Sulaimany polytechnic university

Technical College of engineering

Mechanical Engineering

WORK SHOP
(Casting)
Prepared by: Haryad Hiwa & Asan Nori
Supervised by: m.Lana

(2023-2024)
CONTENT

 Introduction about casting process

 Type of casting

 Sand casting

 Procedure of process

 Type of sand in Sand Casting

 The main required properties of Sand Casting

 The important of Sand Casting tests

 Type of pattern

 Sand Casting equipment

 Advantage of Sand Casting processes

 Disadvantages of Sand Casting processes

Sand Casting
Sand casting is a commonly employed and very ancient metal casting
technique. It involves forming cavities within packed and bonded sand that
is then charged with molten metal. The chosen metal solidifies to reproduce
the cavity shape in fine detail.

casting process are:

1- Selection suitable sand to create sand mold and to control on quality of

casting.

2- Put pattern from wood or metal in sand to create mold cavity.

3- Do small hammering on the sand to make stability of the pattern.

4- Remove the pattern.

5- Fill the mold cavity with molten metal.

6- Allow the molten article to cool.

7- break the sand mold and remove the casting product.

The sand casting process is usually economical for small batch size
production, but with small limitations, some finishing required, small coarse
finish, wide tolerances. The quality of the sand casting depends on the
quality and uniformity of green sand material that is used for making the
mold. Figure (22) schematically show a two of parts of sand mold, also
referred to as a cope and drag sand mold. The molten metal is poured
through the pouring cup and it fills the mold cavity after passing through
down sprue, runner and gate. The core refers to loose piece which are
placed inside the mold cavity to create internal holes or open section. The
riser is used as a container or reservoir to excess molten metal that
facilities additional filling of mold cavity to compensate for volumetric
shrinkage during solidification. Sand castings process provides several
advantages. It can be employed for all types of metal. The tooling cost is
low and can be used to cast very complex shapes. However sand castings
offer poor dimensional accuracy and surface finish.
 Casting Process

Sand Casting

Prepare the sand Pattern making

Mold Making

Melting and pouring themetals

Removal and Trimming

Casting Inspection

.
 TYPE OF SAND IS USED FOR SAND CASTING

GREEN SAND
Green sand refers to the sand molds formed from wet sand and is sometimes
referred to as clay. The sand mold is in an uncured state as the metal is being
poured. Sand casting using green sand is quick and inexpensive since the sand can
be reused. The downside is that the sand is a soft mold and can collapse or shift
during casting, leaving an unusable cast. However, the process is reliable enough
that it has survived for centuries and is still used today.

SODIUM SILICATE OR WATER GLASS

Sodium silicate can also be used to create the mold casting. Sodium Silicate can
quickly go from a liquid to a solid by passing carbon dioxide through it. This causes
the sodium silicate to dehydrate. This process is extremely useful when a cavity is
required within the casting. Though sodium silicate can create a solid core for the
casting it must be mixed with other materials to allow the breakdown after
casting so the core can be removed. If the mixture isn’t correct the core will
become lodged within the casting, causing the casting to be useless.

RESIN SAND
Once mixed and heated, resin sand becomes a solid mold with a smooth surface.
A solid mold means fewer defective castings, but the disadvantage is a higher cost
and slower production rate. Where green sand molds are quick to create, resin
sand molds take more time since each must be mixed and burned to create the
perfect mold. The cost of resin sand is much greater and, though the resin can be
reused, it constantly needs to be replenished. This makes the process more costly.
 The main required properties of Sand casting

The important properties of casting sand are as follows:

Porosity (Permeability)

Porosity, also known as permeability, is a crucial property of molding sand, representing its
ability to allow gases to pass through. During the pouring of molten metal into the sand
cavity, gases and steam are generated. This property depends on the shape, size of sand
particles and the amount of clay, binding material, and moisture in the mixture.

Cohesiveness

Cohesiveness refers to the sand's ability to hold its particles together, providing strength to the
molding sand. It plays a vital role in retaining intricate shapes of the molding. Insufficient
cohesiveness may lead to mold collapse during handling and closing. Clay and betonies improve
cohesiveness.

Adhesiveness

Adhesiveness is the property of sand that causes sand particles to stick to the sides of the moulding
box, facilitating proper lifting of the cope along with the sand.

Plasticity

Plasticity enables the molding sand to flow to all corners around the mold when rammed, ensuring
no left-out spaces and acquiring a predetermined shape under ramming pressure.

Flowability

Flow ability represents the molding sand's ability to free flow and fill the recesses and fine details in
the pattern, with flow ability varying with moisture content.

Collapsibility

Collapsibility is the property of sand that causes the sand mold to collapse automatically after the
solidification of the casting. The mold should disintegrate into small sand particles with minimal
force after the casting is removed.

Refractoriness

Refractoriness is the property of sand to withstand the high temperature of molten metal without
fusion or softening. Molding sands with poor refractoriness may burn when molten metal is poured
into the mold, while sand molds should ideally withstand up to 1650°C.
Sand Testing Methods:
Sand testing methods are used to assess the properties of foundry green sand or
molding sand for casting. The moulding sand after it is prepared should be
properly tested to see that the required properties are achieved. Tests were
conducted on a sample of the standard sand. The moulding sand should be
prepared exactly as it is done in the shop on the standard equipment and then
carefully enclosed in a container to safeguard its moisture content.

Sand tests indicate the molding sand performance and help the foundry men in
controlling the properties of molding sands. Molding sand testing methods
control the molding sand properties and testing through the control of its
composition.

Some of these tests include:

1. Sand Testing:

- Sand Composition: Checking the composition of the molding sand to ensure

it has the right mixture of sand, clay, and other additives.
- Moisture Content: Monitoring the moisture content in the sand to prevent
defects in the casting.

2. Mold Hardness Test:

- This test measures the hardness of the molding sand mixture, which can
affect the quality of the mold.

3. Permeability Test:

- Permeability measures how easily gases can escape from the mold during
metal pouring. Proper permeability is essential to avoid defects like
porosity in the casting.

4. Shrinkage Test:

- Determining the shrinkage allowance is crucial to compensate for the

contraction of the metal as it cools and solidifies.
 5. Pouring Temperature Measurement:

- Ensuring the metal is poured at the correct temperature is essential for

achieving the desired properties in the final casting.

6. Visual Inspection:

- Checking the surface finish and inspecting the casting visually for any
defects, such as cracks, inclusions, or irregularities.

7. Dimensional Inspection:

- Verifying that the final casting meets the specified dimensional

requirements.

These tests collectively help ensure that the sand casting process produces high-
quality and accurate metal parts. The specific tests conducted may vary based on
the type of metal being cast, the complexity of the part, and other factors specific
to the casting process being used.