Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                
Scribd Logo
Upload

Welcome to Scribd!

  • 18 views

    Sand Casting

    Uploaded by

    12dcc1947
    Sand casting is a process where molten metal is poured into a sand mold cavity. There are two main types of sand used: green sand and dry sand. Green sand molds typically produce rougher castings than dry sand molds. The sand casting process involves making a pattern, using the pattern to form the mold cavity and any cores, and then pouring molten metal into the mold. The quality of the sand mold depends on factors like its strength, permeability, and collapsibility.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Sand Casting

    Uploaded by

    12dcc1947
    18 views5 pages
    Sand casting is a process where molten metal is poured into a sand mold cavity. There are two main types of sand used: green sand and dry sand. Green sand molds typically produce rougher castings than dry sand molds. The sand casting process involves making a pattern, using the pattern to form the mold cavity and any cores, and then pouring molten metal into the mold. The quality of the sand mold depends on factors like its strength, permeability, and collapsibility.

    Original Title

    Sand casting

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Sand casting is a process where molten metal is poured into a sand mold cavity. There are two main types of sand used: green sand and dry sand. Green sand molds typically produce rougher castings than dry sand molds. The sand casting process involves making a pattern, using the pattern to form the mold cavity and any cores, and then pouring molten metal into the mold. The quality of the sand mold depends on factors like its strength, permeability, and collapsibility.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    18 views5 pages

    Sand Casting

    Uploaded by

    12dcc1947
    Sand casting is a process where molten metal is poured into a sand mold cavity. There are two main types of sand used: green sand and dry sand. Green sand molds typically produce rougher castings than dry sand molds. The sand casting process involves making a pattern, using the pattern to form the mold cavity and any cores, and then pouring molten metal into the mold. The quality of the sand mold depends on factors like its strength, permeability, and collapsibility.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    You are on page 1of 5

    Overview

    • Sand casting is a process where molten metal is cast in a mould made


    from a sand mixture.
    • In the past, the process was cost effective only for small volume
    production. But nowadays it is also suitable for high volume
    production thanks to automated equipment for making sand moulds.
    • Sand castings generally have a rough surface sometimes with surface
    impurities, and surface variations. Medium to large parts such as
    valve bodies, crankshafts and engine blocks are typically
    manufactured by this process.
    • The dimensional accuracy and surface finish of the casting depend on
    the type of sand and the moulding process.

    Classification
    • There are two main types of sand used for moulding: green sand and
    dry sand.
    • Green sand consists of silica sand, clay, moisture and other additives.
    • Dry sand is a mixture of sand and fast curing adhesive.
    • When dry sand is used, it is often referred to as no bake mould
    casting or air set sand casting.
    • Castings made from coarse green sand typically have a rough surface
    whilst air-set moulds can produce castings with much smoother
    surfaces.
    Schematic showing the sand casting process.

    Pattern

    Pattern Types; (a) solid pattern, (b) split pattern, (c) match-
    plate pattern, (d) cope and drag pattern
    Pattern
    • (a) Solid Pattern: made of one piece, adjusted in size for shrinkage
    and machining, limited to very low production quantities.
    • (b) Split Patterns: consist of two pieces, appropriate for complex parts
    and moderate production quantities.
    • (c) Match-Plate Patterns: two pieces of the split pattern are attached
    to opposite sides of a wood or metal plate, used for higher
    production quantities.
    • (d) Cope and Drag Patterns: s are similar to match-plate patterns
    except that split pattern halves are attached to separate plates, , so
    that the cope and drag sections of the mold can be fabricated
    independently, instead of using the same tooling for both.

    Core

    (a) Core held in place in the mold cavity by chaplets, (b)


    possible chaplet design, and (c) casting with internal cavity.
    Quality of sand mold
    Several indicators are used to determine the quality of the sand mold:
    (1)strength— the mold’s ability to maintain its shape and resist erosion caused by
    the flow of molten metal; it depends on grain shape, adhesive qualities of the
    binder, and other factors;
    (2) permeability—capacity of the mold to allow hot air and gases from the casting
    operation to pass through the voids in the sand;
    (3)thermal stability—ability of the sand at the surface of the mold cavity to resist
    cracking and buckling upon contact with the molten metal;
    (4) collapsibility—ability of the mold to give way and allow the casting to shrink
    without cracking the casting; it also refers to the ability to remove the sand from
    the casting during cleaning; and
    (5)reusability—can the sand from the broken mold be reused to make other molds?
    These measures are sometimes incompatible; for example, a mold with greater
    strength is less collapsible.

    Shell-Mold Casting:
    Shell-Mold Casting:
    • 1- The two pieces pattern (match-plate or cope and drag) is made of
    metal (e.g. aluminum or steel), it is heated to (175-370ºC) and coated
    with a lubricant, e.g. silicone spray.
    • 2- The dump box (which contains a sand) and pattern is inverted
    many times to generate the sand shell onto the pattern.
    • 3- Each heated half-pattern is covered with a mixture of sand and a
    thermoset resin/epoxy binder. The binder glues a layer of sand to the
    pattern, forming a shell. The process may be repeated many time to
    get a thicker shell.

    Shell-Mold Casting:
    • 4- The assembly is baked into oven to cure it.
    • 5- The patterns are removed and the shell molds are generated.
    • 6- The two half-shells are joined together by a clamp to form the
    mold and supported by sand or metal shot in a flask. The molten
    metal is poured into the mold.
    • 7- The shell is broken to get the final casting.

    You might also like