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Aluminum-Manufacturing Methods
Published in Raghu Echempati, Primer on Automotive Lightweighting Technologies, 2021
Advantages of sand casting are that sand as a packing material is reusable, low-cost, permeable, temperature resistant, and nonreactive. Complex and intricate designs can be made with the use of cores. This also makes sand casting an attractive method when low volumes of parts are required due to the destruction of the mold after each part is made. Sand casting can be used to make a wide variety of parts from very small to very large or heavy. Lastly, metals with high melting points can be used. The limitation of using sand casting as a manufacturing process is that the surface is rough compared to die casting or permanent mold casting. Another disadvantage is that after each part is made, the mold is destroyed making this process unsuitable for mass production. Lastly, the mold is very susceptible to erosion when the molten metal is poured into the mold.
Casting process
Published in William Bolton, R.A. Higgins, Materials for Engineers and Technicians, 2020
Sand-casting is a very useful process since very intricate shapes can be produced in a large range of metals and alloys. Moreover, relatively small numbers of castings can be made economically since the cost of the simple equipment required is low. Wooden patterns are cheap to produce, as compared with the metal die which is necessary in die-casting processes. However, the process is labour intensive and so labour costs can be high. The process can be economical for low production runs or where one-offs are required. Typical uses of sand-casting are to produce engine blocks, machine-tool bases and pump housings.
Force-System Resultants and Equilibrium
Published in Richard C. Dorf, The Engineering Handbook, 2018
Sand casting is a metal casting process where sand is mixed with clay, the best-known traditional mold material, and is packed around a wooden pattern that is subsequently removed when the sand casting mold is ready for pouring of liquid metal. A small channel called a gate provides the liquid metal access to the mold cavity, while a riser column becomes the reservoir of liquid metal that feeds the shrinkage of the liquid metal during solidification. The sand-casting process is an inexpensive method for making a small number of parts; a range of ferrous and nonferrous alloys can be made by this method. The rough finish of sand-cast parts usually requires further machining and grinding.
The sand-casting process: a meta-heuristic approach for an environment-friendly and profitable scheduling
Published in International Journal of Production Research, 2023
Sand casting is one of the older techniques and one of the most commonly used casting process. Sand casting foundries in the world are nowadays almost 20,000, producing about 70 millions ton of parts every year (Assofond 2020). The overall process is depicted in Figure 1. Sand casting uses sand as the primary moulding material. The sand grains are mixed with a small amount of other materials (such as clay and water) to improve mould ability and cohesive strength and are then packed around a pattern that has the shape of the desired casting. The pattern is then removed before pouring. Castings are often required to have holes, recesses, etc. of various sizes and shapes, that are obtained through cores. Cores are made of sand compacted into the desired shape and must be included in the mould cavity before pouring so that the molten metal will flow and solidify between the mould cavity and the core to form the casting’s external and internal surfaces.
Casting of adjuster bracket—process optimization and validation
Published in Materials and Manufacturing Processes, 2018
Anwar K. Sheikh, Muhammad A. A. Khan, Hassan Iqbal, Bilal S. Al-Shaer
Sand casting, one of the oldest manufacturing methods, has widespread use in producing cast products made of a range of metals such as ductile and gray iron, steel, aluminum, zinc, brass, bronze, etc. The manufacturing process design in sand casting is iterative due to a series of steps including pattern making, mold, melt preparation, pouring and solidification, cleaning operation, inspection, and quality control. A physical trial-and-error method for developing an optimum mold design results in production delays and higher cost. Also, identification of defects (especially internal) is tricky and thus the quality of castings always remains in question. The efforts to improve quality and integrity of cast products have led to the development of simulation-based sand casting which allows to model, verify, and validate the entire casting process, followed by optimization of design and process parameters before they are actually put into practice in a foundry.