Lab Session: 05

Sand Casting

1. Title:

To study and prepare a casting for the given solid pattern using green sand molding process.

2. Problem Statement:

Casting is one of the oldest, most common and extensively utilizing manufacturing process. It is
being used in every field like mechanical, civil etc., so it is essential to understand the process. It
is required to study different parameters involved, SOPs for the preparation of cast part and
possible hazards encountered while developing casting of a given pattern.

3. Objective:

To understand the working principle, sand mold preparation and basic operating parameters of
Casting.

4. Theory:

4.1. Introduction:
Casting is the oldest known process to manufacture metallic and nonmetallic complements. For
example, it is applied for metals, plastic, porcelain etc. In sand casting the molten metal is poured
into apre- prepared sand mold, dimensioned, and contoured to match the desired casting. Internal
shapes in castings are obtained by placing backed core/cores consisting of silica sand and a binder
in the mold cavity. The molten metal is poured into the pouring basin and flows to the mold cavity
through a gate or system of gates. After filling the mold cavity, the melt enters the risers, which
act as a reservoir of excess metal to compensate for shrinkage during solidification. A new mold
must be made for each casting. The mold box can be designed to manufacture multiple components
to increase productivity. Usually machining and drifting allowances are also considered in mold
design.
 Figure 1: Schematic of Sand Casting

A "foundry" term usually applied to the collection of necessary material, tools and equipments
required to produce castings. Furthermore, "foundry man" term also applied to people produce
castings.

4.2. Principal of Casting:

In casting process, the liquid material is poured into a cavity (mold cavity) that corresponds to the
desired geometry. The shape obtained in liquid state is stabilized usually by solidification and then
removed from the mold as solid-state component.

4.3. Molding sand:

The fundamental requirements of sand is to resist high temperature, strength to retain the mold
shape, withstanding the mechanical load from liquid metal, permeability (to permit the escape of
gases, and collapsibility (to permit shrinkage). Molding sand consists of:

1. Sand material (resist the high temperature and permeability), commonly used are silica
(SiO2) or quartz sand (cheaper). Olivine sand also used for steel castings, Zircon and
synthetic sands also used but more expensive.
2. The binder (give the strength), e.g. Clay (bentonite, kaolin), Cement, Sodium silicate (for
Co2 process), Oil, Resin (shell molding).
3. Additives (gives collapsibility).
4. Water 4-8% (to activate the binder).
5. Sometimes the mold is baked in oven 100-300C, for several hours to obtain dry sand that
helps reduce gas holes, blows or porosity in castings.
4.4. Procedure:
Note: Describe the general procedure adopted to carry out the casting experiment with picture at
each stage.

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4.5. Safety Precautions:

The following safety precautions must be observed while performing casting:
 Read the safety instructions available in the lab for casting experiment.
 Always wear lab coat before starting any work.
 Wear eye protection, gloves, spats (covering top of feet), and thick clothing protecting all
exposed skin on arms and legs.
 NO polyester or synthetic clothing.
 Sand Floor in pouring area shall be clear of all objects not involved in pouring.
 Proper ventilation must be provided in the shop.
 Keep in mind the location of the fire extinguishers.

4.6. Observations:
Take the dimensions of the pattern/cavity and final cast product. Calculate the difference in their
dimensions and find the percentage shrinkage occur in casting a given product. Insert the picture
of mold cavity and final product.

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5. To Do Assignment:

Observe and study the casting process and complete the lab report as per the study questions
given below.
a. Discuss some of the defects produced in casting processes.

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b. Discuss the applications of casting with their pictures.

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c. What is the importance of pouring system in casting process?

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