Table of Contents

1 Title..........................................................................................................................................2
2 Objectives.................................................................................................................................2
3 Apparatus..................................................................................................................................2
4 Picture.......................................................................................................................................2
5 Introduction..............................................................................................................................2
5.1 Casting..............................................................................................................................2
5.2 Pattern...............................................................................................................................3
5.3 Patternmaker decision.......................................................................................................3
5.4 Moulding sand...................................................................................................................3
5.5 Pouring of molten metal....................................................................................................4
6 Sand Casting terminologies......................................................................................................4
6.1 Cope..................................................................................................................................4
6.2 Drag...................................................................................................................................4
6.3 Parting line........................................................................................................................4
6.4 Pouring cap/basin..............................................................................................................4
6.5 Gas vent.............................................................................................................................4
6.6 Riser..................................................................................................................................4
6.7 Sprue.................................................................................................................................4
6.8 Runner...............................................................................................................................4
6.9 Mould Cavity....................................................................................................................4
6.10 Pattern...............................................................................................................................4
7 Major Components of sand mould...........................................................................................4
8 Procedure..................................................................................................................................5
9 Advantages of Sand Casting.....................................................................................................5
10 Disadvantages of Sand casting.............................................................................................5
11 Applications..........................................................................................................................5
12 Result....................................................................................................................................6
13 Conclusion............................................................................................................................6

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1 Title
To perform sand casting process.

2 Objectives
 To learn the process of Sand casting
 To learn how to use tools in sand casting

3 Apparatus
 Mold Board
 Mold Box
 Roller
 Rammer
 Clay Powder
 Slick
 Sprue Pins
 Vent wires
 Lifter
 Cutting Scale

4 Picture

Fig 01: Equipment

5 Introduction
5.1 Casting
 Casting is a manufacturing process in which a molten metal is poured into a mold of
some suitable material having internal cavity/cavities of the desired shape.
 The molten metal is then allowed to solidify.
 After solidification the mold is broken or opened to remove the casted part.

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  This casted part is then sent to the machine shop if further processing required in terms
of fettling and to improve the surface finish of the part.
5.2 Pattern
 In casting, a pattern is a replica of the object to be casted, used to prepare the cavity into
which molten material will be poured during the casting process.
 It provides the shape for object that need to be casted.
 Typically, patterns used in sand casting may be made of wood, metal, plastics or other
materials.
 Patterns are made to exacting standards of construction, so that they can last for a
reasonable length of time.
5.3 Patternmaker decision
 The patternmaker or foundry engineer decides where the sprues, gating systems,
and risers are placed with respect to the pattern.
 Where a hole is desired in a casting, a core may be used which defines a volume or
location in a casting where metal will not flow into.
 Sometimes chills may be placed on a pattern surface prior to molding, which are then
formed into the sand mound.
 Chills are heat sinks which enable localized rapid cooling.
 The rapid cooling may be desired to refine the grain structure or determine the freezing
sequence of the molten metal which is poured into the mold.

5.4 Molding sand

 The molding sand that contains moisture is termed as green sand.
 The sand selected should have enough strength so that the constructed mold retains its
shape.

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  In the meantime, when the moisture in the molding sand is completely expelled, it is
called dry sand.
 While the strength of the sand that is required to hold the shape of the mold cavity then is
called hot strength.
 Finally, the permeability is a term used to measure gas evolution capability during
solidification of a casting.
5.5 Pouring of molten metal
 Pouring of molten metal (melting practice) required a good discipline both from gating
system design and rising system application.
 Several parameters are applied such as pouring time, gating elements, gating ratios, and
slag trap system, methods of solidification behavior, feeding distances and feeding aids.

6 Sand Casting terminologies

There are many terminologies of sand casting that are given below
6.1 Cope
Is the top part of the flask.
6.2 Drag
Is the bottom part of the flask.
6.3 Parting line
Is the line where the drag and cope meet.
6.4 Pouring cap/basin
This is the hole on top of the cope part made to pour the molten aluminum into the flask.

Where we put liquid in the sand that place is pouring.

6.5 Gas vent

This is so when pouring the molten metal, the gas will escape from the vent. A gas vent can be
easily made using a straight wire.
6.6 Riser
The riser will feed more molten metal into the cavity mound when shrinking accurse.
6.7 Sprue
This is under the pouring cup connected to the runner channeling the molten metal into the
mound cavity.
6.8 Runner

The horizontal channel feeding the molten metal into the mound cavity.
6.9 Mold Cavity
This is where all the molten metal sets creating a duplicate of the pattern.

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6.10 Pattern
Any objects placed in the casting sand creating an impression of the pattern to be created. A
pattern could be made from steel, wood, plastic and other materials.

7 Major Components of sand mound

Some major components of sand molds are
 The mold itself, which is supported by a flask. The flask consists of two pieces of molds that
are known as the cope located on the top and a drag on the bottom.
 A pouring basin, into which the molten metal is poured.
 A sprue, the part where molten metal flows through.
 A riser, the section that supplies additional metal to the casting while the metal shrinks in the
solidification stage.
 Vents are placed in molds for the main purpose of releasing existing gases when the molten
metal comes into contact with the sand. They also exhaust air from the mold cavity as the
molten metal flows into the mold.

8 Procedure
 Take the mound box and place it on the mound board.
 Place the single cavity pattern in the mound box.
 Fill the drag of mound box with sand in proper way that pattern can’t be seen.
 After filling, do ramming for smooth surface.
 Roll the roller on sand for proper and fine finish and erase the extra sand with the cutting
scale.
 Invert the sand mound, now the pattern must be show on the mound.
 Now place the cope of mound box on the drag.
 Place sprue pins on both side of pattern.
 Then fill the cope with sand completely.
 Now, in place the sprue pins and cope from the drag.
 After this, remove the pattern from mound box with the help of vent wires.

9 Advantages of Sand Casting

 Relatively inexpensive production costs, especially in low-volume runs.
 The ability to fabricate large components.
 A capacity for casting both ferrous and non-ferrous materials.
 A low cost for post-casting tooling.

10 Disadvantages of Sand casting

 Low strength – Low material strength due to high porosity compared to a machined part.
 Low dimensional accuracy – Because of shrinking and the surface finish
dimensional accuracy is very poor.
 Poor surface finish – Due to internal sand mound wall surface texture.

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11 Applications
Application of sand casting
 Machine Bases
 Large turbines impellers
 Propellers
 Plumbing fixtures
 Agriculture and railroad equipment

12 Result

13 Conclusion
The product is casted successfully based on the proper techniques and methods which started
from the making of the mound using sand, the removal of the pattern, and pouring to the mound
through the sprue and pouring cup. The finishing work should be done to remove the gate and
runner.

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