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The cope and drag (top and bottom halves, respectively) of a sand mold, with cores in place on the drag. Two sets of castings (bronze and aluminium) from the above sand mold. Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand—known as casting sand—as the mold material. The term "sand ...
Green sand is an aggregate of sand, bentonite clay, pulverized coal and water. Its principal use is in making molds for metal casting . The largest portion of the aggregate is a sand, usually silica or sometimes olivine . [ 1 ]
Small-scale molds used for this form of casting have most commonly been made of sand, tufa stone, and cuttlebone [2] as well as charcoal and plaster [3] as these materials are generally easy to shape (unlike iron or steel), do not break down when suddenly exposed to high temperatures (unlike glass, wood, or plastic), do not deform easily ...
This allows the entire mold to be made from green sand and from removable patterns. The disadvantage of this is more mold-making operations are required, but it is usually advantageous when the quantities are low. However, if large quantities of casting are required, it is usually more cost effective to simply use a core. [6]
When the pattern is to be removed from the sand mold, there is a possibility that any leading edges may break off, or get damaged in the process. To avoid this, a taper is provided on the pattern, so as to facilitate easy removal of the pattern from the mold, and hence reduce damage to edges. The taper angle provided is called the Draft angle ...
The pattern is lifted from the sand, leaving a molding cavity. A passageway for metal to enter the mold, called a "gate", is then cut from the sprue hole to the void left by the pattern, and a runner is cut from the sand to allow metal to flow into the riser. The flask is then put back together, and metal can be poured into the mold.
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The pattern is made of wax, wood, plastic, or metal. The molds are constructed by several different processes dependent upon the type of foundry, metal to be poured, quantity of parts to be produced, size of the casting, and complexity of the casting. These mold processes include: Sand casting – Green or resin bonded sand mold.
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