DISCUSSION In the casting process a pattern is made in the shape of the desired part.
Simple designs can be made in a single piece or solid pattern. More complex designs are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom or lower section called a drag. Both solid and split patterns can have cores inserted to complete the final part shape. Cores are used to create hollow areas in the mold that would otherwise be impossible to achieve. Where the cope and drag separates is called the parting line. When making a pattern it is best to taper the edges so that the pattern can be removed without breaking the mold. This is called draft. The opposite of draft is an undercut where there is part of the pattern under the mold material, making it impossible to remove the pattern without damaging the mold. The pattern is made out of wax, wood, plastic or metal. The molds are constructed by several different processes dependent upon the type of foundry, metal to be poured, quantity of parts to be produced, size of the casting and complexity of the casting. Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand as the mold material. The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. Over 70% of all metal castings are produced via a sand casting process.[1] Sand casting is relatively cheap and sufficiently refractory even for steel foundry use. In addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The mixture is moistened, typically with water, but sometimes with other substances, to develop strength and plasticity of the clay and to make the aggregate suitable for molding. The sand is typically contained in a system of frames or mold boxes known as a flask. The mold cavities and gate system are created by compacting the sand around models, or patterns, or carved directly into the sand. In a foundry, molten metal is poured into molds. Pouring can be accomplished with gravity, or it may be assisted with a vacuum or pressurized gas. Many modern foundries use robots or automatic pouring machines for pouring molten metal. Traditionally, molds were poured by hand using ladles. PROCEDURE
1. Place a pattern in sand to create a mold. 2. Incorporate the pattern and sand in a gating system. 3. Remove the pattern. 4. Fill the mold cavity with molten metal. 5. Allow the metal to cool. 6. Break away the sand mold and remove the casting.
Conclusion Filling a metal box having two halves, which is called the flask forms mold. So mold is also made up of two halves, which is separated by a parting line. The reason for this is to remove the tasted part easier from the mold. The upper part of the mold is called the cope and the lower part called the drag. The cope and drag are prepared separately and when they are ready they unites and metal is poured into it through a canal called sprue, which transmits the molten metal via runner into the mold cavity. The runner should not be big because it will increase the amount of the waste metal. It should not be small because this enhances rapid solidification in the runner causing a blockage. At the bottom of the sprue there is a gap called well far the collection of the unwanted sand, which comes with the flowing metal. There is also a riser system, which acts as an inventory of molten metal when the mold cavity is fulfilled with the metal and feeds automatically the cavity of the part that we want to get. This system is essential because as the molten metal cools down it shrinks so the amount needed to replace the shrinked metal comes fom the riser itself eliminating shrinkage cavities. A casting may show microporosity. This can be eliminated with directional solidification either by incorporating a metal chill into the mold or by tapering the thinnest section of the runner. Chills are also used around thicker parts of the casting to provide uniform cooling of these parts with the thinner parts to prevent cracks. Chills, by this way, preserve the mechanical properties of the whole casting. Casting Defects: 1) Misruns (due to rapid solidification in the runner) 2) Cold shuts (due to rapid solidification before complete filling of the mold) 3) Cold shots (due to splattered globules of metal during pouring) 4) Shrinkage cavity (due to lack of riser system) 5) Microporosity (due to localized solidification shrinkage) 6) Hot tearing (due to the die's prevention of contraction)
