC Machines.Somewhat of a general, catchall term for CNC programming language.  Very few machines adhere to this standard today.  There are as many varations as there are manufacturers.

This is how I think of G-Code.  It is a simple language built off of the Cartesian Coordinate System for motion control.  That is a mouthful.  I don’t know if that is exactly right, but you will get my meaning in a second when we go through some code line by line.  You will remember your High School Geometry soon enough.  For the real pros out there, you know there is much more to G-Code then that, but it is a good place to start thinking about it.

You will see many variations of the G-Code name like:
Gcode
gcode
G-Code
g-code
G Code
G-Code

Are there other “Codes?”
In a word…Yes.We will get to that information in just a minute.  G-code is also the name of any command in a CNC program that begins with the letter G.  G-Codes generally tell the machine to perform an action.  G-Codes can tell machines to move a certain distance in the X-Axis for example.Or, make a quick move to another location.  Or, move in an arcing fashion while milling.  An on and on and on.

Here are some good examples of different G-Codes
Remember these codes change to a certain degree between CAM Software packages and CNC Machine Manufacturers.
G00 Rapid positioning
G01 Linear interpolation
G02 CW circular interpolation
G03 CCW circular interpolation
G04 Dwell
G20 Programming in inches
G21 Programming in mm
G28 Return to home position
G40 Tool radius compensation off
G41 Tool radius compensation left
G42 Tool radius compensation right
G43 Tool offset compensation positive
G44 Tool offset compensation negative

Why does the G-Code program file change?
We humans like flexibility.  We also like standards.  G-Codes are standardized in a certain sense.  Once you start to be able to read it, you can read just about any flavor of it.  That is the standardized part.
All CNC machines are not created in the same way.  Even identical machines are different to a certain degree.  They may not have the same tools loaded or they have been slightly modified to produce a certain type of part.Isn't it interesting how people like to customize things.

That is why g-codes are not the same.  You need some flexibility in the programming to accommodate all situations.  Couple that with the fact that every manufacturer thinks their version is the best and you get a myriad of G-Codes out there.

Many CNC machine manufacturers try to force you to only use their G-Code.  For example, they give you a design interface to make parts and a CAM interface to produce code.  They lock you into their “Black Box” so you can’t go elsewhere for service and support.  They lock you in their “Family.”  Sometimes they make up a completely different kind of G-Code language that no one can understand but them.  They do that to keep your hands tied up.

What is an M-Code?
M-Codes are related to G-Codes.  M-Codes control different machine functions.  Some of these functions are turning the machine on and off.  Turning the spindle on or off.  Turning a plasma torch on or off.  Turning coolant on or off.  You get the idea.  When programming your CNC machine you may need to perform these functions.
Like G-Code, M-Codes vary from manufacturer to manufacturer and from machine to machine.  As you can imagine you would need an Machining Code for turning a plasma torch on and off on a CNC Plasma Cutting Machine.You don't need an M-code to turn a CNC machine spindle on and off though.  Hey, the machine doesn’t even have a spindle.  It’s a plasma cutter!

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Computer numerical control overview process

cnc steps

Explanation of the process
This is how I view Computer Numerical Control.  I break it down into simple steps that I can remember.  Now, they all interact, but it is good to keep them in boxes for simplicity sake.  I also like to keep them in a logical, progression type order.  Here they are: Design, CAD, CAM, Control and Machine.

Today you are going on a journey.  You are going to learn about the basics of CNC.I trust you are as excited as I am about this subject.

I have been using CNC equipment in my home shop for six years now.The technology gets better every year.  The software gets better every year.  At one time large companies could only afford this technology.Now there are hundreds of CNC machines working in garages.

There are basically five elements to a CNC Project that you need to know:
Design - planning on what you want to build
Computer Aided Drafting - translating it into the computer
CAM - converting it into machine language
Controlling - getting your CNC machine to move in the correct direction
Machining - building the part to specifications

These five elements are really the building blocks to a CNC project.  As you see them above, that is generally the order people associate them in.For example you can't control your CNC machine until you have a design ready.  You can't use your CAM software before your CAD software.One of the things you need to take into account is how these different elements interact with one another.
Right now this may seem confusing.  Over time, it will seem very basic.  The more you use these elements with one another, the more their order will become second nature.

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What is Metal Casting and how does it Work

Metal Casting

Casting can be defined as a process of manufacturing, which implies pouring of a ‘liquid’ material into ‘A Mold’ containing a desired shaped hollow cavity, and then made to solidify. What needs to be done to finally complete the process is to take out the casting and break it apart so you can see your finished project. The use of casting is ‘forming hot liquid metals’ or numerous metals that are cooled after having the components like clay, plaster, concrete, and epoxies mixed. Really, Casting is one of the only processes that takes complex shapes and can actually make them because other avenues just can't do it. Casting came into being around 6000 years ago. ‘Copper Frog’ is the most ancient casting existing till date since 3200 BC. The process of casting has two distinct subdivisions: non-expendable and expendable mold casting.

‘Non-expendable’ mold casting: This technique is inclusive of at least 4 distinct methods: continuous, centrifugal, die, and permanent casting.

Continuous casting: Continuous Casting can be defined as a refined process of casting for high-volume, continuous production of ‘metal sections’ with constant cross-section. The pouring of molten metal into a water-cooled, open-ended copper mold takes place. This allows a ‘layer’ of ‘solid metal’ to be formed above the ‘still-liquid’ center. Continuous casting is widely accepted due to its cost-effectiveness. The metals continuously cast are aluminum, copper, and steel.

Centifugal casting: Centrifugal DIY Casting is independent of both-pressure and gravity. This is because its own ‘force feed’ is created by the way of using a ‘temporary sand mold’ in ‘spinning chamber’ at 900 N. Lead time is variant with respect to application. True- and semi-centrifugal processing allow 30 to 50 pieces/hr. The batch processing has an upper limit of around 9000 Kg (practically). Before, this method that is being discussed was used to Cast Railroad Wheels. A company knows as Krupp is who it was developed by. It had a German origin. Jewelry is normally cast by this method.

Die-casting: Die Metal Casting can be defined as a process of ‘forcing molten metal’ into cavities of mold under high pressure. Aluminum, Copper and Zinc are what really make up most of these castings. It is even possible to make die castings of metal. The method of die casting is used where finer parts are needed.

‘Permanent Mold Casting’: This casting is made up of non-ferrous metals. It requires some time to set up (some weeks), after which the production rate of about 5 to 50 pieces/hour-mold is achieved. The coating of ‘acetylene soot’ is applied to steel cavities. This helps in removing the work piece easily and promoting longer life (of tools). Permanent molds possess a limited life span. For worn molds, replacement or refinishing is required.

Expendable mold casting: ‘Expendable Mold casting’ can be referred to as a standard classification inclusive of the following:

Sand casting: It is amongst the simplest and most popular casting types used since ages. It involves very small size operations. The bonding of sand takes place by use of clays (as in ‘green sand’) or ‘polymerized oils’, or ‘chemical binders’. Recycling is easily possible.

Plaster Casting can be easily compared to Sand Casting except that instead of sand, you use Plaster. Similarly, there are also plastic and concrete castings.

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A Look At Three Antique Alarm Clocks And The Inside Story

The oldest alarm clock ever is the sun, but antiques dealers and clock historians keep saying that the sun "doesn’t count".  Apparently this is because you can't put the sun under any kind of value guide.  But alarm clocks have existed long before the idea of buying and selling antiques.  Here is a look at just three of these very different antique alarm clocks.

The Great Exhibition Of 1851

Charles Darwin, best known for his theory of evolution, was also a keen observer of his times.  In 1851, he took his children to Hyde Park to the Crystal Palace, also known as The Great Exhibition.  All kinds of new and unusual devices were on display, one of which (had it survived) would be known as the most dangerous antique alarm clock in the world today.

In this antique alarm clock, the sleeper's was made on springs and levers.  When it came time for the sleeper to come out of the Land of Nod, the bed would shoot up, propelling the sleeper into a tub of cold water.  Unbelievably, this kind of antique alarm clock never caught on.  In fact, it's usually not listed in historical papers on the Great Exhibition.  This antique alarm clock is, however, lovingly detailed in Charles Darwin's personal diaries.

The Nuremberg Wall Clock

A much more conventional and dry antique wall clock is thought to have been made in the 1400's in Nuremberg, Germany.  It was made of iron and had bronze bells and worked as a smaller version of the huge town clocks all around European cities since the 1100's.  It was a mere nineteen inches tall.  Its existence is doubtful, especially after the World Wars Germany went through.  We know of this antique wall clock through old writings.

Salisbury Cathedral

The oldest known antique alarm clock still ticking away today can be seen in Salisbury Cathedral in England near Stonehenge, once thought to be a kind of antique alarm clock but now thought to be a place of ancestor worship.  Known as "the Medieval Clock", this antique alarm clock was thought to be made around 1386. 

Alarm clocks were rather large in the fourteenth century – usually only a clock tower or a cathedral could hold one. he big advantage was that the whole town could use one.  Also, you didn’t have to worry about antique alarm clock thieves.  Or, worry about sober thieves, anyway.  If anyone tried to steal this antique alarm clock, they wouldn’t be able to get very far without someone pretending not to notice.

 

CNC routers need controllers

CNC Controller Prices

Machine Controllers take your machining instructions from your G-Code and converts the G-Code into motion.  You are off to the races.The CNC controller reads the signal pulses from your CNC control computer and then instructs the machine to move.

The CNC Machine Controller is made up of various electrical parts.  Remember earlier that I said some electronic junkies flock to CNC.  This is why.  Machine controllers can be built if you are savvy with a soldering iron.  I myself am not.  I personally always default to ordering up a Machine Controller from one of my sources.

Controller builders to me are electronic gods.  They mix power sources, match up Amp, Volts, etc into the item I need.  Generally, you can pick the number of Axis you want before they build the controller.  For example, if you are building a CNC Machine you may want a two-axis controller.  Possibly a three-axis controller if you have a Torch Height Control.  If you have a milling machine or a wood router in mind, then a three axis is your ticket.  If you want to machine with a rotary axis, then you need a four-axis controller.  So on and so forth.

Here are some example controller prices
Here are some prices you might see in the marketplace.  Most come with motor systems and cable as well.  Really, you purchase a whole kit at once if you go this route.Another way to do it is to build it yourself.  I wouldn’t suggest this for the beginner.

Prices
2 Axis – $1000–$3000 - Movement in the X and Y axis, dependent on the size of motors you order
3 Axis – $1500–$4000 - Movement in the X, Y and Z axis, dependent on the size of motors you order
4 Axis – $2000–$6000 - Movement in the X, Y, Z and A axis, dependent on the size of motors you order

Note: The A-axis is the rotational axis.  Why is it called that?  I don’t know.  It is also sometimes called the B-axis.  I have even heard it called the W-axis.  A-axis is the rotational axis around the X-axis. B-axis is the rotational axis around the Y-axis.

Buying a completed CNC Machine
If you purchase a CNC Router outright, it will have a machine controller as part of the package.  Everyone does it a bit different though.  Some try to make it a black box that only they can fix.Other people use commonly used components so you could repair it if need be.  You will just have to ask the manufacturer and see what they say.  My experience says they usually tell you that it uses common components that you can get anywhere if needed.  If something goes wrong, it seems you can only get the part from them.You are going to have to decide.

Internal Machine Controller Parts
There are many different components that go into a machine controller.  I won’t pretend that I am an expert on this.This is a component I buy premade so I don't have to make it.  If you are an electronics junkie you could build your own.I know my skills and it isn't assembling and understanding electronics.

Here is what I know about the guts of a controller.  There will be drivers.  One for each axis.Gecko drivers seem to be the best on the market right now and they also have great support.  I have used Gecko drivers in two of my creations and they work great.  Next, is a processor to do the computing work.  A power source to power the controller.  Finally the external cableling that heads out to the motors at each axis on your machine.
There is more to it than just that, and I have probably left out some parts.  Those are the basic parts of machine controllers.

CNC Control Pendants
I did not know where to put this section.  The Machining Chapter or Machine Controllers Chapter.  It ended up here because the pendant is almost always hooked to the controller.  Any pendant automatically gets a gold star from me.  I love them.  If you use one, I guarantee you will love it.

Pendants are a true lifesaver when machining.  They give you access to commonly used functions about anywhere you want them.  You can jog the machine to a new location.  You can zero out your axis with a click.  You can even control your machining speeds on the fly.  All pendants are different and are usually associated with a purchased Machine Controller.

Pendants can be made.  There are a number of people out there that have pieced them together.  Generally these are the electronic types of people involved with CNC.  They like this extra challenge.  Many of these home brew pendants actually come out very nice.Many of these people are proud of their designs and will share their plans and component lists with you.  The trick is finding them.

Free CNC information community site:
If you would like to know more about CNC, head on over to http://www.cncinformation.com
You can join for Free and you get two free CNC ebooks. One is a G-Code book and the other is the CNC information site book. You also get access to the Free Video Series...Image to CNC Art when you join the community.