Manufacturing processes

1. SAND CASTING
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Pattern
(a copy of the shape you want
to produce, made of wood,
plastic or metal)
Sand,
mixed with clay binder &
water (so it will hold its shape)
plus coal dust to improve
surface finish
Basic materials & equipment for sand-casting
Container of molten metal
(filled from furnace)
Top and bottom mold forms
(made of metal, open at top and bottom)
Rammer (tool to compact the sand; often
a pressing machine is used)

5. MOLDING:
Sand placed
into bottom
mold
form &
compacted
MOLDING:
Pattern placed into mold
Basic summary of the sand casting process. . .
2
1
THEN
First of all,
mix the sand.
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6. MOLDING: Add
the top mold
form
3
4 MOLDING: Fill top form
with compacted sand.
A tube or pipe provides
a path to pour the metal
in
Pattern is still inside!
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7. MOLDING:
Take the top mold off
and remove pattern
& pipe or post
5
6 MOLDING: Replace the top
mold and fasten securely!
Pouring
hole
In the middle of the sand
is a cavity shaped like the
pattern!
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8. 7 CASTING:
Pour the metal (container is filled
from furnace immediately before you
are ready to pour)
8 Wait for the metal to cool
(minutes to days,
depending on the size of
the casting)
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9. 8 SHAKE OUT: Break apart the two halves
of the mold & take out the part—usually
requires vibrating or striking the mold to
break apart the sand
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CLEANING. Sand is
cleaned off the part,
the “tab” where metal
flowed in must be
removed.
A copy of the pattern
has now been made in
metal
10 Mold forms are reused
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Sand is broken up,
screened to remove debris
and clumps, and sent for
remixing
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10. PATTERN
& PATTERN
MAKING
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31. Follow board pattern
A follow board is a wooden board used for
support a pattern during moulding. It acts as a
seat for the pattern. In the former case, the
follow board is provided with a cavity
corresponding to the shape of the pattern in
which the pattern is seated for moulding.

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35. PATTERN MAKING
ALLOWANCES
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42. MOLDING SAND
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43. Molding Sand Constituents
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46. Types of Molding Sand
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54. CORE & CORE MAKING
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67. SAND CONDITIONING
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79. Melting Furnaces
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81. Cupola
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82. Construction of Cupola
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84. Zones in Cupola
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85. Working of Cupola
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87. Electric Arc Furnace
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89. Induction Furnace
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