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Objective

- At the end of this sand casting learning projects, we learned

 The basic techniques of sand casting

 Design consideration of wooden patterns

 Preparation of the mold

Introduction
Casting is a manufacturing process in which a liquid material is usually
poured into a mold, which contains a hollow cavity of the desired shape, and then
allowed to solidify. The solidified part is known also as a casting, which is ejected
or broken out of the mold to complete the process.
Discussion :-
First of all
we made a complete design for the cone by using SolidWorks software,
taking in our minds product consideration.
Considerations of our castings
1. Draft angle and fillets.
2. Allowance for shrinkage (1.3% for aluminum).
3. the mold filling time which calculated by the equation: TMF=V/Q.

Where TMF=mold filling time, s

V=volume of mold cavity, cm^3

Q=volume flow rate, cm^3/s

4. total solidification time: TTS=Cm(V/A)^n

where TTS=total solidification time.

cm=is the mold constant

v=volume of the casting


A=surface area of casting

n= exponent with typical value

5. The last one is manufacturing consideration, Dimensional tolerances and


surface finish of the pattern, the pattern must be very smooth.
The second step
We manufactured wooden patterns which we used two techniques of
manufacturing because we have two patterns
I. The first technique was using traditional method (lathe machine).
II. The second technique was using advanced manufacturing method using
CNC router machine.

The third step

Preparing the mold in our case we used a sand mold because of its properties
which is

1. Strength

2. Permeability

3. Thermal stability

4. Collapsibility

5. Reusability

so for our product we followed the following steps:

1. The cavity in the sand mold is formed by packing sand around pattern,
then separating the mold into two halves and removing the pattern after
making a riser to avoid shrinkage and pouring cup.

2. In our case we used a core because of the internal surface so we


prepared it by heating the core box , filling it with sand and letting it
absorb the heat from the core box

3. Then heating the mold well to get good surface quality and reduce the
moisture of sand.
4. Pouring the metal through the pouring cup taking the pouring rate into
consideration and leaving it to cool.

5. Destroying the mold to get the end product.

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