The level of detail in casting process design primarily depends on the production volume, requirements, and conditions. It typically includes the following documents: casting process drawings, rough casting drawings, mold assembly drawings (mold closing drawings), casting process cards, and operational procedures. Broadly speaking, the design of casting process equipment also falls under the scope of casting process design, such as pattern drawings, core box drawings, flask drawings, weighting device drawings, special gauge and template drawings, and core assembly fixture drawings, among others.
For mass-produced standardized castings or particularly critical single-piece castings, the casting process design tends to be more comprehensive and detailed. However, for general castings produced in small batches or as single pieces, the design content can be simplified. In the simplest cases, only a casting process drawing may be required.
The general content and design procedure of casting process design are outlined below:
Foundry Design Procedure in Simons
1. Analysis of part technical requirements and casting structural manufacturability.
2. Selection of casting and molding methods.
3. Determination of pouring position and parting line.
4. Specification of process parameters.
5. Design of the gating system, risers, chills, and reinforcing ribs, etc.
6. Core design.
7. Design of tooling and fixtures.
8. Completion of the casting drawing based on the finalized casting process drawing.
9. Completion of the mold assembly drawing, typically after flask design.
10. Integration and review of the entire design content.
