CONTENTS:

What is sand casting? .......................................................................................................2

The three primary casting processes……………………….…………………………...3

Pattern…………………………………………………………………………………….3

Sprues and Runners ..................................................................................................…... 4

Design considerations…………………………………...……………………………….5

Sand casting procedure………………………………………………………………….7

Procedure Photos……………………………………………………………..………….8

Mass properties………………………………………………………..………………..11

Calculation…………...………………………………………………………………….12

Conclusion…………………...………………………………………………………….13

Reference………………………………………………………………………………..15
What is Sand Casting?

This technique is usually used for high production volume processes. Sand
moulds are created using various materials, the sand must be bonded together using either
synthetic compounds or clay and water and moulds must be rebuilt after each casting.

The design of moulds is a very complicated process; however, in general, they are
filled simply by gravity without the need for any pressure differentials or mechanical
action.

Casting is generally the quickest way to produce either a small amount pf

prototypes or very production quantities. The casting process is used by almost every
industry as all metal can be cast. Common mill forms such as bar and plate are product
from cast metal.

Sand casting is used to make large parts(typically Iron, but also Bronze, Brass,
Aluminum). Molten metal is poured in to the mold cavity formed out of sand (natural or
synthetic). The processes of sand casting are discussed in this section; include patterns,
sprues and runners, design considerations, and casting allowance.

Many casting processes use patterns that form the cavity of the mold and can be
made of wood, plastic, or metal. Pattern which are expandable (consumed by the mold
making process or by the poured metal during casting) are made of wax, plastic, or
polystyrene foam. Patterns are oversized to make up for metal shrinkage as it solidifies.
They will also have taper (Draft) to ease pattern release and make allowance for finishing
and metal transfer through the mold. Cores are also needed to create any recesses,
undercut, and hollows required in the part.

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 The three primary casting processes are:

• Expandable mold/reusable pattern.

The expandable mold/reusable pattern method includes the sand mold, plaster
mold, and ceramic mold casting.

• Expandable mold/expandable pattern.

Expandable mold/expandable pattern method includes investment casting and

evaporative-foam casting.

• Permanent mold/ no pattern.

Pattern:

The cavity in the sand

is formed by using a pattern (an
approximate duplicate of the
real part), which are typically
made out of wood, sometimes
metal. The cavity is contained
in an aggregate housed in a box
called the flask. Core is a sand
shape inserted into the mold to
produce the internal features of
the part such as holes or
internal passages. Cores are
placed in the cavity to form holes of the desired shapes. Core print is the region added to

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the pattern, core, or mold that is used to locate and support the core within the mold. A
riser is an extra void created in the mold to contain excessive molten material. The
purpose of this is feed the molten metal to the mold cavity as the molten metal solidifies
and shrinks, and thereby prevents voids in the main casting.

In a two-part mold, which is typical of sand castings, the upper half, including the
top half of the pattern, flask, and core is called cope and the lower half is called drag. The
parting line or the parting surface is line or surface that separates the cope and drag. The
drag is first filled partially with sand, and the core print, the cores, and the gating system
are placed near the parting line. The cope is then assembled to the drag, and the sand is
poured on the cope half, covering the pattern, core and the gating system. The sand is
compacted by vibration and mechanical means. Next, the cope is removed from the drag,
and the pattern is carefully removed. The object is to remove the pattern without breaking
the mold cavity. This is facilitated by designing a draft, a slight angular offset from the
vertical to the vertical surfaces of the pattern. This is usually a minimum of 1° or 1.5 mm
(0.060 in), whichever is greater. The rougher the surface of the pattern, the more the draft
to be provided.

Sprues and Runners:

The molten material is poured in the pouring cup, which is part of the gating
system that supplies the molten material to the mold cavity. The vertical part of the gating
system connected to the pouring cup is the sprue, and the horizontal portion is called the
runners and finally to the multiple points where it is introduced to the mold cavity called
the gates. Additionally there are extensions to the gating system called vents that provide
the path for the built up gases and the displaced air to vent to the atmosphere.

The cavity is usually made oversize to allow for the metal contraction as it cools
down to room temperature. This is achieved by making the pattern oversize. To account
for shrinking, the pattern must be made oversize by these factors, on the average. These
are linear factors and apply in each direction. These shrinkage allowance are only
approximate, because the exact allowance is determined the shape and size of the casting.

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In addition, different parts of the casting might require a different shrinkage allowances
and castings generally have a rough surface sometimes with surface impurities, and
surface variations. A machining (finish) allowance is made for this type of defect.

Design considerations:

Location of the parting line/plane. By properly locating the parting plane.

The number of cores can be reduced.
The gating can be made less elaborate.
The material wasted can be reduced.
The dimensional accuracy can be increased.

Use of uniform thicknesses in a casting, where possible. Uniform thicknesses lead

to uniform cooling and solidification. This leads to stress free and distortion free castings.
Heavier sections cool more slowly, and may have shrinkage cavities, porosities and large
grain structures. Voids, porosities and cracks can be sites of subsequent failures and
should gestation be prevented by minimizing variations in cross sections.

When uniform cross-

sections cannot be maintained, then
changes in cross-sections must be
gradual. A recommended way to
achieve this is to use a transition
radius of 1/3 of the thicker section
and blend in the radius with a 15-
degree slope line.

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 When two or more uniform sections
intersect, they create a region of heavy cross-
section, resulting in the problems mentioned
earlier. One way to minimize this is to core
the intersection by a hole, similar to a hub
hole in a wheel with spokes.

When sections intersect to form continuous ribs, contraction occurs in opposite

directions as the material cools down. This leads to a high stress area at the intersections,
causing cracking immediately, or in service. The
way to avoid this is to stagger the ribs and thereby
maintain uniform cross-sections.

Large unsupported areas tend to warp, so they

should be avoided.

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Sand Casting Procedure:

2. The cope and drag are then

1. The pattern first makes an
combined and are ready to accept
impression in the cope and drag.
the metal.
The impression created includes
the gating system as

3. The metal is heated and prepared

metallurgic ally. It is transferred 4. The molten metal is then poured
to a crucible just before pouring. into the mold.

5. The part is allowed to sit and
cool. Once cooled the casting and
gating system are removed from
the mold and the sand is
recycled.
6. The casting is then sent to the
finishing department where any
remains of the gates are ground
off.

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7. The part is the cleaned and ready
to ship.

Procedure Photos:

Main Part (pattern):

Core’s sand preparation:

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Mold making:

Pouring:

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Cleaning:

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Mass properties:

Mass properties of casting drawing ( Part Configuration - Default )

Output coordinate System: -- default --

Density = 0.00 grams per cubic millimeter

Mass = 18.70 grams

Volume = 18700.06 cubic millimeters

Surface area = 15050.22 square millimeters

Center of mass: (millimeters)

X = 0.00
Y = -2.80
Z = 0.00

Principal axes of inertia and principal moments of inertia: (grams * square millimeters)
Taken at the center of mass.
Ix = (0.00, 1.00, 0.00) Px = 4461.49
Iy = (-1.00, 0.00, -0.00) Py = 14488.47
Iz = (-0.00, 0.00, 1.00) Pz = 16603.46

Moments of inertia: (grams * square millimeters)

Taken at the center of mass and aligned with the output coordinate system.
Lxx = 14488.47 Lxy = 0.00 Lxz = 0.04
Lyx = 0.00 Lyy = 4461.49Lyz = 0.00
Lzx = 0.04 Lzy = 0.00 Lzz = 16603.46

Moments of inertia: (grams * square millimeters)

Taken at the output coordinate system.
Ixx = 14634.90 Ixy = 0.00 Ixz = 0.04
Iyx = 0.00 Iyy = 4461.49 Iyz = 0.00
Izx = 0.04 Izy = 0.00 Izz = 16749.89

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Calculation:

Some important equations in pouring:

Velocity of the liquid metal at the base of the sprue:

v = 2.g .h

v= 2.( 9.81 m / s 2 ).( 0.03534 m) = 0.83268889 m/s

Volumetric flow rate:

Q = v. A

Q = (0.000914415 ).( 0.83268889 ) = 7.614182 x10 −4 m 3 / s

Mold filling time:

MFT = V / Q

MFT = 0.83268889 /( 7.614182 x10 −4 ) = 1093 .6 sec ond

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CONCLUSION:

In this report we have tried to explain our casting

project.We discussed

our casting process in this report,also we put some

solidwork and autocad

drawings about our part.

As a first step we choosed our casting part ,and then we made a core for

sand casting.After we finished making core ,we started

to doing sandmold

.Step by step we made our mold.First of all we sieved

the sand and then we

hardened the sand with water.

After these steps we prepare our mold .And then we molt metal ,and we poured

the molten metal in our sand mold.When we finished our casting and opened

the mold. We saw some errors in our part,already our aim is not producing

excelent parts.Our aim is just analysing the errors in our casted part .

When we are doing our core we did some error because of this errors we haven’t

got enough place between core and mold so we have empty surface in our product.
 Because of the wrong riser and runner calculations we have some shrinkage

problem.And again because of the this calculation error we found wrong solidification

time value so we have misrun problem.We have some desıgn fault ,we used 3 riser so we

losed metal.If we use 2 riser and runner we lose lower metal then using 3 risers and

runner . As a conclusion we can say that we saw our mistakes ,we analysed our errors

and we finished our casting project.

Casting Drawing:
Reference:
http://www.world-aluminium.org/production/processing/casting.html.
http://www.efunda.com/processes/metal_processing/permanent_mold.cfm.
http://www.efunda.com/processes/metal_processing/sand_casting_design.cfm.
http://www.mccannsales.com/book/sandcasting.pdf.
http://me.emu.edu.tr/majid/ME%20364/ME364_casting_overview.PDF