Sand Casting Process and Parameters
Sand Casting Process and Parameters
– Spectro analysis ( by etching gas in to metal we can check the material Properties)
Based on Above testing methods we can find the base material properties which can be
used for following grades
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
– Reusability (They will heat the sand cake in Owen How much % we can reuse)
Casting Process Flow
Sand Mixing
Melting
o Sand Squeezing
o Sand Ramming
o Mold Cleaning
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
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
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 No bake process
o Manual nobake process (below 1 ton) - 90 to 95 INR(above 10ton manual 70 to 75INR / kg)
Casting cost/kg including = Raw Material cost + Process cost + Indirect cost