Sand Casting

Sand Casting Process

Sand Casting is a widely employed method for manufacturing larger products using materials such as Steel, Iron, Brass, and Aluminum. The process involves pouring molten metal into a mold cavity formed with sand. This cavity is shaped using a pattern, essentially a replicated model of the intended part, and is commonly crafted from wood.

The mold cavity is enclosed within a container known as a flask. Various components within the mold allow for the incorporation of internal features. These include a Core, a sand shape inserted to create internal features like holes or passages; a Core Print, an added area to the pattern, core, or mold for locating and supporting the core within the mold; and a Riser, an extra void in the mold to accommodate excess molten material. The purpose of the riser is to feed molten metal to the mold cavity, preventing voids in the final casting as the metal solidifies and shrinks.

In a two-part mold, standard in sand castings, the upper half, comprising the top part of the pattern, flask, and core, is termed the cope, while the lower half is called the drag. The parting line separates the cope and drag. The drag is initially filled with sand, and the core print, cores, and gating system are positioned near the parting line. The cope is then assembled to the drag, and sand is poured onto the cope half, covering the pattern, core, and gating system. Vibration and mechanical means compact the sand. Subsequently, the cope is separated from the drag, and the pattern is carefully removed without breaking the mold cavity.

Molten metal is poured into the pouring cup, a part of the gating system supplying molten material to the mold cavity. The vertical part of the gating system is the sprue, and the horizontal part is the runners. These lead to various points, or gates, where the metal enters the mold cavity. Vents in the gating system allow gases and displaced air to escape.

The mold cavity is usually oversized to accommodate metal contraction as it cools, achieved by making the pattern larger. Shrinkage allowances, approximate values determined by factors such as casting size, shape, and material, are added to the pattern. Sand castings often exhibit a rough surface with impurities and variations. A machining (finish) allowance is typically incorporated to address these imperfections.

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Sand Casting

Applications by Vertical Industries

Sand Casting is a versatile manufacturing process that finds applications in various vertical industries due to its ability to produce large, complex parts. Some of the key industries that commonly use sand casting include:

Automotive Industry

Sand Casting is used for producing engine components, transmission parts, and other automotive components.

Aerospace Industry

Critical aerospace components, such as turbine blades, engine housings, and structural parts, are often manufactured using sand casting.

Heavy Equipment Manufacturing

Industries that produce heavy machinery, such as construction equipment and agricultural machinery, often utilize sand casting for components like engine blocks and structural elements.

Oil and Gas Industry

Sand Casting is employed to manufacture components used in the oil and gas sector, including parts for pumps, valves, and drilling equipment.

Energy Sector

Sand casting is utilized to produce components for power generation equipment, such as turbine components, generator parts, and heat exchangers.

Railway Industry

Sand Casting is used to manufacture various components used in railway systems, including train components and rail infrastructure parts.

Mining Industry

Mining equipment, such as crushers, gears, and structural components, can be produced using sand casting.

General Machinery Manufacturing

Sand Casting is widely used in the production of general machinery components, including gears, pulleys, and housings.

Pump and Valve Manufacturing

Components for pumps and valves, crucial in various industries, are often produced using sand casting due to its cost-effectiveness for large and complex parts.

Metal Foundries

Sand Casting is a fundamental process in metal foundries that serve various industries, providing a method for producing a wide range of metal parts.

Marine Industry

Components for ships and marine equipment, such as propellers and engine parts, can be manufactured using sand casting.

Architectural and Artistic Applications

Sand Casting is also employed in creating artistic sculptures, architectural elements, and decorative pieces due to its flexibility in shaping intricate designs.

The adaptability and cost-effectiveness of sand casting make it a popular choice across multiple industries for producing both prototypes and large production runs of metal components.

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