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Manufacturing Processes-I: April 18, 2022

The document summarizes the sand casting process. It discusses that sand casting is the oldest casting method still used today for large components. The key steps are: (1) placing a pattern in sand to create a mold cavity, (2) incorporating gating, (3) pouring molten metal, (4) allowing solidification, and (5) breaking away the sand mold. It also describes that patterns are typically made of wood, metal, or plastic depending on the needed precision, lifespan, and number of castings.

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Mandar Gupte
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39 views8 pages

Manufacturing Processes-I: April 18, 2022

The document summarizes the sand casting process. It discusses that sand casting is the oldest casting method still used today for large components. The key steps are: (1) placing a pattern in sand to create a mold cavity, (2) incorporating gating, (3) pouring molten metal, (4) allowing solidification, and (5) breaking away the sand mold. It also describes that patterns are typically made of wood, metal, or plastic depending on the needed precision, lifespan, and number of castings.

Uploaded by

Mandar Gupte
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Manufacturing

Processes-I
BTMC401

Lecture 5
Sand Casting Process
April 18, 2022

B A J A J I N S T I T U T E O F T E C H N O L O G Y
Previous Lecture
▪ Fluid flow
▪ Fluidity
▪ Terminology
Casting Processes
Sand Casting
▪ Oldest casting method
▪ Still used for many components
▪ Machine bases, large turbine impellers, propellers, plumbing
fixtures etc.
▪ All casting alloys can be sand cast
▪ It involves
▪ Placing a pattern in sand to make an imprint
▪ Incorporating a gating system
▪ Removing the pattern and pouring molten metal in cavity
▪ Allowing the metal to cool as it solidifies
▪ Breaking away the sand mold
▪ Removing the casting
Sand Casting
▪ Process
Sand Casting
▪ Illustration of sand mold
Sand Casting
▪ Pattern
▪ Exact replica of the casting, full-sized model of the part
▪ Slightly oversized to account for shrinkage and machining.
▪ Modified in accordance with requirements of casting process,
metal being cast and particular molding technique.
▪ Selection of pattern materials
▪ Number of castings to be made
▪ The size and shape of casting
▪ Desired dimensional precision
▪ Molding process
Sand Casting
▪ Pattern Materials
▪ Wood
▪ Relatively easy to make and are frequently used
when small quantities of castings are required.
▪ Not dimensionally stable.
▪ Tends to warp, swell and abraded by sand particles.
▪ Limitation of number of times it can be used
▪ Metals: expensive but last longer
▪ Plastic: compromise between metal & wood

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