Sand Casting: Introduction Page 1 of 2

Sand Casting: Intr

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Design
Sand casting is used to make large parts (typically Iron, but also Bronze, B
Allowance
Aluminum). Molten metal is poured into a mold cavity formed out of sand (n
Shell Mold Casting synthetic). The processes of sand casting are discussed in this section, includ
Squeeze Casting patterns, sprues and runners, design considerations, and casting allowance.
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Injection Molding The cavity in the sand is formed by using a pattern (an approximate duplicat
PartSpec real part), which are typically made out of wood, sometimes metal. The cavi
Reinforced Plastics contained in an aggregate housed in a box called the flask. Core is a sand sh
more...
inserted into the mold to produce the internal features of the part such as ho
internal passages. Cores are placed in the cavity to form holes of the desired
Login Core print is the region added to the pattern, core, or mold that is used to lo
support the core within the mold. A riser is an extra void created in the mold
excessive molten material. The purpose of this is feed the molten metal to th
cavity as the molten metal solidifies and shrinks, and thereby prevents voids
main casting.

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Typical Components of a Two-part Sand Casting Mold.

http://www.efunda.com/processes/metal_processing/sand_casting_intro.cfm 3/24/2005
Sand Casting: Introduction Page 2 of 2

In a two-part mold, which is typical of sand castings, the upper half, includin
half of the pattern, flask, and core is called cope and the lower half is called
parting line or the parting surface is line or surface that separates the cope a
The drag is first filled partially with sand, and the core print, the cores, and t
system are placed near the parting line. The cope is then assembled to the d
the sand is poured on the cope half, covering the pattern, core and the gatin
The sand is compacted by vibration and mechanical means. Next, the cope i
from the drag, and the pattern is carefully removed. The object is to remove
pattern without breaking the mold cavity. This is facilitated by designing a d
slight angular offset from the vertical to the vertical surfaces of the pattern.
usually a minimum of 1° or 1.5 mm (0.060 in), whichever is greater. The ro
surface of the pattern, the more the draft to be provided.

Sprues and Runners

The molten material is poured in the pouring cup, which is part of the gating
that supplies the molten material to the mold cavity. The vertical part of the
system connected to the pouring cup is the sprue, and the horizontal portion
the runners and finally to the multiple points where it is introduced to the m
called the gates. Additionally there are extensions to the gating system calle
that provide the path for the built up gases and the displaced air to vent to t
atmosphere.

The cavity is usually made oversize to allow for the metal contraction as it co
to room temperature. This is achieved by making the pattern oversize. To ac
shrinking, the pattern must be made oversize by these factors, on the avera
are linear factors and apply in each direction. These shrinkage allowance are
approximate, because the exact allowance is determined the shape and size
casting. In addition, different parts of the casting might require a different s
allowance. See the casting allowance table for the approximate shrinkage al
expressed as the Pattern Oversize Factor.

Sand castings generally have a rough surface sometimes with surface impur
surface variations. A machining (finish) allowance is made for this type of de
casting allowance table for the finish allowance.

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