Product Description
Sand casting, the most widely used casting process, utilizes
expendable sand molds to form complex metal parts that can be made
of nearly any alloy. Because the sand mold must be destroyed in
order to remove the part, called the casting, sand castings
typically has a low production rate. The sand casting process
involves the use of a furnace, metal, pattern, and sand mold. The
metal is melted in the furnace and then ladled and poured into the
cavity of the sand mold, which is formed by the pattern. The sand
mold separates along a parting line and the solidified casting can
be removed. The steps in this process are described in greater
detail in the next section. In sand casting, the primary piece of
equipment is the mold, which contains several components. The mold
is divided into two halves - the cope (upper half) and the drag
(bottom half), which meet along a parting line. Both mold halves
are contained inside a box, called a flask, which itself is divided
along this parting line. The mold cavity is formed by packing sand
around the pattern in each half of the flask. The sand can be
packed by hand, but machines that use pressure or impact ensure
even packing of the sand and require far less time, thus increasing
the production rate. After the sand has been packed and the pattern
is removed, a cavity will remain that forms the external shape of
the casting. Some internal surfaces of the casting may be formed by
cores. Sand casting is used to produce a wide variety of metal
components with complex geometries. These parts can vary greatly in
size and weight, ranging from a couple ounces to several tons. Some
smaller sand cast parts include components as gears, pulleys,
crankshafts, connecting rods, and propellers. Larger applications
include housings for large equipment and heavy machine bases. Sand
casting is also common in producing automobile components, such as
engine blocks, engine manifolds, cylinder heads, and transmission
cases. Sand casting is able to make
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006
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