Pattern Types

(a) solid pattern
(b) split pattern
(c) match-plate pattern
(d) cope and drag pattern

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The Pattern

A full-sized model of the part, slightly enlarged to
account for shrinkage and machining allowances in
the casting

Pattern materials:

Wood - common material because it is easy to work, but it warps
Metal - more expensive to make, but lasts much longer
Plastic - compromise between wood and metal

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Sand Casting Process

Steps in Sand Casting

1.Pour molten metal into sand mold

2. Allow metal to solidify

3. Break up the mold to remove casting

4. Clean and inspect casting

5. Heat treatment of casting is sometimes required to improve metallurgical properties

 

Making the Sand Mold

 

1.The cavity in the sand mold is formed by packing sand around a pattern, then     

  separating the mold into two halves and removing the pattern

2.The mold must also contain gating and riser system

3.If casting is to have internal surfaces, a core must be included in mold

4.A new sand mold must be made for each part

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Casting Patterns QUIZ

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SAND CASTING QUIZ

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Sand Casting

•Most widely used casting process, accounting for a significant majority of total tonnage cast

•Nearly all alloys can be sand casted, including metals with high melting temperatures,

  such as steel, nickel,and titanium

•Parts ranging in size from small to very large

•Production quantities from one to millions

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Categories of Metal Casting Processes

1. Expendable mold processes - mold is sacrificed to remove part

--Advantage: more complex shapes possible

--Disadvantage: production rates often limited by time to make mold rather than casting itself

2. Permanent mold processes - mold is made of metal and can be used to make many castings

--Advantage: higher production rates

--Disadvantage: geometries limited by need to open mold+

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METAL CASTING PROCESSES

•Sand Casting

•Other Expendable Mold Casting Processes

•Permanent Mold Casting Processes

•Foundry Practice

•Casting Quality

•Metals for Casting

•Product Design Considerations

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