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Objectives: -
To Get A Hands-On Experience On Metal Casting Through The Process Of Sand Casting. To Become Accustomed With The Language And Procedures Of Metal Casting In General And Sand Casting In Particular. To Deploy The Knowledge Of Metal Casting Into Making Useful Products Through The Process Of Sand Casting.
Background: Metal Casting Is The Process In Which Molten Metal Is Poured Into A Mold With A Hollow Cavity Having The Shape Of The Desired End Product. After Cooling Down And Solidifying, The Casting Can Be Taken Out Of The Mold By An Ejection Mechanism Or By Forcing It Out Through The Destruction Of The Mold. Metal Casting Is The Oldest Method Of Metalworking. It Has Been Used By Humans Since Thousands Of Years For Making A Vast Variety Of Tools Such As Weapons, Jewelry, And Sculptures. Lost-Wax Casting, Plaster Mold Casting, And Sand Casting Are The Most Prominent Processes Of Metal Casting. Most Of The Time, Metal Casting Processes Are Categorized Into Two Categories, Depending On Whether The Mold Is Expendable Or Not. Sand Casting, As The Name Implies, Is The Process Of Metal Casting In Which The Mold Used Is Made Of Sand. Cost-Effectiveness And Sufficient Refractory Properties Are The Merits That Make Sand Casting The Most Deployed Metal Casting Process. Sand Casting Takes Place In Specialized Manufactories Called Foundries, In Where The Molds Are Made From A Mixture Of Sand, Clay, And Water. The Mold Cavities And The Gate Systems Are Then Made By Compacting Sand Around A Pattern Or Are Carved Directly Into The Sand.
Equipment: -
Safety Shoes. A Safety Coat. Molding Sand. A Casting Flask. The Metal To Be Molten. A Furnace. A Ladle.
A Cope And A Drag.
Bronze And Aluminum Castings.
Molten Bronze In A Ladle.
Procedure: 1234-
Acquiring The Molding Sand. Acquiring The Pattern. Acquiring The Casting Flask. Placing One Half Of The Pattern In One Half Of The Casting Flask (The Drag). 5- Compacting The Molding Sand Around The Placed Half Of The Pattern. 6- Making Vents Into The Resulting Semi-Mold. 7- Flipping The Semi-Mold Over. 8- Applying Powder To The Flipped Semi-Mold. 9- Precursoring The Sprues. 10- Placing The Other Half Of The Casting Flask (The Cope) On Top Of The Drag. 11- Placing The Other Half Of The Pattern In Top Of The First Half. 12- Compacting The Molding Sand Around The Placed Other Half Of The Pattern. 13- Making Vents Into The Other Semi-Mold. 14- Separating The Two Semi-Molds. 15- Finishing The Precursored Sprues In The First Semi-Mold. 16- Carving The Gate System In The Other Semi-Mold. 17- Combining The Two Semi-Molds Together. 18- Pouring The Molten Metal Into The Mold. 19- Allowing The Poured Molten Metal To Cool Down And Solidify. 20- Breaking The Sand Mold And Acquiring The Casting.
Data And Calculations: There’s None Actually.
Conclusion: Metal Casting Is One Of The Most Wide-Spread Processes In Manufacturing. Its Economic Viability, Technological Simplicity And Overall Naturalness Make Obvious The Reasons Of Its Popularity. However, Metal Casting Is Not The Silver Bullet Of Manufacturing. The Overhead, The Mediocre Quality Of The Castings, And The Potential Hazards Of Metal Casting Are Some Of The Reasons Why It Isn’t So.
