MSE 412 Abstract

Sand Casting

Albarakah, Raed

In this experiment we conduct a sand casting. The mold box contains two half which cope and drag. We used a core with shape of duck to perform this experiment. Moreover, we used a riddle to refine the sand. We filled the cope and the drag with sand. Furthermore, we pressed the sand with rammer to fill any gap. Aluminum was melted in a furnace with 1200 Fo using ladle. We spilled the metal in molding box. We waited until the metal become solid. Furthermore, the cope were removed and the duck were extracted. We removed the sprue and the riser. We finished the surface using grinder paper.

Introduction The sand casting process consists of (a) placing a pattern, having the shape of the desired casting, in sand to make an imprint; (b) incorporating a gating system; (c) filling the resulting cavity wit molten metal; (d) allowing the metal to cool until it solidifies; (e) breaking away the sand mold; and (f) removing the casting and finishing it. Example; part made by sand casting are engine block and cylinder head. The sequence of operation in sand casting is in position; the two halves (cope and drag) are closed, clamped, and weighted down (to prevent the separation of the mold sections under the pressure exerted when the molten metal is poured). The design of the gating system is important for proper delivery of the molten metal into the mold cavity. Turbulence must minimize, air and gases must be allowed to escape by vents or other means, and proper temperature gradients must be established and maintained to eliminate shrinkage and porosity. The design of risers is also important for supplying the necessary molten metal during the solidification of the casting.

MSE 412

Sand Casting

Albarakah, Raed

Experimental Procedure 1- Turn on furnace at 1200 F0 2- Put a core in the drag 3- Put some powder in the drag 4- Place a riddle in the drag 5- Fill the drag with sand using trowels 6- Use hand rammer top press the sand 7- Use vent rod to remove the extra sand 8- place the second half of core in the cope 9- spread some powder in the cope 10- Place a riddle in the cope 11- Fill the cope with sand using trowels 12- Press the sand using hand rammer 13- Make a channel using sprue pin in the cope 14- Use spike to make countersunk in the pouring cup 15- use spike to make countersunk in the riser 16- Use the spike to make a channel to the core in the drag 17- Assemble the cope and the drag 18- Put aluminum in the ladle 19- Place the ladle in the furnace 20- Spill the melting metal in the sprue 21- Stop when the metal filled the riser 22- Waite until the metal become solid 23- Remove the cope 24- Break the sprue and the riser 25- Smooth the surface using lathe machine. 2

MSE 412

Sand Casting

Albarakah, Raed

Figure 1: lab experiment with duck shap.

Results and Discussion Duck shape was the result of this experiment. We obtained this shape by using sand casting. Sand casting is best way to make large equipment. For example, Engine Block, Valves and pumps because of the space you need to make these parts. Furthermore, CNC machine is alternative method, hoverer; CNC machine has a limitation in producing engine blocks because of the size of the engine blocks. Sand cast usually an easy way to produce such a part. Moreover, this process much cheaper and saving time.

Conclusions Sand casting can be used with any material such as aluminum, Iron and steel. Sand casting less expensive than other processes and produce large equipment. The melting process need to be conducted carefully because every metal has different melting characteristics. For example, Aluminum melting point is 1200 Fo. Moreover, Type of sand is very important to obtain good surface also the sand should be changed after number of casting.

MSE 412

Sand Casting

Albarakah, Raed

References 1) SEROPE KALPAKJIAN, STEVEN R. SCHMID, 2008 ,MANUFACTURING PROCESSES FOR ENGINEERING MATERIALS, PRENTICE HALL , NEW JERSEY