Name Usama Arif

Roll no 2020-ME-15
Experiment 1
Solid Pattern
Objective
To understand the use of and carry out sand casting with a solid pattern to cast
an object.

Apparatus
 Ladle
 Single Pattern
 Roller
 Runner
 Gate
 Molasses
 Clay Powder
 Slick
 Strike off bar
 Lifter
 Molding Flask
 Sand Mixer Machine
 Gate Cutter
 Mallet
 Cope
 Drag
 Screw Pin

Procedure
The first step in the sand casting process is to create the mold for the casting.
In an expendable mold process, this step must be performed for each casting. A
sand mold is formed by packing sand into each half of the mold. The sand is
packed around the pattern, which is a replica of the external shape of the
casting. When the pattern is removed, the cavity that will form the casting
remains. Any internal features of the casting that cannot be formed by the
pattern are formed by separate cores which are made of sand prior to the
formation of the mold. Lubrication is applied to the surfaces of the mold cavity
in order to facilitate removal of the casting.
Once the mold has been made, the cores are positioned and the mold halves are
closed and securely clamped together. It is essential that the mold halves remain
securely closed to prevent the loss of any material.
The metal is melted in a furnace. After the mold has been clamped, the molten
metal is ladled from its holding container in the furnace and poured into the
mold. Enough molten metal must be poured to fill the entire cavity and all
channels in the mold. The filling time is very short in order to prevent early
solidification of any one part of the metal.
The molten metal that is poured into the mold will begin to cool and solidify
once it enters the cavity. When the entire cavity is filled and the molten metal
solidifies, the final shape of the casting is formed. The mold cannot be opened
until the cooling time has elapsed. The desired cooling time can be estimated
based upon the wall thickness of the casting and the temperature of the metal.
After the predetermined solidification time has passed, the sand mold can simply
be broken, and the casting removed. In the industry sand blasting is sometimes
used to remove any remaining sand, especially from internal surfaces, and reduce
the surface roughness.
During cooling, the material from the channels in the mold solidifies attached to
the part. This excess material must be trimmed from the casting either manually
via cutting or sawing, or using a trimming press. The scrap material that results
from this trimming is either discarded or reused in the sand casting process.

Experiment 2
Split Pattern

Objective
To understand the use of and carry out sand casting with a solid pattern to cast
an object.

Apparatus
 Ladle
 Split Pattern
 Roller
 Runner
 Gate
 Molasses
 Clay Powder
 Slick
 Strike off bar
 Lifter
 Molding Flask
 Sand Mixer Machine
 Gate Cutter
  Mallet
 Cope
 Drag
 Screw Pin

Procedure
The first step in the sand casting process is to create the mold for the casting.
In an expendable mold process, this step must be performed for each casting. A
sand mold is formed by packing sand into each half of the mold. The sand is
packed around the pattern, which is a replica of the external shape of the
casting divided into two parts. One for the cope and one for the drag. When the
pattern is removed, the cavity that will form the casting remains. Any internal
features of the casting that cannot be formed by the pattern are formed by
separate cores which are made of sand prior to the formation of the mold.
Lubrication is applied to the surfaces of the mold cavity in order to facilitate
removal of the casting.
Once the mold has been made, the cores are positioned and the mold halves are
closed and securely clamped together. It is essential that the mold halves remain
securely closed to prevent the loss of any material.
The metal is melted in a furnace. After the mold has been clamped, the molten
metal is ladled from its holding container in the furnace and poured into the
mold. Enough molten metal must be poured to fill the entire cavity and all
channels in the mold. The filling time is very short in order to prevent early
solidification of any one part of the metal.
The molten metal that is poured into the mold will begin to cool and solidify
once it enters the cavity. When the entire cavity is filled and the molten metal
solidifies, the final shape of the casting is formed. The mold cannot be opened
until the cooling time has elapsed. The desired cooling time can be estimated
based upon the wall thickness of the casting and the temperature of the metal.
After the predetermined solidification time has passed, the sand mold can simply
be broken, and the casting removed. In the industry sand blasting is sometimes
used to remove any remaining sand, especially from internal surfaces, and reduce
the surface roughness.
During cooling, the material from the channels in the mold solidifies attached to
the part. This excess material must be trimmed from the casting either manually
via cutting or sawing, or using a trimming press. The scrap material that results
from this trimming is either discarded or reused in the sand casting process.

Theory
One of the most anciently used (about six thousand years ago) and
commonly used type of casting is sand casting which can be used for the
casting of complex geometries even which can be used in large machines
(after proper finishing). In this report, we will discuss casting, its
types particularly sand casting, mold formation in sand casting and the
materials added to sand in sand casting.
Casting
“The manufacturing process in which molten metal is poured into cavity
(mold) under the action
of gravity or under pressure where is solidifies to give the required
product is called casting.”
The term casting also refers to the product or part obtained after this
process.
The principle of casting is very simple, first of all melt the
metal to be casted, pour it into the cavity or mold and then
finally allow it to solidify. Various factors have to be
encountered during the entire process.

Types of Casting
On the basis of mold, casting can be classified into following types:
i. Expendable Mold Casting
ii. Permanent Mold Casting
Expendable Mold Casting
“The type of casting in which the mold has to be destroyed in order to
remove the casting is
called expendable mold casting.”
A typical expandable mold is made up of sand, plaster and ceramics etc.
with binders added to them. Sand casting is the most common example of
this type.

Permanent Mold Casting

“The type of casting in which the same mold can be used again and again
for multiple castings is
called permanent mold casting.”
Metals capable of bearing high temperature as used as a mold material in
this case. Die casting is the common example of this type.
Sand Casting
“The type of expendable mold casting in which mold is made up of sand is called
sand casting.”
Sand molding consists of pouring the molten metal into sand mold,
allowing it to solidify and then destroying the mold to remove the part.
Mold formation in Sand Casting
The following steps are followed for mold formation:

(a) A pattern is placed between the drag and cope of the flask.

(b) Sand is then packed into drag of the flask.Runners and sprues and then
adjusted on the cope of the flask.

(c) The pattern, runners and sprues are removed.

(d) The cope and drag are placed over each other and the mold are ready to
use.
 Figure 8.2: Steps in Mold Formation

Components added to sand in Casting

The following components can be added to sand in sand casting in
order to improve its binding strength:
i. Granular materials (e.g., Silica, Olivine, Zircon, Chromite sand etc.)
ii. Water
iii. Clay
iv. Binder (e.g., Molasses etc.)

Comments on Performance
A large number of factors are involved in sand casting in order to make
it successful. First of all, proper mixing of binder with sand is very
important otherwise proper mold will not be formed. Second, the
selection of sand type is very important in order to achieve proper
strength and permeability (to allow the trap gases to escape). The skill
of a worker is very crucial to the success of sand casting. Proper
pouring rate should be achieved in order to allow the molten metal to
fill into the cavity and to avoid turbulence. Pouring temperature should
also be sufficient enough to allow proper casting.