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    Casting & Welding Engineering (IE 203)

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    Ganesh Badgire Reddy
    This document discusses the process of sand casting, including the types of sand used to make molds, the steps involved such as creating molds, pouring molten metal, and removing castings, and different mold properties like strength, permeability, and reusability that are important for the casting process. Common binders for molds include clay, water, and organic resins, and the main types of molds are green sand, dry sand, and skin dried molds.

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    Casting & Welding Engineering (IE 203)

    Uploaded by

    Ganesh Badgire Reddy
    86 views23 pages
    This document discusses the process of sand casting, including the types of sand used to make molds, the steps involved such as creating molds, pouring molten metal, and removing castings, and different mold properties like strength, permeability, and reusability that are important for the casting process. Common binders for molds include clay, water, and organic resins, and the main types of molds are green sand, dry sand, and skin dried molds.

    Original Description:

    Foundr Process by using Sand Casting, All basic concepts will be clear using this document.

    Original Title

    Sand Casting

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    This document discusses the process of sand casting, including the types of sand used to make molds, the steps involved such as creating molds, pouring molten metal, and removing castings, and different mold properties like strength, permeability, and reusability that are important for the casting process. Common binders for molds include clay, water, and organic resins, and the main types of molds are green sand, dry sand, and skin dried molds.

    Copyright:

    © All Rights Reserved
    Download as PPSX, PDF, TXT or read online from Scribd
    Download as ppsx, pdf, or txt
    86 views23 pages

    Casting & Welding Engineering (IE 203)

    Uploaded by

    Ganesh Badgire Reddy
    This document discusses the process of sand casting, including the types of sand used to make molds, the steps involved such as creating molds, pouring molten metal, and removing castings, and different mold properties like strength, permeability, and reusability that are important for the casting process. Common binders for molds include clay, water, and organic resins, and the main types of molds are green sand, dry sand, and skin dried molds.

    Copyright:

    © All Rights Reserved
    Download as PPSX, PDF, TXT or read online from Scribd
    Download as ppsx, pdf, or txt
    of 23

    Casting & Welding Engineering

    (IE 203)
    Second Year,
    Industrial Engineering Dept.,
    Faculty of Engineering,
    Fayoum University

    Dr. Ahmed Salah Abou Taleb


    Sand Casting
    Sand Casting
    Most widely used casting process, accounting for
    • A significant majority of total tonnage cast.
    • Nearly all alloys can be sand casted, including
    metals with high melting temperatures, such as
    steel, nickel, and titanium.
    • Castings range in size from small to very large.
    • Production quantities from one to millions.
    Sand Casting

    • Sand casting weighing over 680 kg (1500 lb) for an air


    compressor frame.
    Mould
    Mould Features
    Casting Terms
    Flask Is one which holds the sand mould intact. It
    is referred to be various names such as drag,
    cop and cheek.
    It is made up of wood or metals.

    Drag Lower moulding flask

    Cop Upper moulding flask

    Cheek Intermediate moulding flask used in three


    pieces mould.

    Pattern Is the replica of the final object to be made


    with some modifications. The mould cavity is
    made with the help of the pattern.
    Casting Terms (Cont.)
    Parting line This is a dividing line between the two
    moulding flasks that make up the sand mould.
    It is also the dividing line between the two
    halves of the split pattern.

    Pouring basin A small funnel shaped cavity at the top of the


    mould into which the molten metal is poured

    Spur The passage through which the molten metal


    from the pouring basin reaches the mould cavity.

    Runner The passageways in the parting plane through


    which molten metal flow is regulated before
    they reach the mould cavity.
    Casting Terms (Cont.)
    Riser It is a reservoir of molten metal provided in
    the casting so that hot metal can flow back
    into the mould cavity when there is a
    reduction in volume due to solidification.

    Gate The actual entry point through which molten


    metal enters mould cavity.

    Core It is used for making hollow cavities.

    Chaplet Used to support cores inside the mould cavity.

    chill Metallic objects which are placed in the


    mould to increase the cooling rate of casting
    to provide desired cooling rate
    Casting Terms (Cont.)
    Bottom board A board made from wood and used at the
    start of the mould making.

    Facing sand The small amount of carbonaceous material


    sprinkled on the inner surface of the
    moulding cavity to give better surface finish
    to the casting.
    Moulding sand It is the freshly prepared refractory material
    used for making the mould cavity.

    Baking sand This is made up from used and burnt sand.


    Sand Casting
    Sand Casting Steps
    1. Make the mould.
    2. Melt the required metal.
    3. Pour the molten metal into sand mould
    4. Allow time for metal to solidify
    5. Break up the mould to remove casting
    6. Clean and inspect casting
    – Separate gating and riser system
    7. Heat treatment of casting is sometimes
    required to improve metallurgical properties
    Sand Casting Steps
    • The cavity in the sand mould is formed by packing
    sand around a pattern, then separating the mould
    into two halves and removing the pattern.
    • The mould must also contain gating and riser
    system.
    • If casting is to have internal surfaces, a core must
    be included in mould.
    • A new sand mould must be made for each part
    produced.
    Sand Casting Steps

    Outline of production sequence in a typical sand-casting


    operation.
    Sand Casting Steps (Cont.)

    A typical metal match-plate pattern used in sand casting.


    Sand Casting Steps (Cont.)

    Schematic illustration of the sequence of operations for


    sand casting.
    (a) A mechanical drawing of the part is used to generate a
    design for the pattern. Considerations such as part
    shrinkage and draft must be built into the drawing.
    (b-c) Patterns have been mounted on plates equipped
    with pins for alignment. Note the presence of core prints
    designed to hold the core in place.
    Sand Casting Steps (Cont.)

    (d-e) Core boxes produce core halves, which are pasted


    together. The cores will be used to produce the hollow
    area of the part shown in (a).
    (f) The cope half of the mould is assembled by securing
    the cope pattern plate to the flask with aligning pins, and
    attaching inserts to form the sprue and risers.
    Sand Casting Steps (Cont.)

    (g) The flask is rammed with sand and the plate and
    inserts are removed.
    (h) The drag half is produced in a similar manner, with
    the pattern inserted. A bottom board is placed below the
    drag and aligned with pins.
    (i) The pattern, flask, and bottom board are inverted, and
    the pattern is withdrawn, leaving the appropriate
    imprint.
    Sand Casting Steps (Cont.)

    (j) The core is set in place within the drag cavity.


    (k) The mould is closed by placing the cope on top of the
    drag and the molten metal will be pouring inside the
    created cavity.
    (l) After the metal solidifies, the casting is removed from
    the mould. (m) The sprue and risers are cut off and
    recycled and the casting is cleaned, inspected, and heat
    treated (if necessary).
    Mould Properties
    • Strength - to maintain shape and resist erosion.
    • Permeability - to allow hot air and gases to pass
    through voids in sand.
    • Thermal stability - to resist cracking on contact
    with molten metal.
    • Collapsibility - ability to give way and allow
    casting to shrink without cracking the casting.
    • Reusability - ability to used sand from broken
    mould to make other moulds.
    Foundry Sand
    Silica (SiO2) or silica mixed with other minerals
    • Good refractory properties - for high
    temperatures.
    • Small grain size - for better surface finish on cast
    part.
    • Large grain size - is more permeable, allowing
    gases to escape during pouring
    • Irregular grain shapes - strengthen moulds due
    to interlocking, compared to round grains
    – Disadvantage: interlocking reduces permeability
    Binders Used with Foundry Sand
    • Sand is held together by a mixture of water and
    bonding clay.
    – Typical mix: 90% sand, 3% water, and 7% clay.
    • Other bonding agents also used in sand moulds:
    – Organic resins (e g , phenolic resins).
    – Inorganic binders (e g , sodium silicate and
    phosphate)
    • Additives are sometimes combined with the
    mixture to increase strength and/or
    permeability.
    Types of Sand Mould
    • Green Sand Moulds - mixture of sand, clay, and
    water.
    – “Green" means mould contains moisture at time of
    pouring .
    • Dry Sand Mould - organic binders rather than
    clay.
    – Mould is baked to improve strength.
    • Skin Dried Mould - drying mould cavity surface
    of a green sand mould to a depth of 10 to 25
    mm, using torches or heating lamps

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