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Sand Casting Process and Parameters

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187 views

Sand Casting Process and Parameters

Uploaded by

t.ramana
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 PDF, TXT or read online on Scribd
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Sand Casting process steps

 Raw Material incoming inspection


 Pattern making & inspection
 Core making & inspection
 Metal melting
– Electric Arc furnace
 Pouring
– Curing time of 1hr
 Shake out (differentiate sand and casted part)
 Runner & gates removing (de gating)
 Sand blasting (sand) / shot blasting ?(shots, steel balls)
 Deburring / parting line grinding or matching
 Sand blasting (sand) / shot blasting ?(shots, steel balls)
 Painting
 Manual inspection
 Dispatch
Sand Casting process steps
Raw Material incoming inspection

– Spectro analysis ( by etching gas in to metal we can check the material Properties)

Raw Materials preparation for melting

 Based on Above testing methods we can find the base material properties which can be
used for following grades

– Grey Cast iron (FG-180, 200, 220, 240,260, 300, 400)

– Ductile cast iron (SG-400/12, 400/18)

 Then based on your product Material specification we need to add Alloys to base

metals while melting (EX:- Carbon, Silicon, Manganese, Sulphur, Zinc, Copper and

etc….)
Sand Casting Process
• Sand Mixing by sand mixture machine (New sand 5% + return sand 95%+
bentonite clay+ water) They will mix all this materials then they will do below

listed tests for sand cake.

 Sample Checking (sand properties)

– Strength (By applying pressure , we need to check where it is breaking)

– Permeability (how well gases pass through the sand)

– Thermal Stability ( Heat withstand stability)

– Collapsibility (How much load is required to break this sand cake)

– Reusability (They will heat the sand cake in Owen How much % we can reuse)
Casting Process Flow
Sand Mixing

Pattern Mold / Core Metal


Preparation Solidification
Making Pouring

Melting

Flashes Sand Flask


Cleaning De-Gating
Grinding Removal

Inspection Painting Packing Dispatch


Core Making Process
 Co2 Core Making – Hand core making (by using co2 gas @ 7%)
– Core Material – sand 100%
– Bonding – catalyst 3%
– Only one time use of this sand
– After core making 2days we can store this for production
– It is 2 part agent (2 materials used)
 Machine core making – Cold box core making (by using Amine gas @0.8%)
– Core Material – sand 100%
– Bonding – oil A (1%) & Oil B (1%) with Amine Gas
– Only one time use of this sand
– After core making 15 days we can store this for production
– It is 3 part agent (3 materials used)
 Shell Moulding core making – Very fine finish and less wall thickness
– Core Material – Phenolic Resin sand 100%
– Bonding – Ready to Use sand
– Only one time use of this sand
– After core making 30 days we can store this for production
Green sand Moulding process
o Sand Filling

o Sand Squeezing

o Sand Ramming

o Pouring Cup & Venting

o Core Fixing , Chillers placing

o Mold Cleaning

o Cope & Drag Closing

o Clamping
Melting
 Electric Arc Furnace ( furnace liners cost 15,000 inr – Liners life 1ton capacity x 30 times)
– 1 Ton melting cycle time – 1hrs

– Melting cost per kg – 11 to 12 inr

Pouring
 Metal pouring – 6 to 7kgs per second
 Ladle is used for pouring of material (They will do Magnesium treatment while taking
molten metal to ladle

After pouring - line inspection


 Raw Material Pouring – After casting line inspection
– Image analyser (Micro structure Ex. Elite company material structure image)

– Tensile Strength checking (by creating sample Test piece , by pulling)


Imp Parameters cost calc– Sand casting
o Melting cost per kg – 11 to 12 INR
o Metal Melting furnace time – 1 Ton/ 1 hr

o Shot blasting – 1Ton weight part / 2.5kgs balls (steel balls – per kg 55 INR)
o 1 Ton sand mixing time Automated – 3mins
o Sand preparation /kg – 6.5 to 7.5 INR

o Sand Casting

o Green sand moulding per kg – 70 to 75 INR (Machine moulding)

o No bake process

o Manual nobake process (below 1 ton) - 90 to 95 INR(above 10ton manual 70 to 75INR / kg)

o Automate nobake process - 120 to 130 INR

Casting cost/kg including = Raw Material cost + Process cost + Indirect cost

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