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Answer:: 2.3 What Are The Major Types of Sand Molds? What Are Their Charactaristics ?

The document discusses the major types of sand molds used in casting and their characteristics. It identifies 8 major types: green sand, dry sand, loam sand, facing sand, parting sand, backing/floor sand, system sand, and core sand. Each type has different compositions and properties making them suitable for different casting applications and requirements.

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Ishaan Islam
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94 views7 pages

Answer:: 2.3 What Are The Major Types of Sand Molds? What Are Their Charactaristics ?

The document discusses the major types of sand molds used in casting and their characteristics. It identifies 8 major types: green sand, dry sand, loam sand, facing sand, parting sand, backing/floor sand, system sand, and core sand. Each type has different compositions and properties making them suitable for different casting applications and requirements.

Uploaded by

Ishaan Islam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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2.3 What are the major types of sand molds?

What are their


charactaristics ?

Answer: According to the use, moulding sand may be classified as below:


1. Green Sand:
The green sand is the natural sand containing sufficient moisture in it. It is
mixture of silica and 15 to 30% clay with about 8% water. Clay and water act as a
bonding material to give strength. Molds made from this sand are known as
green sand mould.

The green sand is used only for simple and rough casting products. It is used for
both ferrous and non-ferrous metals.

2. Dry Sand:
When the moisture is removed from green sand, it is known as dry sand. The
mould produced by dry sand has greater strength, rigidity and thermal stability.
This sand is used for large and heavy castings.

3. Loam Sand:
Loam sand is a mixture of 50 percent sand and 50 percent clay. Water is added
in sufficient amount. It is used for large and heavy moulds e.g., turbine parts,
hoppers etc.

4. Facing Sand:
A sand used for facing of the mould is known as facing sand. It consists of silica
sand and clay, without addition of used sand. It is used directly next to the
surface of the pattern. Facing sand comes in direct contact with the hot molten
metal; therefore it must have high refractoriness and strength. It has very fine
grains.
5.  Parting Sand:
A pure silica sand employed on the faces of the pattern before moulding is
known as parting sand. When the pattern is withdrawn from the mould, the
moulding sand sticks to it.

To avoid sticking, parting sand is sprinkled on the pattern before it is embedded


in the moulding sand. Parting sand is also sprinkled on the contact surface of
cope, drag and cheek.

6. Backing or Floor Sand:


The backing sand is old and repeatedly used sand of black colour. It is used to
back up the facing sand and to fill the whole volume of the box. This sand is
accumulated on the floor after casting and hence also known as floor sand.

7. System Sand:
The sand employed in mechanical heavy castings and has high strength,
permeability and refractoriness, is known as system sand. It is used for machine
moulding to fill the whole flask. In machine moulding no facing sand is used. The
system sand is cleaned and has special additives.

8. Core Sand

A sand used for making cores is known as core sand. It is silica sand mixed with
core oil (linseed oil, resin, mineral oil) and other binding materials (dextrine, corn
flour, sodium silicate). It has remarkable compressive strength.

9. Molasses Sand:
A sand which carries molasses as a binder is known as molasses sand. It is used
for core making and small castings of intricate shapes.

2.4 List important considerations when selecting pattern


materials.
Answer:
Pattern materials
The main pattern materials are wood, metal, and plastic. The selection of pattern
material depends on the size, complexity of pattern, dimensional accuracy
required and volume of (no of) the casting need to be make from one pattern.  In
this article we are about to discuss the various pattern material, their properties
and application.

Factors affecting the selection of pattern materials


1. Size and shape of the object to be casted.
2. The volume of production.
3. The surface finish and dimensional accuracy required.
4. The possibility of design change.
5. Molding method used.
6. Cost of the pattern material

2.5 What is the function of core ?

Answer: Core is a pre-prepared shape of the mould. It is used to provide


internal cavities, recesses, or projections in the casting. It is usually positioned
into a mould after the removal of the pattern.
A core is usually made of the best quality sand and is placed into desired position
in the mould cavity. Core prints are added to both sides of the pattern to create
impressions that allow the core to be supported and held at both ends.

When the molten metal is poured, it flows around the core and fill the rest of the
mould cavity. Cores are subjected to extremely severe conditions, and they must,
therefore, possess very high resistance to erosion, exceptionally high strength,
good permeability, good refractoriness, and adequate collapsibility.

2.6 What is the difference between sand-mold and shell mold


casting ?
Answer: shell molds and sand molds both use sand as a mold medium, but in
different ways. sand molds create cavities with in the sand and pours the molten
metal inside the cavity.
while shell molds create a pattern, places the patter in a box with sand /binder
mix. the sand/ binder is then placed on the to the pattern and creates a sand
mold over the pattern the mold is removed from the pattern and the molten metal
is poured into the mold.

Shell and sand molding both use sand but in different ways where sand mold
creates a cavity inside the sand in a flask. while, shell molding uses sand mixed
with a bonding resin to cover a heated pattern to create a mold.
2.11 List the advantages and limitations of die casting.
Answer:
Advantages and limitations of die casting:
Advantages of die casting:
 High productivity.
 Good dimensional accuracy.
 Good surface finish: 2-100 µinch (0.5-2.5 µm) Ra.
 Thin wall parts may be cast.
 Very economical process at high volume production.
 Fine Grain structure and good mechanical properties are achieved.
 Intricate shapes may be cast.
 Small size parts may be produced.
 Casting tensile strength as high as 415 MPa (60 ksi).

Limitations of die casting:


 Limited to high-fluidity metals.
 Not applicable for high melting point metals and alloys (eg. steels)
 Large parts can not be cast. Casting must be smaller than 600 mm (24 in.).
 High die cost.
 Too long lead time.
 Some gases my be entrapped in form of porosity.

2.12 What is the purpose of riser ? A vent ?


Answer: Risers are used to add molten metal to the casting during shrinkage
vents are used to release any gasses that may build when the metal comes in
contact with mold.

2.14 What are the advantages of the lost foam-casting process ?


Answer: The advantages of lost foam casting are:

 Neither additives, binders, nor cores are required.


 Scrap volumes are minimized; the equipment’s footprint is small; energy
and manpower requirements, as well as insurance premiums are reduced;
as are the machining and finishing requirements.
 Once installed, lost foam casting offers flexibility in casting design and is
environmentally friendly.

2.19 Why does die casting produce the smaller cast part ?
Answer:  Note that because of the high pressures involved in die casting, wall
thicknesses less than those a t t a i n a b l e b y o t h e r c a s t i n g m e t h o d s a r e
p o s s i b l e . A l s o , b e c a u s e o f   t h e h i g h   p r e s s u r e s ,   t h e velocity of metal
in the runners is higher than other processes; small parts can be cast
beforethe runner solidifies. This can even be accelerated by using
vacuum in the die. It should benoted that small parts can also be
produced in processes such as investment casting, but thesmallest
parts are in die casting for these reasons.

2.21 What differences, if any, would you expect in the properties


of casting made by permanent-mold versus sand-casting
processes ?

Answer: This is an open-ended problem, and a large number of

answers are acceptable. Most of thedifferent answers are associated


with the students’ interpretation of the word ‘properties’,whic h  can be
restricted to mechanical properties or  can incorporate design
attributes. Ex-amples of answers are that permanent-mold castings generally
possess a better surface finish,closer dimensional tolerances, more uniform
mechanical properties, and more sound thin-walled sections than sand
castings. However, sand castings generally will be of more
intricateshapes, larger overall sizes, and (depending upon the alloy) lower in
cost than permanent-moldcasting.

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