Engineering project 1 11/21/2009

Sand Casting

A sand casting or a sand molded casting is a cast part produced by forming a

mold from a sand mixture and pouring molten liquid metal into the cavity in the
mold. The mold is then cooled until the metal has solidified. In the last stage the
cast is separated from the mold. These can be broken down into 6 basic steps.
1. Place a pattern in sand to create a mold.
2. Incorporate 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.

There are 2 main types of sand used to create a mold. Firstly, there is a ‘Green
sand’ which is made from a mixture of silica sand, clay, moisture and other
additives. Secondly, The 'Air set’ method uses dry sand bonded to materials
other than clay, by using a fast curing adhesive.
Both of these methods use the sand mixture to pack around a master pattern
forming a mold cavity. If necessary, a temporary plug is placed to form a
channel for pouring the fluid to be cast. Air-set molds often form a two-part
mold having a top and bottom, referred as cope and drag respectively.
The sand mixture is tamped while it is added to form a mold, and the finishing
mold assembly is sometimes vibrated to compact the mixture together and to rid
any unwanted void or air spaces, this process is called ramming. Next, the
pattern is removed with the channel plug and leaving the mold cavity.
The casting liquid, typically molten metal, is then poured into the mold cavity.
After the metal has solidified and cooled, the casting is separated from the sand
mold. There is no simple tools or no mold release agent, thus, the mold is
generally destroyed in the removal process.
The accuracy of the casting is limited by the type of sand and the molding
process. Sand castings made from coarse green sand impart a rough texture on
the surface of the casting, and this makes them easy to identify. Air-set molds
can produce castings with much smoother surfaces. However, surfaces can also
be ground and polished. After molding, the casting is covered in a residue of
oxides, silicates and other compounds. This residue can be removed by various
means, such as grinding or shot blasting.
Most of the time, during casting, some of the components of the sand mixture
are lost in the thermal casting process. Green sand can be reused after adjusting
its composition to replenish the lost moisture and additives. The pattern itself
can be reused indefinitely to produce new sand molds.

For patterns, from the design of the object, the mold or pattern is built using
wood, metal, or a plastic such as expanded polystyrene. Sand can be ground,
swept or even stickled into shape. The metal to be cast will contract during
solidification, and this may be non-uniform due to uneven cooling. Therefore,
the pattern must be slightly larger than the finished product, which is known as
contraction allowance. These can be gauge using 'Contraction rules'. Different
scaled rules are used for different metals because each metal and alloy contracts
by an amount distinct from all others

Elaborating on the chilling process. To control the solidification structure of the

metal, it is possible to place metal plates, chills, in the mold. The associated
rapid local cooling will form a finer-grained structure and may form a
somewhat harder metal at these locations. In ferrous castings the effect is
similar to quenching metals in forge work. Controlling the way a casting freezes
it allows possible ways to prevent internal voids or porosity inside castings.

Foundry

A foundry is a factory that produces metal castings from either ferrous or

non-ferrous alloys. Metals are made into parts by melting them into liquid
phase, pouring it in a mold , and removing the molded metal or casting after it
has solidified as it cools.

Sourced from http://en.wikipedia.org

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Milling Machine

Milling is the process of machining flat, curved, or irregular surfaces by feeding

the work piece against a rotating cutter containing a number of cutting edges.
The usual Mill consists basically of a motor driven spindle, which mounts and
revolves the milling cutter, and a reciprocating adjustable worktable, which
mounts and feeds the work piece. Milling machine is a machine used for
shaping of metal and other solid materials. Milling machines exist in two basic
forms: horizontal and vertical, which are referred to the orientation of the
cutting spindle. These machines are also classified as knee-type, ram-type,
manufacturing or bed type, and planer-type. Most milling machines have self-
contained electric drive motors, coolant systems, variable spindle speeds, and
power-operated table feeds.
Elaborating on one of the types. Knee-type mills are characterized by a
vertically adjustable worktable resting on a saddle which is supported by a knee.
The knee is a massive casting that rides vertically on the milling machine
column and can be clamped rigidly to the column in a position where the
milling head and milling machine spindle are properly adjusted vertically for
operation. The plain vertical machines are characterized by a spindle located
vertically, parallel to the column face, and mounted in a sliding head that can be
fed up and down by hand or power. Modern vertical milling machines are
designed so the entire head can also swivel to permit working on angular
surfaces. The turret and swivel head assembly is designed for making precision
cuts and can be swung 360° on its base. Angular cuts to the horizontal plane
may be made with precision by setting the head at any required angle within a
180° arc. The plain horizontal milling machine's column contains the drive
motor and gearing and a fixed position horizontal milling machine spindle. An
adjustable overhead arm containing one or more arbor supports projects forward
from the top of the column. The arm and arbor supports are used to stabilize
long arbors. Supports can be moved along the overhead arm to support the arbor
where support is desired depending on the position of the milling cutter or
cutters. The milling machine's knee rides up or down the column on a rigid
track. A heavy, vertical positioning screw beneath past the milling cutter. The
milling machine is excellent for forming flat surfaces, cutting dovetails and
keyways, forming and fluting milling cutters and reamers, cutting gears, and so
forth. Many special operations can be performed with the attachments available
for milling machine use. the knee is used for raising and lowering. The saddle
rests upon the knee and supports the worktable. The saddle moves in and out on
a dovetail to control cross feed of the worktable. The worktable traverses to the
right or left upon the saddle for feeding the work piece past the milling cutter.
The table may be manually controlled or power fed.
Milling machines require special safety precautions while being used. Firstly,
do not make contact with the revolving cutter. Secondly, place a wooden pad or
suitable cover over the table surface to protect it from possible damage. Thirdly,
use the buddy system when moving heavy attachments. Fourthly, do not attempt
to tighten arbor nuts using machine power. Fifth, when installing or removing
milling cutters, always hold them with a rag to prevent cutting your hands.
Sixth, while setting up work, install the cutter last to avoid being cut. Seventh,
never adjust the work piece or work mounting devices when the machine is
operating. Lastly, chips should be removed from the work piece with an
appropriate rake and a brush.
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Lathe Machine

The lathe is a machine tool used principally for shaping pieces of metal and
sometimes wood or other materials by causing the work piece to be held and
rotated by the lathe while a tool bit is advanced into the work causing the
cutting action. The basic lathe that was designed to cut cylindrical metal stock
has been developed further to produce screw threads, tapered work, drilled
holes, knurled surfaces, and crankshafts. Modern lathes offer a variety of
rotating speeds and a means to manually and automatically move the cutting
tool into the work piece.
There are three types of lathe. These are engine lathe, turret lathe, and special
purpose lathes. The small version of lathes are bench mounted and semi-
portable while the large version of lathes are floor mounted and may require
special transportation if they must be moved.
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Shaper machine

A shaper function is shaping or surfacing metal and other materials.

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CNC machine