Sand Casting: An Overview
The sand casting process, also known as sand molded casting, is a metal casting technique that utilizes sand as the mold material. This method accounts for over 60% of all metal castings. Let's delve into the key aspects of sand casting.
Process Flows of Sand Casting:
The general flow of the sand casting process involves four main steps: sand making, core making, casting, and post-processing. Refer to the diagram below for a visual representation of the process flows.
Insert Sand Casting Process Flows Diagram
Parameters to Consider in the Sand Casting Process:
Machining Allowance:
Design consideration for surfaces requiring machining on the casting.
Dependent on casting alloy, molding method, size of the casting, and location of machined surfaces in the mold.
Draft Angle:
Slope on the vertical mold wall for easy removal of the casting.
Facilitates the extraction of the casting from the mold.
Casting Fillet:
Designing fillets at joints and corners to prevent stress, cracks, and damage to sharp corners.
A measure to avoid the formation of sand holes.
Core Head:
Essential for positioning, fixing, and venting of the core in both the mold and core.
Shrinkage Allowance:
Compensation for dimensions affected by shrinkage after pouring.
Advantages of Sand Casting:
Abundant and Inexpensive Material:
Clay, a primary component of green sand, is abundant and recyclable.
Short Casting Mold Production Period:
High molding efficiency due to a short production period for casting molds.
Long Service Life of Molding Sand:
Molding sand has a prolonged service life.
Versatility:
Applicable to small or large, simple or complex workpieces.
Suitable for individual production or mass production.
Disadvantages of Sand Casting:
Single Use of Sand Molds:
Each sand mold can only be used once, requiring remolding and reducing production efficiency.
Lower Rigidity and Dimensional Accuracy:
Casting exhibits lower rigidity, leading to poor dimensional accuracy.
Susceptibility to Defects:
Prone to defects such as sand washing, sand trapping, and blowholes.
In summary, while sand casting offers advantages such as cost-effectiveness and versatility, it comes with challenges related to mold reusability and dimensional accuracy. Understanding these aspects is crucial for effective utilization of the sand casting process.
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