机械制造专业英语第7章SANDCASTING(砂型铸造)讲解.docx

SAND CASTING Most metal castings are made by pouring molten metal into a prepared cavity and allowing it to solidify. The process dates from antiquity. The largest bronze statue in existence today is the great Sun Buddha in Nara, Japan. Cast in the eighth century, it weighs 551 tons (500 metric tons) and is more than 71 ft (21m) high. Artisans of the Shang Dynasty in China (1766 - 1222B.C.) created art works of bronze with delicate filigree as sophisticated as anything that is designed and produced today. There are many casting processes available today, and selecting the best one to produce a particular part depends on several basic factors, such as cost, size, production rate, finish ,tolerance, section thickness, physical-mechanical properties, intricacy of design, machinability, and weldability. Sand casting, the oldest and still the most widely used casting process, will be presented in more detail than the other processes since many of the concepts carry over into those processes as well. Green Sand Green sand generally consists of silica sand and additives coated by rubbing the sand grains together with clay uniformly wetted with water. More stable and refractory sands have been developed, such as fused silica, zircon, and mullite, which replace lower-cost silica sand and have only 2% linear expansion at ferrous metal temperatures. Also, relatively unstable water and clay bonds are being replaced with synthetic resins, which are much more stable at elevated temperatures. Green sand molding is used to produce a wide variety of castings in sizes of less than a pound to as large as several tons. This versatile process is applicable to both ferrous and nonferrous materials. Green sand can be used to produce intricate molds since it provides for rapid collapsibility; that is, the mold is much less resistant to the contraction of the casting as it solidifies than are other molding processes. This results in less stress and strain in the casting. The sand is rammed