UNIVERSITY OF MAURITIUS

FACULTY OF ENGINEERING
MECHANICAL & PRODUCTION ENGINEERING DEPARTMENT

Sand Casting Of A Door

Handle
Submitted by: GROUP 13
JEETUNSIV RATNAVARA (ID 1316842)
JHUGROO RUDY PURANANDA (ID 1414231)
JORY VINIT VYAS (ID 1414502)
MAUTHOOR FARHAAN KALECK (ID 1410593)

Course: BEng (Hons) Mechanical Engineering (minor: Energy systems) E443 Level 2
Module: MECH 2013Y-Materials & Production Engineering
Lecturer: Ms Jankee. P

Date of Submission: 29.04.2016

Table of Contents

1.0 Introduction .................................................................................................................................1

2.0 Literature Review .........................................................................................................................1
2.1 Description and labelling of casting system........................................................................................ 2
2.2 Advantages of casting ......................................................................................................................... 3
2.3 Metallurgical Advantages of Casting of Metals .................................................................................. 3
2.4 Limitations of Casting process ............................................................................................................ 4
3.0 Design And Manufacture Process ..................................................................................................5
3.1 Project outline..................................................................................................................................... 5
3.2 Chosen design ..................................................................................................................................... 6
3.3 Pattern making .................................................................................................................................... 6
3.3.1 Considerations to be taken for pattern making........................................................................... 6
3.3.2 Selection of material for Pattern ................................................................................................. 7
3.3.3 Engineering drawing .................................................................................................................... 9
3.3.4 Manufacture process of pattern ................................................................................................ 10
3.4 Molding ............................................................................................................................................. 11
3.4.1 Flask construction ...................................................................................................................... 11
3.4.2 Important considerations for molding sand .............................................................................. 11
3.4.3 Types of Molding Sands ............................................................................................................. 12
3.4.4 Binders ....................................................................................................................................... 13
3.4.5 Mold making .............................................................................................................................. 14
3.5 Melting and Pouring.......................................................................................................................... 16
3.6 Cleaning and Finishing ...................................................................................................................... 17
4.0 Pictorial representation of the component .................................................................................. 18
5.0 Remark and Acknowledgements ................................................................................................. 18
6.0 References ................................................................................................................................. 18

1.0 Introduction
Metal casting is a manufacturing process whereby molten metal is poured into a mold and allowed to
solidify to obtain a desired shape. The object manufactured out of this process is also called a casting.
Casting can be used to make a full panoply of products that can have extremely complex and intricate
3D shapes. Cast parts can range in size from centimeters and grams to over 10 metres in length and
many tonnes. Metals commonly used in casting include iron, steel, alumininium, zinc, copper,
magnesium and titanium.
There are different types of casting processes namely sand casting, die casting, plaster mould casting,
shell molding and investment casting. This report describes the design and manufacture of a door
handle by sand casting while the manufacturing processes are practically performed in the workshop.

2.0 Literature Review

Sand casting is whereby sand is used to define the cavity inside a mold. In addition, sand is used to make
any cores that are contained in the mold. The molten metal solidifies in the cavity between the interior
of the mold and the exterior of the core.

Figure 1: Casting process schematic

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2.1 Description and labelling of casting system

Figure 2: Casting set up

Production of mold must have following parts:

The flask is the rigid metal or wood frame that holds the molding aggregate.
Cope is the name given to the top half of the flask or mold.
Drag refers to the bottom half of the flask or mold.
Core is a sand shaped that is used to produce the hollow castings.
The Mold Cavity is the shaped hole into which the molten metal is poured and solidified to
produce desired casting.
The Riser is the channel through which the metal rises so as to know when complete pouring of
metal in the mold is achieved
The Runner gives a flow to molten metal into the mold cavity.
Gating System (pouring cup + sprue + runner) is the network of connected channels used to
deliver the molten metal to the mold cavity.
Metal travels down a sprue is the vertical portion of the gating system.
Pouring cup is the portion of gating system that initially receives the molten metal and control
its delivery to the rest of the mold.
Vents are small holes for the escape of gases.
The parting line is the interface that separates the cope and the drag in the flask.

(Mehrvi, 2013)

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2.2 Advantages of casting

There is no limitation of producing castings of any size or weight. This advantage does not apply
to other manufacturing processes.
Complicated shape castings can be produced. Complicated patterns are key to complex shapes.
Hollow castings can be produced.
Any composition of materials can be used for producing required casting
Metal casting is a process highly adaptable to the requirements of mass production. Large
numbers of a given casting may be produced very rapidly.
Weight saving is possible.
Component made with casting process is lighter than the component made with other
machining processes.
Casting can be made with hair like precision or accuracy provided proper molding and casting
technique is employed.
In soft material casting, melting is not always necessary- In some cases only pressing
deformation is enough for soft material that is entered into the cavity.
(Mehrvi, 2013)

2.3 Metallurgical Advantages of Casting of Metals

This process can give any required micro structure to obtain the required mechanical
properties. The microstructure can be altered by changing the grain boundaries.

Grain size control is possible in casting process by controlling the rate of solidification. High rate
of solidification gives fine size grain which has high strength as compared to coarse size that is
achieved at low rates of solidification. During solidification, the uniformity of crystallization gives
strength. So mechanical properties are controlled by the solidification rate.

Strength and lightness in certain light metal alloys, which can be produced only by casting.

Casting provides versatility. Wide range of properties can be attained by adjusting percentage
of alloying elements.

Casting is one of cheapest method for mass production.

Cast products can have extremely complex shapes

(Mehrvi, 2013)

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2.4 Limitations of Casting process

Though casting is cheapest for mass production, it becomes non economical for job production.

Sand casting leaves rough surface which needs machining in most of cases. It adds up the cost in
production.

Cast products are superior for compressive loads but they are very poor in tensile or shock
loads. They are brittle.

In sand casting, porosity becomes an issue.

To manufacture small sized castings with high accuracy, good machining and finishing, the
casting process becomes expensive.

The various casting process are distinguished primarily by the mold material (whether sand,
metal or other material) and pouring method (gravity, vacuum, low pressure or high pressure).
All share the requirement that the material should solidify in a manner that will maximize the
properties and avoid the formation of defects.

Possesses structures that are produced by solidification and are therefore, subject to such
defects as shrinkage and porosity. Cavities may form in the casting.

(Mehrvi, 2013)

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3.0 Design And Manufacture Process

3.1 Project outline
This section gives an overview of how the manufacturing process is carried out

3.2 Research

3.3 Pattern making

3.4 Molding

Understand the basics of sand casting (covered in

section 2)
Review existing door handles and selecting a
design

Produce an engineering drawing of the chosen

design
Review important considerations about pattern
making
Manufacture the pattern in the workshop

Review important considerations about mold

making.
Selecting the materials for the mold and
manufacturing the latter.

3.5 Melting and

Pouring

Perform melting and pouring in the workshop

(performed by an experienced lab technician)
Outline the safety measures pertaining to pouring

3.6 Cleaning and

finishing

Machine the casting and perform relevant benchwork

to improve the shape of the cast object.
Filing and polishing to improve surface finish

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3.2 Chosen design

The chosen design will in the form of a "C-shaped" pull handle. Existing models are shown below in
Figure 3.

Figure 3: Selected idea of door handle

3.3 Pattern making

The first step in sand casting is patternmaking. The pattern is a model, replica or duplicate of the
component to be manufactured. For a solid, non-hollow component, the pattern will only constitute the
exterior of the casting. If the casting is to be hollow, additional patterns called cores need to be created
to produce the desired cavities in the finished product.
Patterns are usually made of wood, plastic, metal, or plaster; however, other materials or combinations
of materials are used if there are additional specific properties required of the pattern. The number of
castings to be made from the mold and the specifications required of the finished casting are two of the
criteria that determine which material is selected for the creation of the pattern.
3.3.1 Considerations to be taken for pattern making

Shrinkage allowance

Almost all metals shrink or contract volumetrically after solidification and therefore the pattern has
to be made slightly larger by an amount equal to the shrinkage or contraction. This is referred to as
shrinkage allowance and depends upon mainly on the cast metal or alloy used for the casting as well
as the pouring temperature.
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Machining allowance
In case the cast component requires machining and surface finishing after pouring to remove
surface imperfections, the pattern is made slightly larger than the actual casting dimensions
because layers of materials are removed by grinding and filing.
The amount machining allowance to be applied to the pattern depends on the size and shape of
the casting- Longer castings tends to warp and hence, their patterns require more allowance.

Burrs and rough edges

A pattern should be free of burrs or rough edges to ensure that when it is imprinted in the sand, it
does not damage the mold cavity. Therefore the pattern must be as smooth as possible. In case, it
isnt, polishing may be required

3.3.2 Selection of material for Pattern

The following factors are taken into consideration when selecting a proper pattern material:

The number of castings to be produced. Metal patterns are preferred when the production
quantity is large.
The desired dimensional accuracy and surface finish.
Nature of molding process. E.g. sand casting frequently use wood pattern while investment
casting require wax pattern.
Shape, complexity and size of casting.
The chances of repeat order.

For this project, wood, being the most common material for making pattern for sand casting was used
for the following reasons:

Wooden patterns are used where the number of castings to be produced is small and the
pattern size is large. In this case, only one casting is required and its size is relatively large.
Inexpensive and easily available.
Easy machining and shaping.
Easy to obtain good surface finish.
Can be used for complex shapes and large castings.
Light in weight.
Can be repaired easily and reproduced in case of damage

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However some limitations of using wood are:

Absorbs moisture and hence swelling is there.

Short life patterns.
Poor wear and abrasion resistance.
Cannot withstand rough handling.

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3.3.3 Engineering drawing

Figure 4: Top view of component

Figure 5: Isometric projection of component

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3.3.4 Manufacture process of pattern

Outline:
1) Starting from wood plate of thickness 10mm. The top and bottom halves of the overall pattern
was marked on the wood plate
2) Marking tools such as pencil, ruler, compass were used to mark the workpiece.
3) The pattern was cut out of the wood using a hacksaw.
4) The hacksaw allowed cutting only in straight lines. Hence a file, suitable for wood, was used to
give the pattern the required curvature.
5) The pattern was further improved using sand paper to give it a smooth surface, free of burs or
rough edges.

Figure 6 : Filing the pattern.

Figure 7 : Pattern manufactured in workshop using wood.

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3.4 Molding

Molding is the multi-step process in which molds are created. In horizontal casting, the mold is
contained in a two piece frame, called a flask. The upper portion of the flask is called a cope and the
lower portion is a drag. First, molding sand is packed into a flask around the pattern. After the pattern is
removed, gating and runner arrangements are positioned in the drag half of the mold cavity and the
sprue is placed the cope portion. Gating systems are necessary for the molten metal to flow into the
mold cavity. Cores are also placed in the drag portion of the mold if they are needed. To finish the mold,
the cope (top) section is placed on the drag (bottom) section, and the mold is closed and clamped
together.
3.4.1 Flask construction
The flask is the rigid wood frame that holds the molding aggregate. It has been observed during the
practical that the surface of the wood frame plays an important role in the packing of sand- A polished
smooth wooden surface makes it difficult to pack the sand mixture as the latter does not stick to the
flask but rather slips. Hence, a rough wooden surface is preferred for the interior of the flask.
3.4.2 Important considerations for molding sand

Refractoriness
Refractoriness is the property of sand that allows the latter to withstand high temperatures
without melting, fracture or deterioration. The basic nature of the sand determines its
refractoriness. This property is very important for very high MP metals/alloys such as steel
whose high M.P depends upon the ingredients. Zircon sand has highest refractoriness and can
be used to make sand mold. For low melting MP metals, silica sand or chromite sand can be
used.

Cohesiveness
Cohesiveness is the ability of the molding sand to retain a given shape when packed into a flask.
It is obtained by using binders such as clay (bentonite, kaolinite or illite) that becomes cohesive
when moistened. Molasses (not for cores, only for molding sand), resins, oils and sodium silicate
are also used. (Volcanic ash)

Permeability
It is the ability of mold or core to allow gases to escape through the sand. It is a function of the
size and shape of sand particles, the amount and type of clay used or any binder, the moisture
content and the compacting pressure. Gases are produced due to sand ingredients also. If

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permeability is present, there is likelihood for cracking. Retention of air or gases in the molten
metal may result in casting defects.
To increase permeability, saw dust or wood dust are added (in large amount for fine particle
sands). For gas escape facilitation, gas vents are also produced through the mold.

Collapsibility
It is the ability to accommodate metal shrinkage after solidification and to provide easy removal
of the casting through the mold during its dismantling (shakeout).
This property is sometimes enhanced by adding cereals or other organic materials, such as
cellulose that burn out when they come into contact with the hot metal. This property can also
be enhanced by adding talcum powder, graphite powder. Graphite powder plays role to avoid
stickiness of casting to the molding sand cavity.

3.4.3 Types of Molding Sands

Some commonly used sands in casting are:

Silica sand
Olivine sand
Zircon sand
Chromite
Chamotte

For the project, silica sand was used for mold making for the following reasons:

Easily available on coastal regions and beaches.

Because of abundance, it is of low cost.

Composition may change with geological changed, but for silica sand, the main contents do not
changed. The main component in silica sand is silica (SiO2) and it accounts for 94 to 98 % for the
sand.

The Fusion point of pure silica sand is 17600C (pure) but usually melting point is less than this
temperature due to the presence of impurities. Use of silica sand does not apply to metals with
high MP such as steel, but is suitable for aluminium which has a low MP.

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Limitations of silica sand

It has poor refractoriness. It is mixed with other sands to get the good refractoriness.

Bad surface finish. Machining is required in the sand used casting process.

It is chemically reactive with certain basic metals.

It has high thermal expansion which can cause casting defects with high melting point metals.

It has low thermal conductivity which can lead to unsound casting.

3.4.4 Binders
Binders are used to adhere the particles of sand to each other for the strength of molds. It can be
defined as the glue that holds the mold together. Binders improve cohesiveness.
Types of Binders:

Clay and water

Oil

Resin

Sodium silicate

For this project, clay and water were used as binder to be mixed with the silica sand. The clay content is
approximately less than 15% in the molding sand. Bentonite clay was used in a ratio 1:10 with the silica
sand.
Mixing the sand with its binder is an important step in the preparation of the world. Hence time has to
be spent in mixing to obtain a homogenous, consistent and cohesive mixture.

Figure 8 : Mixing sand with binders

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3.4.5 Mold making

After mixing, sand is packed into the flasks to will them completely. The sand is then compacted
thoroughly. The sand mixture should stick to the flask's frames- no gap should exist.

The drag is first filled and half the pattern is set into the sand, on its compacted surface.

The other half of the pattern is then lightly clipped to the one initially placed in the drag. This is
to ensure that both halves of the pattern are aligned properly.

A cylindrical tube is placed in the mold such that when sand is filled, the space occupied by the
tube will leave behind a cavity- The runner.

Figure 9: Setting the pattern and the runner in the mold

The cope is now aligned on the drag and sand is packed into it and then compacted.

Talc powder or limestone powder is applied to the flask and on the compacted sand surface
such that when the cope is aligned on the drag, neither halves of the mold stick together.

Figure 10 : Limestone powder applied to the flask/mold

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When both halves of the flask are completely filled and compacted, the top half is inverted and
the pattern is removed. The same is applied to the bottom half, except that there is no need to
invert it.

The Mold cavity has now been formed in both halves of the flask. The two halves are again
aligned.

Another cavity, the riser , has to be made. The runner and the riser should allow the molten
metal to flow into and out of the mold cavity respectively

Other small holes (gas vents) are made in the sand. They can be made using a very thin stick.

Figure 11 : Cope (top) and Drag (bottom)

From the above picture, the cope has to be inverted and placed onto the drag.

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3.5 Melting and Pouring

Melting is the preparation of the metal for casting, and its conversion from a solid to a liquid state in a
furnace. It is then transferred in a ladle to the molding area of the foundry where it is poured into the
molds. After the metal has solidified, the molds are vibrated to remove the sand from the casting, a
process called shakeout.
The melting point of aluminium is approximately 660oC.
The furnace temperature was set to 700oC to melt the aluminium chips. A higher temperature also
compensates for the impurities present in the aluminium.
During melting, a fair amount of impurities were actually obtained and had to be separated from the
useful aluminium to be poured.

Figure 12 : Melting aluminium in the furnace.

Figure 13 : Pouring aluminium into the runner of the mold

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Figure 14 : Mold, after pouring- Runner (big cavity) and rise (small cavity)

Safety measures during melting and pouring

Wear safety overcoat and safety shoes.

Wear heat resistant apron.
Wear heat resistant gloves.
Wear face and eye protection mask.

3.6 Cleaning and Finishing

Cleaning and finishing are the final stages of the manufacturing process. The excess solidified
metal that is tied to the component due to the runner and riser is cut using a hacksaw and
separated from the component.

Any relevant machining process such as drilling or milling is performed on the component if
required.

Filing, grinding and polishing can also be performed to obtain a more smooth finish.

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4.0 Pictorial representation of the component

Figure 15: 3-D model of the component (AutoCad drawing)

5.0 Remark and Acknowledgements

We wish to inform that we have not been able to perform the pouring due to our mold not retaining its
shape because of mold cohesiveness. We however express our gratitude towards the University of
Mauritius Metal Workshop and their devoted and helpful lab technicians and our lecturer Ms Jankee
who made provision for us to assist the pouring process. We would also like to thank our friends who
have been able to perform pouring and allowed us to click photos of the process and their work.

6.0 References
Anon,
(2016). Guide
to
Casting
and
Molding
Processes.
http://www.afsinc.org/files/methods.pdf [Accessed 26 Apr. 2016].

[online]

Available

at:

Holi, S. (2016). Chapter 1 introduction to casting process. [online] Slideshare.net. Available at:
http://www.slideshare.net/SureshHoli/chapter-1-introduction-to-casting-process [Accessed 26 Apr.
2016].
Mehrvi, N. (2013). Casting and working of metal. [online] Slideshare.net. Available
http://www.slideshare.net/NadeemMehrvi/casting-and-working-of-metal [Accessed 26 Apr. 2016].

at:

Metal-technologies.com.
(2016).
[online]
Available
at:
http://www.metaltechnologies.com/docs/default-source/education/sandcasting.pdf?sfvrsn=6 [Accessed 26 Apr. 2016].
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Slideshare.net.
(2016). Topic
3
metal
casting.
[online]
Available
http://www.slideshare.net/Huai123/topic-3-metal-casting-160214 [Accessed 26 Apr. 2016].
What-when-how.com. (2016). SAND CASTINGS. [online] Available at:
how.com/materialsparts-and-finishes/sand-castings/ [Accessed 26 Apr. 2016].

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at:

http://what-when-