INTRODUCTION

Casting process is a production process where the metal

is formed directly from the molten state, pouring it into a mould
and allowing it to cool and solidify, expelled from the mould to
be clean or machine for finishing.

The sand casting process is usually chosen for the
production of small quantities of identical castings, complex
castings with intricate cores, large castings and structural
castings.
TOOLS AND EQUIPMENT
PROCEDURE
FIRST STEP
-the drag (lower moulding box) in upside down position
and placed on top of a flat and clean plate
-ensure the floor also flatted
Moulding box for sand mould casting


SECOND STEP
-lower part of the split pattern placed in the drag
-the parting powder scattered over the pattern
and the plate
Preparing the pattern for the sand ramming
THIRD STEP
- finer sand gain from sieving process place around
and over the pattern for 3cm of thickness
- by pressing with the fingers, the finer sand then
pressed to the pattern and around it compactedly
-ensure that the pattern are still while the
sand compacted











Pressing the finer sand around and over the pattern
FOURTH STEP
- then add the rest of the sand for into the moulding box
- use a rammer to compact the sand with slow stroke
- add more sand over the moulding box and compressed it
with harder stroke
-continue/ repeat this process until gaining compacted
sand over the moulding box






Adding and compressing the sand


FIFTH STEP
- by using a strip bar, stripped/flatten
the surface of the compressed sand
- the bar pulled from a conner to another
by moving it to the right and left Stripped/ flatten the sand surface






SIXTH STEP
- flip the drag so that the pattern would be on top,
then place the cope on top of the drag
- lock both cope and drag together
The position of cope and drag




SEVENTH STEP
- upper split pattern placed on top of the
lower pattern in the drag perfectly,
then placed the sprues (runner and riser)
in the suitable positions
- shattered the parting powder over the
pattern,sprues and the sand surface in
the drag.

EIGHT STEP

- sieve the sand in the moulding box to gain
-3cm of finer sand around and over the pattern
-compress the sand with fingers
-add and ram the sand same as the fourth step

The position of the pattern and the sprues
The sand mould after eighth step

NIGHT STEP

- use a strip bar to striped/flatten
the surface of sand in the cope
- use a ladle to strip the sand surface
around the sprues.

TENTH STEP

- twist the sprues, then pull it
out slowly
- use a ventilation rod to make
ventilation holes at the sand
mould surface



Strippen/flatten the sand mould using a strip bar
Pulling out the sprue
The ventilation rod usage
ELEVENTH STEP

- separate both boxes (cope and drag)
and flip it to retrieve the split pattern
- before retrieve the pattern,
knock it slowly so that the pattern
and the sand surface are loosen
- use draw pins to retrieve both
pattern sides from the mould
- the cavity will formed after
retrieving the pattern

The boxes part (cope and drag) are separated to retrieve the pattern
TWELTH STEP
-a channel for molten metal
flow create using gate cutter and squire
-the channel should connect
the sprue cavities and the mould cavity
- the channel function as a guide
for the molten metal to flow to
the mould cavity through sprue cavities .

Channels for molten metal flow
THIRTREETH STEP
- core will be place in the lower cavity mould then the upper
moulding box (cope) will be place back to its position
(on top of drag)





Core position in the moulding box
FOURTREETH

- using moulding throwel, a basin for pouring the molten metal
into are made on the surface of the cope beside
a sprue cavity called the runner .
- the ready for pouring molten metal mould brought closer to
the furnace .
- the molten metal poured into the basin, flowing through the
runner and straight to the cavity
- after the molten metal solidify, the product can be retrieve
by breaking the mould .

Pouring the molten metal into the mould process
Casting molten metal activity
The sand casting process is usually chosen for the production of small
quantities of identical castings, complex castings with intricate cores, large
castings and structural castings.
First step is you must prepare molding box for sand mold casting. the
drag (lower moulding box) in upside down position and placed on top of a flat
and clean plate. Ensure the floor also flatted. Then you must preparing the
pattern for the sand ramming. Lower part of the split pattern placed in the
drag and the parting powder scattered over the pattern and the plate.
Next step is pressing the finer sand around and over the pattern. In
this step, finer sand gain from sieving process place around and over the
pattern for 3cm of thickness. By pressing with the fingers, the finer sand then
pressed to the pattern and around it compactedly and ensure that the pattern
are still while the sand compacted. After that, adding and compressing the
sand. Add the rest of the sand for into the moulding box, use a rammer to
compact the sand with slow stroke and add more sand over the moulding box
and compressed it with harder stroke. Then, continue/ repeat this process
until gaining compacted sand over the moulding box

Next, The position of cope and drag is set up. In this step, you must
flip the drag so that the pattern would be on top, then place the cope on top
of the drag and lock both cope and drag together . After that, you must set up
the position of the pattern and the sprues . Upper split pattern placed on top
of the lower pattern in the drag perfectly, then placed the sprues (runner and
riser) in the suitable positions and shattered the parting powder over the
pattern, sprues and the sand surface in the drag.
The sand mould after eighth step. In this step, sieve the sand in the
moulding box to gain 3cm of finer sand around and over the pattern, compress
the sand with fingers and add and ram the sand same as the fourth step. Next,
strippen orn flatten the sand mould using a strip bar. use a strip bar to
striped/flatten the surface of sand in the cope and use a ladle to strip the sand
surface around the sprues.
Next step, pulling out the sprue and the ventilation rod usage. Twist
the sprues, then pull it out slowly and use a ventilation rod to make ventilation
holes at the sand mould surface. Then, the boxes part (cope and drag) are
separated to retrieve the pattern . Separate both boxes (cope and drag) and
flip it to retrieve the split pattern. Before retrieve the pattern, knock it slowly
so that the pattern and the sand surface are loosen. Use draw pins to retrieve
both pattern sides from the mould

Then, make a channels for molten metal flow. A channel for molten
metal flow create using gate cutter and squire and it should connect the sprue
cavities and the mould cavity. The channel function as a guide for the molten
metal to flow to the mould cavity through sprue cavities. After that, core
position in the moulding box. Core will be place in the lower cavity mould then
the upper moulding box (cope) will be place back to its position (on top of
drag).
Finally, pouring the molten metal into the mould process. In this final
step, using moulding throwel, a basin for pouring the molten metal into are
made on the surface of the cope beside a sprue cavity called the runner. The
ready for pouring molten metal mould brought closer to the furnace and the
molten metal poured into the basin, flowing through the runner and straight
to the cavity. After the molten metal solidify, the product can be retrieve by
breaking the mould