1 Experiment No.

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1.1 Objective
To develop a mold for sand-casting of aluminum using the solid pattern.
1.2 Theory
1.2.1 Casting
Casting is a process in which the liquid molten metal is poured into the casting cavity whose shape is the
same as that of the shape of the casting to be produced, allowing it to solidify after solidification, the
casting will be taken out by breaking the mold called as Casting Process. Casting processes involve the
use of molten material, usually metal. This molten material is then poured into a mold cavity that takes
the form of the finished part. The molten material then cools, with heat generally being extracted via the
mold, until it solidifies into the desired shape
1.2.2 Types of Casting
There are various types of Casting Processes but out of which, I will be explaining only four types of
casting processes in detail. They are:
 Sand Casting Process
 Die Casting Process
 Shell Mold Casting Process
 Investment Casting Process
1.2.2.1 Sand Casting Process
Sand casting is one of the most popular and easiest types of casting and has been used for centuries.
Sand casting enables smaller batches than permanent mold casting at a very reasonable cost. Not only
can manufacturers use this method to produce products at a low cost, but sand casting also offers other
advantages, such as very small operations. The process allows castings that are small enough to fit in the
palm of the hand to castings or large enough like train beds. Sand casting can also cast most metals,
depending on the type of sand used to make the molds. Sand casting is typically based on silica-based
materials, such as synthetic or naturally bound sand. Cast sand generally consists of finely ground,
spherical grains that can be tightly packed together to form a smooth mold surface. The casting is
designed to reduce the risk of cracks, tears, or other defects by allowing a moderate amount of flexibility
and shrinkage during the cool-down phase of the process. The sand can also be strengthened by adding
clay, which will make the particles more closely bond. Automotive products such as engine blocks are
made by sand casting.

Figure 1 Sand Casting

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1.2.2.2 Die Casting Process
Die casting is a method of molding materials by forcing molten metal under high pressure into a mold
cavity. Most die castings are made from non-ferrous metals especially zinc, copper, and aluminum-
based alloys. However, iron metal die-cast parts are possible. The die-casting process is particularly
suitable for applications in which many small to medium-sized parts with good details, fine surface
quality, and dimensional accuracy are required.

Figure 2 Die Casting

1.2.2.3 Shell Mold Casting Process

If the mold is made like a shell called shell mold casting. Shell means the thin mold or Hollow mold.
The material used for mold is a Phenolic resin (Thermosetting Plastic) that has a viscosity of (Dynamic
Viscosity equal to 1500 to 2000 Centipoise). You can dip the pattern into phenolic resin for 1 to 2
minutes and take the pattern out. This method is used for producing the symmetrical and circular shape
of castings only.

Figure 3 Shell Molding Process

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1.2.2.4 Investment Casting Process
Investment casting is also known as a lost wax casting, it uses a disposable wax pattern for each cast
part. In this type of Casting, wax is directly injected into a mold, removed, and then coated with
refractory material and binding agent, usually in several stages, to build a thick shell. Several samples
are put together to form common sprues. Once the shells have hardened, the patterns are inverted and
heated in ovens to remove the wax. These patterns require extreme care as they are not strong enough to
withstand the forces involved in making molds. One advantage of investment casting is that the wax can
be reused. Investment casting is widely used to make parts for the automotive, power generation, and
aerospace industries, such as turbine blades. These castings ensure that high-quality components are
made with the key benefits of accuracy, repeatability, versatility, and integrity.

Figure 4 Investment Casting Process

1.2.3 Types of Molds

Mold contains the cavity whose geometry determines the shape of the cast part. Molds are slightly
oversized due to shrinkage produced as a result of solidification. There are two major types of molds
are:
 Open Mold
 Closed Mold

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1.2.4 Components of Casting apparatus
Most of the features of sand-casting mold are similar to other types of casting molds.
 Cope: Upper half portion of the mold is called cope.
 Drag: The bottom half portion of the mold is called drag.
 Flask: Cope and drag are placed in a container called a flask. Flask is also divided into two parts
(one for cope and one for drag).
 Parting Line: Cope and drag meet at a parting line.
 Pattern: Cavity is produced inside the mold by using the pattern. The pattern is made up of
wood, metal, or plastic. It has the shape of the part to be cast. It is usually oversized as compared
to the casting.
 Core: It is used to produce internal geometries in the casting.
 Gating System: Network of channels or passage through which metals flows into the cavity.
 Riser: It stores the extra metal. It makes the metal readily available when the metal shrinks due
to solidification.
 Air Vents: In the case of sand casting, air escapes the mold from the spacing present between
sand particles.

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 Figure 5 Components of Sand Casting

1.2.5 Procedure
While each casting method creates unique challenges and process enhancements, all techniques retain
the same basic steps. These steps are:
 Pattern Making: To create a casting mold, a manufacturer must first design a physical model.
The process of fabricating this model is called patternmaking. Using computer-assisted design
(CAD) systems, the manufacturer designs the dimensions and geometry of a mold, and then
packs an aggregate material, such as sand, concrete, or plastic, around the pattern. Once the
pattern is removed, the mold cavity in the sand can be filled.
 Core Making: Many part designs require the inclusion of cores in the casting mold. Cores are
solid materials placed inside the mold cavity to create interior surfaces of a casting. For example,
metal pipefitting will require a cylindrical core inside the mold cavity to create the hollow
construction of the component's interior.
 Molding: At this point, the manufacturer can create the casting mold. A material such as sand,
plaster or wax is used in expendable mold casting, whereas metal and other durable materials are
used in non-expendable mold casting techniques. The material fills the casting mold model and
is allowed to harden, at which point the manufacturer removes it from the cavity and the casting
of the component can now begin.
 Melting and Pouring: Metal must be properly melted prior to being placed in the mold.
Typically, this is done by using what is known as a crucible. Crucibles are containers made of
porcelain or another melt-resistance substance in which a manufacturer can heat a metal beyond
its melting point. Once properly melted, the molten metal is poured into the casting mold to cool
and harden.

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  Finishing: Because metal can sometimes fill in cracks in a casting mold or sprues, the pouring
channel for the mold, manufacturers must often finish the metal following casting. This can be
accomplished through a variety of finishing techniques, including sanding, grinding and buffing.
Once proper appearance and surface texture has been achieved, further post-treatment processes
such as painting or electroplating may be necessary for some applications.
1.2.6 Advantages of Casting
Casting has the following advantages over other manufacturing processes.
 It can create any complex structure economically.
 The size of the object doesn’t matter for casting.
 The casting objects have high compressive strength.
 All structure made by casting has a wide range of properties.
 This can create an accurate object.
 All material can be cast.
 It creates an isotropic structure.
 It is the cheapest among all manufacturing processes.
 Composite components can be easily made by casting.
1.2.7 Disadvantages of Casting
The disadvantages of the casting processes are as follows:
 Dimensional accuracy: Because of shrinkage in the casting, the dimensional accuracy might be
at risk. So, the designers must take care of providing the allowance to the product (Pattern)
before pouring the molten metal.
 Low strength: Due to high porosity compared to a machined part.
 Post-processing: It requires Secondary machining operations in order to improve the surface
finish.
 Lower Melting Point: Generally limited to metals of the lower melting point.
 Not suitable for low-volume production.
1.2.8 Applications of Casting Process
 Household: appliances, kitchen, and gardening equipment, furniture and fittings
 Art objects: sculptures, idols, furniture, lamp stands, and decorative items.
 Municipal castings: pipes, joints, valves, and fittings
 Defense: vehicles, artillery, munitions, storage, and supporting equipment
 Machine tools: machining, casting, plastics molding, forging, extrusion, and forming
 Heavy equipment: construction, farming, and mining
 Transport: automobile, aerospace, railways, and shipping
 Electrical machines: motors, generators, pumps, and compressors
 Plant machinery: chemical, petroleum, paper, sugar, textile, steel, and thermal plants
1.3 Solid Pattern
Solid-type patterns are the simplest method for simple shape casting. This pattern can be made in the
mold without any sub-parts or joints. In this type of pattern only simple shapes are produced and can be
very easily removed from the mold. The solid pattern is placed in a drag. It is used to make a flat surface
like gear blanks, square blocks, etc. This type of pattern molding process is quite inconvenient and time-
consuming. Therefore, such patterns are used to make some large castings.

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 Figure 6 Solid Pattern
1.4 Comments
 Do not mix any chemicals unless directed to do so in a procedure or by your teacher.
 Inform your teacher immediately if you spill chemicals or get any chemicals on your skin or in
your eyes.
 Never taste any chemicals or substances unless directed to do so by your teacher.
 Keep your hands away from your face when working with chemicals.
 Wash your hands with soap and water after handling chemicals.

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2 Experiment No. 2
2.1 Objective
To develop a mold for sand casting of aluminum using the split pattern.
2.2 Theory
2.2.1 Tools Required
The following tools are required for sand casting are:
 Molding board
 Drag and Cope boxes
 Molding Sand
 Parting Sand
 Rammer
 Strike-off bar
 Bellows
 Riser and sprue pins
 Gate cutter
 Vent rod
 Draw spike
 Wire Brush
2.2.2 Properties of Sand
The basic properties required in molding sand and core sand are:
 Adhesiveness: Adhesiveness is a property of molding sand to get the stick or adhere to other
material i.e., sticking of molding sand with the inner wall of the molding box.
 Cohesiveness: Cohesiveness is the property of molding sand by which the sand grain particles
interact and attract each other within the molding sand. Sand must contain good cohesiveness
that gives good strength to sand mold. Zr, Olivine and clay, etc. are added to increase
cohesiveness.
 Collapsibility: It is the property providing ease to breaking of sand mold during removal of
casting product after its solidification. The sand mold must be collapsible so that free contraction
of the metal occurs and this avoids the tearing or cracking of the contracting metal. So, sand
must be non-sticky to casting the product.
 Permeability: Permeability is also termed as the porosity of the molding sand in order to allow
the escape of any air or gases present or generated in the mold when the molten metal is poured
into it. Sand must have good permeability. The permeability of mold can be further increased by
venting using vent rods.
2.2.3 Sand Molds
There are many types of molds used during the casting process some of which are given below:
 Green Sand Mold: Sand casting uses sand molds formed from wet sand which contains water
and organic bonding compounds, typically referred to as clay. This sand is called green sand

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 because the sand mold is not set and it is still in the green or uncured state even when the metal
is poured into the mold.
 Dry Sand Mold: Dry sand casting is a processed form of green sand process, in which the sand
mold is baked at a temperature of 300 degrees F to remove moister and make it stronger. It
improves collapsibility. This technique is not so common due to the difficult using technique.
 Facing Sand Mold: The sand that is in contact with the casting is called facing sand, and is
designed for the casting on hand. This sand will be built up around the pattern to a thickness of
30 to 100 mm (1.2 to 3.9 in). The sand that fills in around the facing sand is called backing sand.
 Backing Sand Mold: Backing sand or floor sand is used to back up the facing sand and is used
to fill the whole volume of the molding flask. Backing sand is sometimes called black sand
because of old, repeatedly used molding sand is black in color due to the addition of coal dust
and burning on coming in contact with the molten metal.

Figure 7 Types of Sand Molds

2.2.4 Products formed by Sand Casting

Commonly following products are formed by sand casting:
 Small engine parts
 Gears
 Bearings
 Nuts
 Pumps
 Pulleys
2.3 Split Pattern
The pattern is split into two half parts. One part of the pattern is in the drag and the other part is in the
cope. Split patterns are used to manufacture intricately shaped parts and large casting products. It has
two dowel pins and two dowel holes which are used to join and align the two pieces together.

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 Figure 8 Split or two-Piece Pattern

The split pattern for sand casting was setup as shown in fig 10.

Figure 9 shows Split Pattern

2.4 Comment
 Do not mix any chemicals unless directed to do so in a procedure or by your teacher.
 Inform your teacher immediately if you spill chemicals or get any chemicals on your skin or in
your eyes.
 Never taste any chemicals or substances unless directed to do so by your teacher.
 Keep your hands away from your face when working with chemicals.
 Wash your hands with soap and water after handling chemicals.

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