Professional Documents
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1 Title..........................................................................................................................................2
2 Objectives.................................................................................................................................2
3 Apparatus..................................................................................................................................2
4 Picture.......................................................................................................................................2
5 Introduction..............................................................................................................................2
5.1 Casting..............................................................................................................................2
5.2 Pattern...............................................................................................................................3
5.3 Patternmaker decision.......................................................................................................3
5.4 Moulding sand...................................................................................................................3
5.5 Pouring of molten metal....................................................................................................4
6 Sand Casting terminologies......................................................................................................4
6.1 Cope..................................................................................................................................4
6.2 Drag...................................................................................................................................4
6.3 Parting line........................................................................................................................4
6.4 Pouring cap/basin..............................................................................................................4
6.5 Gas vent.............................................................................................................................4
6.6 Riser..................................................................................................................................4
6.7 Sprue.................................................................................................................................4
6.8 Runner...............................................................................................................................4
6.9 Mould Cavity....................................................................................................................4
6.10 Pattern...............................................................................................................................4
7 Major Components of sand mould...........................................................................................4
8 Procedure..................................................................................................................................5
9 Advantages of Sand Casting.....................................................................................................5
10 Disadvantages of Sand casting.............................................................................................5
11 Applications..........................................................................................................................5
12 Result....................................................................................................................................6
13 Conclusion............................................................................................................................6
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1 Title
To perform sand casting process.
2 Objectives
To learn the process of Sand casting
To learn how to use tools in sand casting
3 Apparatus
Mold Board
Mold Box
Roller
Rammer
Clay Powder
Slick
Sprue Pins
Vent wires
Lifter
Cutting Scale
4 Picture
5 Introduction
5.1 Casting
Casting is a manufacturing process in which a molten metal is poured into a mold of
some suitable material having internal cavity/cavities of the desired shape.
The molten metal is then allowed to solidify.
After solidification the mold is broken or opened to remove the casted part.
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This casted part is then sent to the machine shop if further processing required in terms
of fettling and to improve the surface finish of the part.
5.2 Pattern
In casting, a pattern is a replica of the object to be casted, used to prepare the cavity into
which molten material will be poured during the casting process.
It provides the shape for object that need to be casted.
Typically, patterns used in sand casting may be made of wood, metal, plastics or other
materials.
Patterns are made to exacting standards of construction, so that they can last for a
reasonable length of time.
5.3 Patternmaker decision
The patternmaker or foundry engineer decides where the sprues, gating systems,
and risers are placed with respect to the pattern.
Where a hole is desired in a casting, a core may be used which defines a volume or
location in a casting where metal will not flow into.
Sometimes chills may be placed on a pattern surface prior to molding, which are then
formed into the sand mound.
Chills are heat sinks which enable localized rapid cooling.
The rapid cooling may be desired to refine the grain structure or determine the freezing
sequence of the molten metal which is poured into the mold.
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In the meantime, when the moisture in the molding sand is completely expelled, it is
called dry sand.
While the strength of the sand that is required to hold the shape of the mold cavity then is
called hot strength.
Finally, the permeability is a term used to measure gas evolution capability during
solidification of a casting.
5.5 Pouring of molten metal
Pouring of molten metal (melting practice) required a good discipline both from gating
system design and rising system application.
Several parameters are applied such as pouring time, gating elements, gating ratios, and
slag trap system, methods of solidification behavior, feeding distances and feeding aids.
The horizontal channel feeding the molten metal into the mound cavity.
6.9 Mold Cavity
This is where all the molten metal sets creating a duplicate of the pattern.
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6.10 Pattern
Any objects placed in the casting sand creating an impression of the pattern to be created. A
pattern could be made from steel, wood, plastic and other materials.
8 Procedure
Take the mound box and place it on the mound board.
Place the single cavity pattern in the mound box.
Fill the drag of mound box with sand in proper way that pattern can’t be seen.
After filling, do ramming for smooth surface.
Roll the roller on sand for proper and fine finish and erase the extra sand with the cutting
scale.
Invert the sand mound, now the pattern must be show on the mound.
Now place the cope of mound box on the drag.
Place sprue pins on both side of pattern.
Then fill the cope with sand completely.
Now, in place the sprue pins and cope from the drag.
After this, remove the pattern from mound box with the help of vent wires.
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11 Applications
Application of sand casting
Machine Bases
Large turbines impellers
Propellers
Plumbing fixtures
Agriculture and railroad equipment
12 Result
13 Conclusion
The product is casted successfully based on the proper techniques and methods which started
from the making of the mound using sand, the removal of the pattern, and pouring to the mound
through the sprue and pouring cup. The finishing work should be done to remove the gate and
runner.
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