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SAND CASTING

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Sand,

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

Pattern(a copy of the shape you want to produce, made of wood, plastic or metal)

Basic materials & equipment for sand-casting

Container of molten metal(filled from furnace)

Top and bottom mold forms(made of metal, open at top and bottom)

Rammer (tool to compact the sand; often a

pressing machine is used)

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MOLDING:

Sand placed into bottom mold

form & compacted

MOLDING:

Pattern placed into mold

Basic summary of the sand casting process. . .

21THEN

First of all, mix the sand.

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MOLDING: Add the top mold form

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4 MOLDING: Fill top form with compacted sand.

A tube or pipe provides a path to pour the metal in

Pattern is still inside!

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MOLDING:Take the top mold off and remove pattern & pipe or post

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6 MOLDING: Replace the top mold and fasten securely!

Pouring hole

In the middle of the sand is a cavity shaped like the

pattern!

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7 CASTING:Pour the metal (container is filled from furnace immediately before you are ready to pour)

8 Wait for the metal to cool(minutes to days, depending on the size of the casting)

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8 SHAKE OUT: Break apart the two halves of the mold & take out the part—usually requires vibrating or striking the mold to break apart the sand

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

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A copy of the pattern has now been made in metal

10 Mold forms are reused

11Sand is broken up, screened 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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