JF 302 Material Technology 1

AE 301 COMMUNICATIVE ENGLISH 2PROCESS OF SAND CASTINGLecturers Name: Madam Ting Lee FahGroup members:Nur Hasanah binti Rohaizat06DKM12F1163Muhammad Faridz bin Anuwar06DKM12F1128Muhammad Nizam bin Muhammad Zainal06DKM12F1141Muhamad Azzaiherin bin Ribut06DKM12F1146

SAND CASTING PROCESS

Why we choose this process ?This process is relate to our field of study; Mechanical Engineering.

Sand casting process is world-wide used.

Sand Casting ProcessThe sand casting process is usually chosen for the production of small quantities of identical castings, complex castings with intricate cores, large castings and structural castings.Sand casting toolsSAND MOULD containing 85% silica sand, 8% bentonite and 7% water.MOULDING BOX/FLASK a box where use to made a mould in it, containing 2 parts (cope and drag), made by wood or metal.PATTERN a model or replica of product, made according to the real shape of the product, made by wood, metal, plastic, wax or plaster.

CORE to produce a hollow product, made by plaster, metal, ceramic or silica sand.BELOS to aired the sand grain in the mould or the cavity.STRIP BAR to strip or flatten the sand on the surface of the moulding box, made by steel.LADLE for mould finishing job as to fix broken mould, make a groove for molten metal steam, adding or reducing mould parts.

GATE CUTTER & SQUIRE, MOULDING THROWEL tofix small damage in the cavity and create a channel for molten metal flow.RAMMER to compact or compress the sand casting while making the mould in the moulding box, made by wood or metal.VENTILATION ROD to create ventilation holes os that the heat and air contain in the mould can be departed.SPRUE to create a channel for getting system of the molten metal (runner and riser)

DRAW PIN to draw out the pattern from sand mould.SKIMMING LADLE to skim the slag/impurities floating in the molten metal in the furnace.DEGASING PLUNGER to release the gas trapped in the molten metal.SIEVER to gain finer sand before ramming the sand

Figure below shows the process for preparing a mould for casting. For that, the type of pattern use is split pattern and also using a green sand core.

Processing steps of sand casting

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Advantages of sand casting processAdvantages:Manufacturing process for multiple usage.Suitable to produce one until thousand of casting units.Freedom in designing from weight, size and shape.Can be use to produce component with the weight in grammes until tones.Bigger size product can be cast in hollow casting techniquesTypical shape can be make by using varius of cores.Can be use for all kind of metal including metal that cannot be manufactured by other process such as cast iron.Cost for making the mould are low because low in sand price and reusable.Disadvantages of casting processDisadvantages:The cast exposed to crack while cooling if the design are not suitable.Limited to small quantities production is the process done manually.Surface finishing quality are low and need to be machine.The ira (grain) are not compacted, therefore low in compactability and weak.Low in ductility.Unsuitable for thinner casting product.