Sand Casting

Mr. Ankur Chaurasia,

Faculty,
School of Technology,
PDPU, Gandhinagar
 Casting
Different types of sands:

1. Green sand
2. Core sand
3. Dry sand
4. Loam sand
5. Facing sand
6. Baking sand
7. Parting sand
 Sand Casting
Green sand composition because it is mostly used sand:

Base sand : 85 to 90 % (Silica sand, Zircon sand, Olivian

sand, Chromite sand, Aluminum silicate sand)

Binder clay : 6 to 11 %

Additives : 2 to 8 %

Water : 2 to 5 %
 Binders
 Binders are added to give cohesion to the moulding
sand.
 Binders provide high strength to moulding sand
Types of binder.

1. Bentonite (southern and western bentonite)

2. Fire clay (found near to coal mines)
3. Illite
4. Limonite
5. kaolite
 Additives
 Used to prevent oxidation ,smooth surface on
casting, to prevent metal penetration, to improve the
collapsibility

1. Coal dust (make smooth surface)

2. Dextrin (increase dry compression strength and
erosion resistance)
3. Pitch ( increase hot strength )
4. Wood flour (improve collapsibility)
5. Dead clay (above 500 degree bentonite becomes
dead clay which reduces the expansion of sand.)
 Process
of
Sand Casting
The half of the split pattern to form the drag is
placed on a board and surrounded with a
moulding flask.

This is then filled with sand mixed with a

binder. Care is taken to ensure no voids are
included.

This 'half mould' is then inverted, the board

removed and the upper half of the split
pattern is located accurately on its lower
partner.
A parting agent (traditionally French
chalk) will often be dusted over the area
where the sand in the drag will contact the
sand to be poured into the cope.

Provision will be made for the 'runner' and

'riser'.
Sand mixed with a binder is now poured into the flask that forms the cope.

Having a good head of molten metal assists in ensuring a complete fill.

The two parts of the mould are separated
and the pattern is withdrawn by screwing a
tool into the lifting plate.

The moulder is seen applying the threaded

tool to the lifting plate between the two
dowels. The dowels ensure the two halves
of the pattern align accurately.

Final preparation of the mould is made

before the core is accurately located
within the mould supported on its core
prints.
The two halves of the mould are brought together. A dowel and
corresponding hole at each end of the two parts of the flask ensure the
cope and drag align.
 Steel of the correct mix is prepared in an electric
furnace.

Pouring from the furnace to a crucible that will

be taken to the mould by means of an overhead
crane

The pour from crucible to mould. Note full safety

equipment worn by the foundry man.
Molten steel is to be treated with great respect!
The filled moulds are now left to cool.
With a casting this size the mould will
be opened tomorrow.

One very nice pair of taper-shank buffers

ready for machining before being fitted
Thanks you