UCF

SAND CASTING
Prepared By-
Eng/yaser m abas elkelawy
Quality control manager in united
company for foundries UCF
Mobile / +201000732365

Email / yasernor@mail.ru
 Different Components…Different Aspects

Simple
Small

23 feet,
6 tonnes ,
99.72% iron,
No rust since 5th
century AD

Big Complex

Iron pillar

Courtesy: Google images

 Casting
Casting =
Pattern making + Mold making + Pouring
Molten Metal + Cooling + Removal + Inspection

Types of Casting :
Expendable Mold, Multiple Use Mold

Sand Casting :
Expendable Mold casting process uses sand as
molding material
 Casting Terminology

Parting line

Courtesy: efunda
 Pattern Making

What is pattern?
Approximate duplicate of product
Pattern material: Wood, Metals, Urethanes etc.
Types of Patterns:
One Piece or solid pattern, Split Pattern,
Match-plate pattern, Drag & Cope Pattern

Allowances:
Shrinkage, Machining, Draft, Distortion
 Pattern Making

One piece or Solid Pattern Split Pattern

Match Plate Pattern Cope & Drag Pattern

 Mold Making
 Consists : Sand Preparation and Mold Making

 Sand Properties :
Refractoriness, Cohesiveness, Permeability,
Collapsibility
 How to get these properties?

 Mold Making Methods:

Hand Ramming, Sand Slinger, Jolting, Squeezing,
Combination
 Pouring
Pouring System:
Pouring cup/Basin:
Rectangular Shape-No
vortex-No suction of
Gases
Sprue: Short-Less
KE –Less
turbulence-
Tapered shape

Sprue Well :
Dissipate KE-
Prevent splashing –
less turbulence
 Pouring
Riser
 Need :
Directional Solidification
Feeding molten metal to compensate for solidification
shrinkage

Criteria: Riser should solidify after the casting.

Types:

Image Courtesy: wiki

 Cooling/Solidification
Cooling Curve for a Pure Metal:
Pouring Temp.: Temp of first liquid
entering Mold cavity
Alloy-Distinct M.P.-freezing
range

Start of High Cooling Rate-fine

Solidification structures-good
mechanical properties

Chvorino’s rule :
ts=B(V/A)n
End of
Solidification B=Mold constant
n=1.5 to 2
 Solidification
Effect of Cooling rate:
Yield Tensile
Process Elongation(%)
Strength(MPa) strength(MPa)
Sand Casting 55 131 8
Permanent Mold 62 158 10
Die Cast 110 227 9

Cast Structure:

Image Courtesy: wiki

Removal of Casting:
Shake out-vibrating machine
Shot blasting-Removal of internal surface sand

Trimming:
Excess material-manual cutting, sawing-
Trimming Press

Inspection:
Nobody is perfect…Sand Casting too…Defects…
 Casting Defects:

Image Courtesy: IITM, Manufacturing Processes, Lecture notes

 Different Sand Casting Processes:

Green Sand Casting:

88% silica sand, 9% clay,3% water

CO2 Molding:
Sodium Silicate(3-6%)-CO2 flow- Strength Gain

Shell Molding:
Silica Sand + Thermo setting phenolic resin+ heat sensitive liquid catalyst-
shot on preheated metal pattern-shell formation
 Summary:

Includes :Casting=PMPCRI

Sand Casting -versatile process -produce almost all size &

shape of components -poor surface finish and dimensional
accuracy.

Sand Casting Methods : Green Sand, CO2 sand , Shell

 Acknowledgements:

1. Materials and Processes in Manufacturing, J T Black

and Ronald A Cohser, 10 th edition.

2. Assistant Professor M P Gururajan

http://mogadalai.wordpress.com/2006/01/14/some-
thoughts-on-making-presentations/
Thank you…