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Sand Casting Process Overview and Patterns

Sand casting is a process where molten metal is poured into a sand mold cavity. There are two main types of sand used: green sand and dry sand. Green sand molds typically produce rougher castings than dry sand molds. The sand casting process involves making a pattern, using the pattern to form the mold cavity and any cores, and then pouring molten metal into the mold. The quality of the sand mold depends on factors like its strength, permeability, and collapsibility.

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19 views5 pages

Sand Casting Process Overview and Patterns

Sand casting is a process where molten metal is poured into a sand mold cavity. There are two main types of sand used: green sand and dry sand. Green sand molds typically produce rougher castings than dry sand molds. The sand casting process involves making a pattern, using the pattern to form the mold cavity and any cores, and then pouring molten metal into the mold. The quality of the sand mold depends on factors like its strength, permeability, and collapsibility.

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12dcc1947
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Overview

• Sand casting is a process where molten metal is cast in a mould made


from a sand mixture.
• In the past, the process was cost effective only for small volume
production. But nowadays it is also suitable for high volume
production thanks to automated equipment for making sand moulds.
• Sand castings generally have a rough surface sometimes with surface
impurities, and surface variations. Medium to large parts such as
valve bodies, crankshafts and engine blocks are typically
manufactured by this process.
• The dimensional accuracy and surface finish of the casting depend on
the type of sand and the moulding process.

Classification
• There are two main types of sand used for moulding: green sand and
dry sand.
• Green sand consists of silica sand, clay, moisture and other additives.
• Dry sand is a mixture of sand and fast curing adhesive.
• When dry sand is used, it is often referred to as no bake mould
casting or air set sand casting.
• Castings made from coarse green sand typically have a rough surface
whilst air-set moulds can produce castings with much smoother
surfaces.
Schematic showing the sand casting process.

Pattern

Pattern Types; (a) solid pattern, (b) split pattern, (c) match-
plate pattern, (d) cope and drag pattern
Pattern
• (a) Solid Pattern: made of one piece, adjusted in size for shrinkage
and machining, limited to very low production quantities.
• (b) Split Patterns: consist of two pieces, appropriate for complex parts
and moderate production quantities.
• (c) Match-Plate Patterns: two pieces of the split pattern are attached
to opposite sides of a wood or metal plate, used for higher
production quantities.
• (d) Cope and Drag Patterns: s are similar to match-plate patterns
except that split pattern halves are attached to separate plates, , so
that the cope and drag sections of the mold can be fabricated
independently, instead of using the same tooling for both.

Core

(a) Core held in place in the mold cavity by chaplets, (b)


possible chaplet design, and (c) casting with internal cavity.
Quality of sand mold
Several indicators are used to determine the quality of the sand mold:
(1)strength— the mold’s ability to maintain its shape and resist erosion caused by
the flow of molten metal; it depends on grain shape, adhesive qualities of the
binder, and other factors;
(2) permeability—capacity of the mold to allow hot air and gases from the casting
operation to pass through the voids in the sand;
(3)thermal stability—ability of the sand at the surface of the mold cavity to resist
cracking and buckling upon contact with the molten metal;
(4) collapsibility—ability of the mold to give way and allow the casting to shrink
without cracking the casting; it also refers to the ability to remove the sand from
the casting during cleaning; and
(5)reusability—can the sand from the broken mold be reused to make other molds?
These measures are sometimes incompatible; for example, a mold with greater
strength is less collapsible.

Shell-Mold Casting:
Shell-Mold Casting:
• 1- The two pieces pattern (match-plate or cope and drag) is made of
metal (e.g. aluminum or steel), it is heated to (175-370ºC) and coated
with a lubricant, e.g. silicone spray.
• 2- The dump box (which contains a sand) and pattern is inverted
many times to generate the sand shell onto the pattern.
• 3- Each heated half-pattern is covered with a mixture of sand and a
thermoset resin/epoxy binder. The binder glues a layer of sand to the
pattern, forming a shell. The process may be repeated many time to
get a thicker shell.

Shell-Mold Casting:
• 4- The assembly is baked into oven to cure it.
• 5- The patterns are removed and the shell molds are generated.
• 6- The two half-shells are joined together by a clamp to form the
mold and supported by sand or metal shot in a flask. The molten
metal is poured into the mold.
• 7- The shell is broken to get the final casting.

Common questions

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Dimensional accuracy depends on the uniformity and compactness of the sand and the moulding process. Different sand types, such as green sand and air-set sand, have different compaction and binding properties, affecting the smoothness and accuracy of the final cast .

In shell-mold casting, a metal pattern is heated and coated with lubricant, then covered with sand and resin to form a shell. This shell is baked to cure, removed from the pattern, and joined to form the mold. Metal is poured into this mold, and upon cooling, the shell is broken to retrieve the casting. Advantages include better surface finish and dimensional accuracy due to the precise shell formation .

Shell thickness affects thermal insulation and structural integrity during casting. Thicker shells provide better support and can withstand greater mechanical stresses, but they may also prolong cooling times. The right shell thickness ensures inadequate support and accurate transference of the mold pattern without compromising on cooling efficiency .

Thermal stability of the sand mold affects its ability to resist cracking and buckling upon contact with molten metal. If the surface of the mold cannot withstand rapid temperature changes, it can degrade, leading to defects in the casting surface and shape .

Reusability of sand reduces waste and material costs, supporting sustainable manufacturing. However, sand reusability might be limited by the degradation of binding qualities and contamination with impurities, affecting the quality of subsequent molds. A balance is needed to ensure consistency in mold performance while maximizing resource efficiency .

Automation has made sand casting suitable for high volume production by streamlining the process of making sand moulds, which was previously cost-effective only for small volume production .

Chaplets are used to hold cores in place within the mold cavity during casting. They help ensure the stability and correct positioning of the core, contributing to the dimensional accuracy and structural integrity of the final casting. Without chaplets, the core might shift or float, leading to defects .

Green sand castings generally have a rough surface due to the coarse nature of the sand, whereas air-set moulds can produce castings with much smoother surfaces because of the finer sand and adhesive used .

Incompatible qualities include strength and collapsibility. A mold with high strength may resist deformation during metal pouring but can be less collapsible, leading to difficulties in removing the casting and potential risk of cracking it as the metal cools and shrinkage occurs. Balancing these qualities is critical for quality castings .

Solid patterns are used for very low production quantities due to their one-piece nature and need for size adjustment for shrinkage. Split patterns are two-piece and better suited for moderate quantities and complex shapes. Match-plate patterns are higher production quantities, having two sides attached to a plate, streamlining the molding process. Cope and Drag patterns, similar to match-plate but with separate plates, allow fabrication of mold sections independently .

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