Download - Sand Casting
1
SAND CASTING
2
3
4
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)
5
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.
6
MOLDING: Add the top mold form
3
4 MOLDING: Fill top form with compacted sand.
A tube or pipe provides a path to pour the metal in
Pattern is still inside!
7
MOLDING:Take the top mold off and remove pattern & pipe or post
5
6 MOLDING: Replace the top mold and fasten securely!
Pouring hole
In the middle of the sand is a cavity shaped like the
pattern!
8
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)
9
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.
9
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
10
PATTERN
&
PATTERN MAKING
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PATTERN MAKING
ALLOWANCES
35
36
37
38
39
40
41
MOLDING SAND
42
Molding Sand Constituents
43
44
45
Types of Molding Sand
46
47
48
49
50
51
52
53
CORE & CORE MAKING
54
55
56
57
58
59
60
61
62
63
64
65
66
SAND CONDITIONING
67
68
69
70
71
72
73
74
76
77
78
79
80
Melting Furnaces
81
82
Cupola
83
Construction of Cupola
84
85
Zones in Cupola
86
Working of Cupola
87
88
Electric Arc Furnace
89
90
Induction Furnace
91
92
