Recommended Process:

Most recommended process to make anchor is sand casting. Most companies

uses sand casting process especially to make anchor.

Molds used:
The type of mold used is green sand mold.
Green sand mold:
A green sand mold is very typical in sand casting manufacture, it is simple
and easy to make, a mixture of sand, clay and water. The term green refers
to the fact that the mold will contain moisture during the pouring the casting.

Binders
Clay, water and additives are used in the process.

Reason to Use:
Because of its high collapsibility, permeability, reusability, low cost and
sufficient strength.

MOLD ACCESSORIES:

Green sand
Flask
Cope and drag
Aluminum Pattern
Core
Core print
Sprue with pouring cup
Riser
Runner
Gate
Chaplets
Well

Sequence of
Manufacturing Process:
2

MATERIAL SELECTION:
Carbon steel is used for the manufacturing of an anchor.

CASTING:
As Carbon steel is ferrous related high melting point material, hence we prefer sand
casting for its manufacturing.

PATTERN
The patterns are made of metal because of mass production.
We have used one pattern in mold in our process.

CORE MAKING:
In the anchor we have selected; core is not always required as there is no inner part
to be formed.

MOLD MAKING:
The most suitable type of mold for this process is green sand mold as the
requirements is to have high collapsibility , permeability, less cost and the strength
of material. Here we also incorporate the addition of riser sprue runner and gating
system.

MELTING OF RAW MATERIAL:

The raw material is collected in a furnace and then heated till the temperature
reaches 2000C above the melting point of the carbon steel which is 1426-1523C.

POURING:
The molten metal is then poured in the mold with the help of ladle.

SOLIDIFICATION AND COOLING:

After pouring the total system should be kept for cooling.

REMOVAL OF MOLD:
Mold is removed by shaking it with machine.

Finishing Operation:
3

Machining operation:
REMOVAL:
After the predetermined solidification time has passed, the sand mold can simply
be broken, and the casting removed. This step, sometimes called shakeout, is
typically performed by a vibrating machine that shakes the sand and casting out of
the flask.

TRIMMING:
During cooling, the material from the channels in the mold solidifies attached to the
part. This excess material must be trimmed from the casting either manually via
cutting or sawing, or using a trimming press.
Some sort of mechanical finishing would be required to remove that parting line.

INSPECTION & TESTING:

Inspection follows, to check for defects in the casting as well as to ensure that the
casting has the dimensions specified on the drawing.

VISUAL INSPECTION:
It consists of inspecting the surface of the casting with naked eye or sometimes with
a magnifying glass or microscope. It can only indicate surface defects such as blow
holes, fusion, swells, external cracks, and mismatch.

DIMENSIONAL INSPECTION:
Dimensional inspection is carried out to make sure that the castings produced have
the required overall dimensions including allowances for machining.

ULTRASONIC TESTING:
Ultrasonic rays are passed to check defects like cracks and voids within the interior
of the casting.

Pattern:
4

Final product:

Mold:
5

1)Cope

2)Drag:

2D Sketch of Anchor:
6