SandCastingNotes-WorldCollegesInformation.docVIP

Sand Casting Contents 1. Capabilities 2. Process Cycle 3. Equipment 4. Tooling 5. Materials 6. Possible Defects 7. Design Rules 8. Cost Drivers Sand casting, the most widely used casting process, utilizes expendable sand molds to form complex metal parts that can be made of nearly any alloy. Because the sand mold must be destroyed in order to remove the part, called the casting, sand casting typically has a low production rate. The sand casting process involves the use of a furnace, metal, pattern, and sand mold. The metal is melted in the furnace and then ladled and poured into the cavity of the sand mold, which is formed by the pattern. The sand mold separates along a parting line and the solidified casting can be removed. The steps in this process are described in greater detail in the next section. Sand casting overview Sand casting is used to produce a wide variety of metal components with complex geometries. These parts can vary greatly in size and weight, ranging from a couple ounces to several tons. Some smaller sand cast parts include components as gears, pulleys, crankshafts, connecting rods, and propellers. Larger applications include housings for large equipment and heavy machine bases. Sand casting is also common in producing automobile components, such as engine blocks, engine manifolds, cylinder heads, and transmission cases. Return to top Capabilities Typical Feasible Shapes: Thin-walled: ComplexSolid: CylindricalSolid: CubicSolid: Complex FlatThin-walled: CylindricalThin-walled: Cubic Part size: Weight: 1 oz - 450 ton Materials: MetalsAlloy SteelCarbon SteelCast IronStainless SteelAluminumCopperMagnesiumNickel LeadTinTitaniumZinc Surface finish - Ra: 300 - 600 μin 125 - 2000 μin Tolerance: ± 0.03 in. ± 0.015 in. Max wall thickness: 0.125 - 5 in. 0.09 - 40 in. Quantity: 1 - 1000 1 - 1000000 Lead time: Days Hours Advantages: Can produce very large partsCan form complex shapesMany material optionsLow tooling and equipment cos