Casting Technology

Solidification Modeling

J.B has extensive expertise with solidification modeling. Solidification modeling enables J.B to simulate the INVESTMENT CASTING process on the computer prior to actual trials. When solidification modeling is combined with statistical experimentation it can yield significant results.
Click here to view the detailed Solidification Simulating Process

Engineering Guide

Cost consideration

WEIGHT
Weight is the most critical factor in determining casting part cost. Unnecessary mass should always be removed by correct engineering practices to reduce part weight.

RISER
When possible, a single riser on one part should be considered. This will generally yield higher casting come-out-rate.

CASTABILITY
If the design contains features that will raise scrap or rework rates (and the piece price), Our Engineer will recommend design modifications to keep the piece price down.

MATERIAL SELECTION
Elements like Nickel and Molybdenum is very expensive and price is uncertain while Chromium is much cheaper in china. Therefore, for some alloy steels, “Cr” would be a best choice in stead of “Ni” and “Mo” contained in material if mechanical properties can meet your requirements.
Recommend 20Cr, 40Cr used.

HEAT TREATMENT
Properties of hardness, mechanical, corrosion resistance, and surface treatments are achieved by Heat treatment Unless otherwise indicated, all plain carbon steel & iron are quoted without H-treatment charges, all alloy steels are quoted with a normalize or Q+T. All 300 series stainless steels are quoted with a solution anneal. A cost savings is generated if the casting can be used in the as-cast condition.

STRAIGHTENING
Straightening adds cost, but sometimes cannot be avoided. The actual straightening costs are often dependent on the tightness of the tolerance specified, so do not specify tighter flatness, straightness, roundness, or other requirements than you actually require. ( J.B straightens parts using die sets and press machine that will increase piece price.)

NDT
Sample castings are non-destructively tested by MPT & FPT and selectively by X-Ray in order to establish right pouring-gate system.
However, this is generally not required in batch production; doing so will add costs. The following non-destructive tests are listed from least to greatest cost:
1. Magnetic Particle
2. Fluid Penetrant, Ultra-Sonic
3. X-Ray

Material Specification

Material Specification
CARBON AND LOW ALLOY STEELS
ASTM	Condition	Tensile Strength (psi)	0.2% Yield Strength (psi)	% Elongation Range	Hardness Range or Max
1010	Annealed	50-60,000	30-35,000	30-35	50-55 Rb
1020	Annealed	60-70,000	40-45,000	25-40	80 Rb
1025	Annealed	63-73,000	42-47,000	25-35	80 Rb
WCB	Normalized	70-95,000	36-42,000	22-30	78-93 Rb
1030	Annealed	65-75,000	45-50,000	20-30	75 Rb
1035	Annealed	70-80,000	45-55,000	20-30	80 Rb
1045	Annealed	80-90,000	50-60,000	20-25	100 Rb
1050	Annealed	90-110,000	50-65,000	20-25	100 Rb
1060	Annealed	100-120,000	55-70,000	12-20	25 Rc
4130	Hardened	130-170,000	100-130,000	5-20	23-49 Rc
4140	Hardened	130-200,000	100-155,000	5-20	29-57 Rc
4150	Hardened	140-200,000	120-180,000	5-10	25-58 Rc
4330	Hardened	130-190,000	100-175,000	5-20	25-48 Rc
4340	Hardened	130-200,000	100-180,000	5-20	20-55 Rc
4620	Hardened	110-150,000	90-130,000	10-20	20-32 Rc
6150	Hardened	140-200,000	120-180,000	5-10	30-60 Rc
8620	Hardened	100-130,000	80-110,000	10-20	20-45 Rc
8630	Hardened	120-170,000	100-130,000	7-20	25-50 Rc
8640	Hardened	130-200,000	100-180,000	5-20	30-60 Rc
52100	Hardened	180-230,000	140-180,000	1-7	30-65 Rc

ALLOY STEELS
GB	Condition	Tensile Strength (MPa)	0.2% Yield Strength (MPa)	% Elongation Range	Hardness Range or Max
40Mn2	Q+T	885	735	≥12	≤217 HBS
45Mn2	Q+T	885	735	≥10	≤217 HBS
20Cr	Q+T	835	540	≥10	≤179 HBS
30Cr	Q+T	885	685	≥11	≤187 HBS
35Cr	Q+T	930	735	≥11	≤207 HBS
40Cr	Q+T	980	785	≥9	≤207 HBS
45Cr	Q+T	1030	835	≥9	≤217 HBS
50Cr	Q+T	1080	930	≥9	≤229 HBS
38CrSi	Q+T	980	835	≥12	≤255 HBS
30CrMo	Q+T	930	785	≥12	≤229 HBS
15CrMn	Q+T	785	590	≥12	≤179 HBS
20CrMn	Q+T	930	735	≥10	≤187 HBS
40CrMn	Q+T	980	835	≥9	≤229 HBS
20CrMnSi	Q+T	785	635	≥12	≤207 HBS
30CrMnSi	Q+T	1080	885	≥10	≤229 HBS
20CrMnMo	Q+T	1180	885	≥10	≤217 HBS
40CrMnMo	Q+T	980	785	≥10	≤217 HBS
20CrMnTi	Q+T	1080	850	≥10	≤217 HBS
30CrMnTi	Q+T	1470	---	≥9	≤229 HBS
20CrNi	Q+T	785	590	≥10	≤197 HBS
12CrNi3	Q+T	930	685	≥11	≤217 HBS
20Cr2Ni4	Q+T	1180	1080	≥10	≤269 HBS

Tolerance

Normal Dimension (mm)		Class CT
from	to	3	4	5	6	7	8	9	10
0	3	0.14	0.20	0.28	0.40	0.56	0.80	1.2	--
3	6	0.16	0.24	0.32	0.48	0.64	0.90	1.3	--
6	10	0.18	0.26	0.36	0.52	0.74	1.0	1.5	2.0
10	16	0.20	0.28	0.38	0.54	0.78	1.1	1.6	2.2
16	25	0.22	0.30	0.42	0.58	0.82	1.2	1.7	2.4
25	40	0.24	0.32	0.46	0.64	0.90	1.3	1.8	2.6
40	63	0.26	0.36	0.50	0.70	1.0	1.4	2.0	2.8
63	100	0.28	0.40	0.56	0.78	1.1	1.6	2.2	3.2
100	160	0.30	0.44	0.62	0.88	1.2	1.8	2.5	3.6
160	250	0.34	0.50	0.70	1.0	1.4	2.0	2.8	4.0
250	400	0.4	0.56	0.78	1.1	1.6	2.2	3.2	4.4
400	630	-	0.64	0.90	1.2	1.8	2.6	3.6	5.0
630	1000	-	-	1.0	1.4	2.0	2.8	4.0	6.0
1000	1600	-	-	1.1	1.6	2.2	3.2	4.6	7.0
1600	2500	-	-	-	-	2.6	3.8	5.4	8.0
2500	4000	-	-	-	-	-	4.4	6.2	9.0
4000	6300	-	-	-	-	-	---	7.0	10.0

J.B can achieve:Investment Casting: CT5-6, some parts to CT4.
Diameter Tolerance (mm)

Tol Dia	12.5	25	38	50	64	125	200	250	400	630
Lost Wax	±0.10	±0.15	±0.20	±0.25	±0.30	±0.40	±0.8	±1.2	±1.5	±4.0
Sand	±0.20	±0.25	±0.30	±0.35	±0.40	±0.55	±1.5	±2.0	±2.5	±5.0

Casting Capacity

PROCESS	WEIGHT	SIZE	DIAMETER	THICKNESS	MIN R	ROUGHNESS
Lost Wax	5g~85kg	≦1350mm	1~1000mm	≧0.3mm	R0.1	Ra 1.6~3.2μm
Sand	0.5kg~3T	≦4000mm	1~3000mm	≧0.4mm	R0.3	Ra 6.3~25μm

·Premium Tolerances
·Tighter tolerances can be obtained by:
·1. Straightening/Re-Shape
·2. Grinding/Polishing
·3. Machining


1	2	3

Machining Allowance (mm)

AMD★(mm)		RMA
from	to	A	B	C	D	E	F	G	H
0	40	0.1	0.1	0.2	0.3	0.4	0.5	0.5	0.7
40	63	0.1	0.2	0.3	0.3	0.4	0.5	0.7	1.0
63	100	0.2	0.3	0.4	0.5	0.7	1.0	1.4	2.0
100	160	0.3	0.4	0.5	0.8	1.1	1.5	2.2	3.0
160	250	0.3	0.5	0.7	1.0	1.4	2.0	2.8	4.0
250	400	0.4	0.7	0.9	1.3	1.4	2.5	3.5	5.0
400	630	0.5	0.8	1.1	1.5	2.2	3.0	4.0	6.0
630	1000	0.6	0.9	1.2	1.8	2.5	3.5	5.0	7.0
1000	1600	0.7	1.0	1.4	2.0	2.8	4.0	5.5	8.0
1600	2500	0.8	1.1	1.6	2.2	3.2	4.5	6.0	9.0
2500	4000	0.9	1.3	1.8	2.5	3.5	5.0	7.0	10.0
4000	6300	1.0	1.4	2.0	2.8	4.0	5.5	8.0	11.0
Note: ★AMD(After Machining Dimension)

· J.B can reach:·
Investment Casting: C-E.

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J.B Machinery(Ningbo)Co.,Ltd

J.B Machinery (Ningbo) Co.,Ltd

Casting Technology