Professional Documents
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Prepared for
Md. Abul Bashar
Course Instructor
MEC-238-Manufacturing process Lab
Prepared By
MD. Ismail Morshed
ID# 13307017
Program: BSME
Section: Day
Date of Submission
Experiment name:
object by
Manufacturing a simple
sand casting
Objectives:
To study the construction and operations of sand casting.
Introduction:
Sand casting, also known as sand molded casting, is a metal casting
process characterized by using sand as the mold material. The term
"sand casting" can also refer to an object produced via the sand
casting process. Sand castings are produced in specialized factories
called foundries. Our assignment was to select a pattern from the
existing set of patterns found in the Manufacturing Lab for this
experiment. We then were to create the mold we were to use for the
sand casting and cast the part using aluminum. Removing the cast
part after it was cooled from the sand was the next step and then our
job was to cut the attachments from the part and grind and polish if
necessary.
To complete this lab, we had to go back and refer to previous class
lecture notes to review the process of sand casting. We also had to
refer to the book on the correct procedures to follow when completing
this lab. Important safety actions were used in this lab because there
was use of an extremely hot furnace that heated the molten metal
that was to be poured in the pattern.
Design Approach:
Before starting Lab 6, we investigated different aspects of the process
that we are to perform in the sand casting process, we uses sand as
the mold material. Sand grains, mixed with small amounts of other
materials are used to improve the mold ability and cohesive strength.
The sand grains are packed around a pattern that has the shape of the
desired casting. New mold must be made for each casting, and gravity
usually is employed to case the metal to flow into the mold. We
created an opening called a sprue hole is provided through the sand
and connected to the cavity through a system of channels, called
runners. Molten metal is poured into the sprue hole and it enters the
cavity through the runners and an opening called a gate, which
controls the rate of flow. Also the design of the gating system is
important for proper delivery of the molten metal into the mold cavity.
We took in consideration that turbulence must be minimized, air and
gases must be allowed to escape by such means as vents, and proper
temperature gradients must be established and maintained to
minimize shrinkage and porosity. "The design of risers is also
important in order to supply the necessary molten metal during
solidification of the casting. The pouring basin may also serve as a
riser." (p. 297, Manufacturing engineering & tech, by Kaplan)
Equipment Used:
Bellow
Gate Cutter
Sprue
Hand Rammer
Lifter
Sifter
Furnace
Drag
Pin
Molding Board
Parting Sand
Molding Sand
Cope
Pattern
Strike off Board
Molten Metal
Micrometer
Ruler
Procedure:
Analysis:
For our last Brown Team effort we created an Indian Head. In creating
this part we had first hand experience with sandcasting. In analyzing
our part versus the original pattern there are many changes that
occurred.
First we looked at the percentage of shrinkage of our part. The
average shrinkage of our part was approximately a decrease from the
original part by 1.048%. An aluminum sand casted part should usually
undergo shrinkage of approximately 1-1.30% so, our part fell into a
normal category as far as the percent shrinkage that occured.
To find these calculations we measured the part and the pattern with a
micrometer and a ruler and then divided the results over the
corrections. The following is a list other values we received:
Bottom Thickness:
0.595" / 0.590" = 1.001% decrease from original
Top Thickness:
0.470" / 0.530" = 1.12% decrease from original
Thickness:
0.145" / 0.153" = 1.05% decrease from original
Left side:
0.888" / 0.885" = 1.01% decrease from original
can appear on the surface or through cracks that initiate during the
cooling of casting."(pg.68, Wakil )
To correct the sand wash we filled our part. The filling created a
smooth surface for our part. We didn't try to correct the hot tear,
because we were told not to correct the defects to our part. Our part
had jagged edges so we in turn filled the rough edges to make them
smooth.
Shrinkage occurred in our part and we talked about the percentages of
shrinkage in the previous section of our paper. There are two methods
we could have used to prevent shrinkage. Out of the two, we are going
to discuss the method that we would have suggested. We should have
used a bigger part so that we could compensate for shrinkage. Once
we made a bigger part we could have machined our part to the point
where the measurements would have corresponded to the
measurements of the pattern.
The most noticeable defect in our finished casted part occurred at the
bottom left side of the Indian's head on our part. If you look at the
cavities you will notice that there is a steep incline from the part to the
actual Indian's head. The steep incline is the reason that the
intricacies on the Indian's head didn't cast correctly. In viewing the
right side of the Indian head, you will find that, the parts intricacy was
cast correctly. The reason it casted this side, was because instead of
having a steep cavity, the right sides cavity had and incline. And thus,
the incline made it easier for the part to be cast.
Conclusion:
In concluding, the aforementioned sections: Introduction, Design
Approach, Theory and Calculations, Experimental Procedure, Analysis
and Discussion of the Results and Corrections, described in detail, the
processes that we used to produce our final piece. We did as predicted
in the introduction, overcome all trials, tribulations, and obstacles set
before us, yet we still ran into errors. These errors were added to the
write-up in an effort to document all mistakes for learning purposes.
These admissions of error will aid our team in preventing the same
errors from occurring.
Most of the errors occurring in this lab were attributed to the packing
of the sand and the way the molten metal was distributed when it was
poured into the sprue holes.
References:
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