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Sand Casting

The sand casting process involves first mixing sand with a binder to create molds. A pattern is placed in the bottom mold form and sand is compacted around it. Then the top mold form is added and more sand is compacted, leaving a cavity of the pattern shape. Once the mold fully forms, molten metal is poured in, taking the shape of the cavity. After cooling, the mold is broken apart to reveal the finished casting, which is then cleaned of sand. The process allows for metal parts to be formed by pouring liquid metal into a sand mold.

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Dhananjay Shimpi
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393 views92 pages

Sand Casting

The sand casting process involves first mixing sand with a binder to create molds. A pattern is placed in the bottom mold form and sand is compacted around it. Then the top mold form is added and more sand is compacted, leaving a cavity of the pattern shape. Once the mold fully forms, molten metal is poured in, taking the shape of the cavity. After cooling, the mold is broken apart to reveal the finished casting, which is then cleaned of sand. The process allows for metal parts to be formed by pouring liquid metal into a sand mold.

Uploaded by

Dhananjay Shimpi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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SAND CASTING

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Basic materials & equipment for sand-casting
Pattern
(a copy of the shape you want
to produce, made of wood,
plastic or metal)

Sand,
mixed with clay binder &
water (so it will hold its
shape) plus coal dust to
improve surface finish

Container of molten metal Top and bottom mold forms


(filled from furnace) (made of metal, open at top and bottom)

Rammer (tool to compact the sand; often a


pressing machine is used)

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Basic summary of the sand casting process. . .

First of all,
mix the sand.

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THEN MOLDING: 2 MOLDING:
Sand placed into Pattern placed into mold
bottom mold
form &
compacted

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3 MOLDING: Add A tube or pipe provides a
the top mold path to pour the metal in
form

Pattern is still inside!

4 MOLDING: Fill top form with


compacted sand.

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MOLDING:
5 Take the top mold off In the middle of the sand is
and remove pattern & a cavity shaped like the
pipe or post pattern!
Pouring
hole

6 MOLDING: Replace the top


mold and fasten securely!

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8 Wait for the metal to cool
(minutes to days, depending
7 CASTING: on the size of the casting)
Pour the metal (container is filled from
furnace immediately before you are
ready to pour)
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A copy of the pattern has
now been made in metal

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CLEANING. Sand is cleaned
off the part, the “tab” where
metal flowed in must be
removed.

8 SHAKE OUT: Break apart the two halves of 10 Mold forms are reused
the mold & take out the part—usually
requires vibrating or striking the mold to Sand is broken up, screened
break apart the sand 11 to remove debris and
clumps, and sent for remixing

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PATTERN
&
PATTERN MAKING

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PATTERN MAKING
ALLOWANCES

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MOLDING SAND

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Molding Sand Constituents

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Types of Molding Sand

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CORE & CORE MAKING

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SAND CONDITIONING

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Melting Furnaces

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Cupola

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Construction of Cupola

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Zones in Cupola

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Working of Cupola

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Electric Arc Furnace

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Induction Furnace

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