Manufacturing Process

M.Bilal Yousaf12-MT-17

Casting Terminology

THIS IS THE CONTAINER BOX THAT HOLDS THE MOLDING SAND. THE BOX I S OPENED FROM THE TOP AND THE BOTTOM AND COULD BE CREATED IN ANY SHAPE AND SIZE. MOST SIMPLE FLASKS CONTAIN TWO PARTS. MOST FLASKS ARE MADE OF ALUMIMUM, STEEL OR WOOD AND HAVE DIFFERENT TYPES OF ALIGNING "SYSTEMS" SUCH AS PINS OR JUST TIMBER PARTS ALIGINING THE COPE AND DRAG TO THE SAME POSITION.

Flask

COP IS THE TOP PART OF FLASKDRAG IS BOTTOM PART OF FLASK

Cope And Drag

IS USE FOR CLEANING THE SAND FROM IMPURETIES

Riddle

IS USE TO PRESING THE SAND AND REMOVE THE SAND FROM MOLD

Rammer

THIS IS THE HOLE ON TOP OF THE COPE PART MADE TO POUR THE MOLTEN ALUMINUM IN TO THE FLASK.

Pouring Cap And Basin

THIS IS SO WHEN POURING THE MOLTEN METAL THE GAS WILL ESCAPE FROM THE VENT. A GAS VENT CAN BE EASILY MADE USING A STRAIGHT WIRE.

Gas Vent

THE RISER WILL FEED MORE MOLTEN METAL INTO THE CAVITY MOULD WHEN SHRINKING ACCURSE.

Riser

THIS IS UNDER THE POURING CUP CONNECTED TO THE RUNNER CHANNELING THE MOLTEN METAL INTO THE MOULD CAVITY.

Sprue

THE HORIZENTAL CHANNEL FEEDING THE MOLTEN METAL INTO THE MOULD CAVITY

Runner

THIS IS WHERE ALL THE MOLTEN METAL SETS CREATING A DUPLICATE OF THE PATTERN

Mould Cavity

ANY OBJECTS PLACED IN THE CASTING SAND CREATING AN IMPRESSION OF THE PATTERN TO BE CREATED. A PATTERN COULD BE MADE FROM STEEL, WOOD, PLASTIC AND OTHER MATERIALS

Pattern

GREEN SAND IS AN AGGREGATE OF SAND, (NOT GREEN IN COLOR). GREEN SAND IS COMBINED OF VERY FINE SAND SUCH AS SILICA, OLIVINE OR EVEN PLAY SAND MIXED WITH BENTONITE CLAY AND WATER. THERE ARE MANY RECIPES THAT CAN BE FOUND ON THE INTERNET FOR THE DIFFERENT TYPES AND QUANTITIES AND MIXING RATIO. ADDING TO MUCH WATER CAN LEAD TO "POROSITY", CASTING DEFECTS AS RESULT OF GAS BUBBLES ACCOURING WHILE POURING THE MOLTEN METAL. SOME METAL CASTERS USE BLOW TORCHES (HEAT-DRY) OVER THE FINISHED MOULDED SAND TO ACHIEVE A MORE RIGID MOULD. MAKING A GOOD MIX OF GREEN SAND IS A MUCH CHEAPER SOLUTION THEN BUYING A READY MIX.

Green Casting Sand

GREEN SAND

THIS TYPE OF SAND COULD BE BOUGHT AS READY MADE. THE SAND IS VERY GOOD FOR HIGH DETAIL MOULDINGS AND IS EASY TO WORK WITH. IT'S LESS LIKELY TO GET HIGH PERCENTAGE OF POROSITY BECAUSE THIS TYPE OF SAND IS OIL BONDED AND NOT MIXED WITH WATER. THE DOWN SIDE IS IT'S EXPENSIVE AND BURNT SAND SMOKE IS NOT THE BEST TO INHALE.

Oil Bonded Sand

MIXING BIG QUANTITIES OF SAND BY HAND IS QUIT A TASK AND FOR THAT THERE IS A GREAT INVENTION CALLED A SAND MULLER. THE MULLER IS A CLEAN WAY OF MIXING THE SAND WITHOUT GETTING UNWANTED CONTAMINATORS INTO THE SAND AND SAVING A LOT OF HARD LABOUR TIME. THE MULLER MIXES THE SAND, CLAY AND WATER WITH ITS CRUSHING WHEELS.

Sand Muller

ANOTHER OPTION OF SAND CASTING IS TO MAKE A FOAM PATTERN WITH POLYSTYRENE OR STYROFOAM. THE PATTERN DISSOLVES WHEN POURING THE MOLTEN METAL FORMING THE DESIRED OBJECT. THE MOULD PATTERN CAN BE EASILY CARVED OUT OR CUT WITH A HOT WIRE FOAM CUTTER, THE CUTTER COULD BE MADE DIY OR YOU CAN BUY ONE. MOLDED FOAM IS A COST EFFECTIVE SOLUTION

Lost Foam Casting