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The halves are referred to as the cope and drag flask respectively. A crucible containing bronze is poured into the Green Sand, which contains a hollow shape below, that will become the finished cast. Not all Green sand is green in color. But considered "green" in the sense that it is used in a wet state (akin to green wood).
The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. In 2003, over 60% of all metal castings were produced via sand casting. [1] Molds made of sand are relatively cheap, and sufficiently refractory even for steel foundry use.
In foundry work, the terms cope and drag refer respectively to the top and bottom parts of a two-part casting flask, used in sand casting. The flask is a wood or metal frame, which contains the molding sand, providing support to the sand as the metal is poured into the mold.
A flask is a type of tooling used to contain a mold in metal casting. A flask has only sides, and no top or bottom, and forms a frame around the mold, which is typically made of molding sand . The shape of a flask may be square, rectangular, round or any convenient shape.
When casting a reentrant angle, instead of using a core a cheek can be used. This is a third segment in the flask, in addition to the cope and drag. This allows the entire mold to be made from green sand and from removable patterns.
A molding sand mixture, usually green sand or bentonite, is blown into a rectangular steel chamber using compressed air. The molding sand is then squeezed between two patterns, which are on the two ends of the chamber. After squeezing, one of the chamber plates swings open and the opposite plate pushes the finished mold onto a conveyor.
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Sand casting requires a lead time of days, or even weeks sometimes, for production at high output rates (1–20 pieces/hr-mold) and is unsurpassed for large-part production. Green (moist) sand, which is black in color, has almost no part weight limit, whereas dry sand has a practical part mass limit of 2,300–2,700 kg (5,100–6,000 lb).
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