ENT 244 LAB 1: SAND CASTING

MANUFACTURING ENGINEERING PROCESS

LAB 1: SAND CASTING

OBJECTIVE

1. To observe the basic elements of the casting process.

2. To inspect the casting for visible surface defects.

INTRODUCTION AND THEORY

There are numerous casting techniques, including sand casting, die casting, investment
casting, and continuous casting. Sand Casting is a technique used to make many metal
copies from a master part. Sand casting is the oldest and simplest means of manufacturing
shaped components and is still widely used today.

The first step in casting is the design and construction of a master part, called pattern. This
is the duplicate of the part to be cast. The pattern is placed in a 2 part box, called a flask,
and is covered on all sides by special sand. The preparation and the bonding of this sand
mould are the critical step and very often are the rate-controlling step of this process. A
pattern should be removed before pouring the molten metal, producing a copy of the
original pattern.

There are many types of patterns used in the foundry; some of them are listed below:

1. One-piece or Solid Pattern: In this type, the pattern is in one piece.

2. Split Patterns: In this type pattern is in two pieces, and this type is used where one
piece pattern is no applicable.

3. Match-plate-Pattern: This type is similar to split type pattern, the only difference is
that the pattern is mounted on the metal plate. The plates are used to align the two
metals.

4. Lose Piece Pattern: Pattern is made in pieces and they are assembled and cavity is
made. When the cavity is ready and the metal is casted then they are disassembled.

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ENT 244 LAB 1: SAND CASTING
MANUFACTURING ENGINEERING PROCESS

Fig. 1: Parts of the mould

Fig. 2: Furnace

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ENT 244 LAB 1: SAND CASTING
MANUFACTURING ENGINEERING PROCESS

EQUIPMENTS / APPARATUS

1. Molding bench
2. Molders sand shovel
3. Foundry riddles
4. Bottom board
5. Molding flasks
6. Patterns
7. Rammers
8. Strike off bar
9. Molding trowels
10. Gate cutter and square
11. Sprue pins
12. Vent wire
13. Wet brush
14. Draw pins
15. Rapper
16. Bellows
17. Spray can
18. Hacksaw
19. Crucible furnace
20. Metal pick-up tongs

Materials: Parting dust, Molding sand, Chemical additives

Safety wear: Eye glasses and face shield, Heat resistant gloves, Knee leggings and Bib
type aprons

Metals: Aluminum

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ENT 244 LAB 1: SAND CASTING
MANUFACTURING ENGINEERING PROCESS

PROCEDURE

1. Place the drag with pattern plate in front of you. Make sure that the drag box is pointing
upwards.

2. Parting dust is spread on the patterns. Coal, wood dust, or graphite can also replace the
function of parting dust.

3. Use riddle to cover pattern with sand.

4. Ram the sand in three to four layers slightly above the edge of the mould. A good
pressing along the edges of the pattern is particularly important.

Fig. 3: Pressing the sand

5. Flatten the surface by using a scraper or Strike Off Bar.

6. With 1/4" of loose sand on level surface of Drag, lay bottom board on Drag.

7. Move bottom board back and forth about 1" pressing down until board sits firmly.

8. Flip Drag, clamps can be used to simplify this process.

9. Turn now the moulding box and place the cope section in position. Insert the downgate
as well as the big and small riser. Apply parting dust.

10. Riddle sand on the Cope.

11. Ram the sand.

12. Strike off the Cope and smooth with trowel.

13. Remove the downgate and both risers by slightly moving them back and forth

14. Remove Cope by lifting straight up. Then remove the pattern. Apply parting dust on
both cope and drag.

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ENT 244 LAB 1: SAND CASTING
MANUFACTURING ENGINEERING PROCESS

15. Ram up the core box with sand and insert the core rod from the small borehole
vertically. Flush bottom and surface of core with the scraper. Open core box.

16. Remove the core and place the core into the drag box.

17. Place cope on the drag and screw them together.

Fig. 4: Completed Mold.

18. Put casting ladle with metal in the furnace and heat up to max 74C (depends to the
metal type). Cast as speedy as possible. CAREFUL! The molten metal is very hot!
Safety attire should be wear when pouring the molten metal into the mould.

19. Cope flask removed.

20. Drag the casting from the flask. Casting complete.

21. Clean the casting and cut off the sprue and runner.

22. Inspect the casting for visible surface defects.

23. Then cut the casting through its thickest section with the band saw and inspect for
visible internal defects.

24. To view the surface better, etching process is applied to the cross section (optional).

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ENT 244 MANUFACTURING PROCESSES LAB REPORT

1) Draw the flow chart the sequences for making sand casting mould.

25 Marks

2) Discuss the significance of sifting process to get refined green sand for making the sand
casting mould.

25 Marks

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ENT 244 MANUFACTURING PROCESSES LAB REPORT

3) Discuss the purpose of pressing the green sand during making the sand casting mould.

25 Marks

4) Discuss the function of pouring basin, sprue, runner, gates, blind riser, and vents in sand
casting mould.

25 Marks