This document provides an overview of sand casting, including: 1) Sand casting is a process where molten metal is poured into a sand mold cavity and solidifies. It can be used to manufacture metal or non-metal parts like iron and aluminum. 2) Sand casting has a long history dating back thousands of years and was widely used in ancient China. Modern developments improved molding speed and efficiency. 3) Sand casting has advantages like low costs and ability to produce complex shapes, though it also has disadvantages like poor surface finish and accuracy. Future improvements could enhance casting efficiency and quality control.

1. A report on
“Sand Casting”
By
SHIWANSH JAISWAL
1519240217
Bachelor of technology, Mechanical Engineering.
Greater Noida.

2. Table of content-
1. Abstract
2. History of sand casting.
3. Sand casting
4. Advantages and disadvantages
5. Future scope.

3. 1. Abstract
Sand casting is used in industries to manufacture parts that are made of
metals or non-metals like iron, aluminium, brass, bronze. The material
can be choseaccording to need. It is melted in furnace and then poured in
mould cavity formed of sand. Sand casting is relatively simple. Sand
casting is inexpensive. Some defects are also present in sand casting.

4. 2.History of Sand Casting
Sand casting seems to come from 1600 to 1046 BC. China used to make clay
models from shang dynasty.
In 1300 BC the famous Houmuwu ding was made using sand casting.
Bronze casting was done in 704-681 BC.
Sand casting moulding method was recorded by Vannoccio biringuccio in his
book published in 1840.
By 1924 Ford company has made a record to make its engines from sand casting
excessively in USA.
From here the need of increased casting efficiency grew. From here the need of
high rate of casting process was forecasted.
Improvements were made in moulding speed, sand preparation, sand mixing, core
manufacturing process, and slow metal melting in cupola furnace.

5. 3. Sand Casting
What is casting process?
Casting means pouring molten metal into a refractory mould with a cavity of the
shape to be made, and allowing it to solidify. The solidified object is called
Casting and the process by which it is made is called casting process.
Terms associated with casting-
Fig. Sand casting

6. Flask –
A moulding flask is one which holds the sand mould tightly or intact. It has
different names depending upon the position of the flask. It is named as cope,
drag or cheek.
Fortemporary applications it is made up of wood, for long term use it is made up
of metal.
Pouring Basin –
A small funnel shaped cavity at the top surface of mould into which the molten
metal is poured.
Sprue –
It is the passage through which molten metal reaches to the mould cavity from
pouring basin. In many cases it controls the flow of metal in mould.
Runner –
It is the pass way in the parting plane. It regulates the flow of molten metal before
molten metal reaches the mould cavity.
Gate –
The actual entry point through which molten metal enters into the mould cavity.
Riser –
It serves three functions –
 It acts as a reservoir.
 It acts as a indicator.
 It acts as the escape passage for trapped gases.
Core –
It is used to make hollow cavities in the casting. Generally, it is made up of sand.
Cavities can be of any shape.
Chaplets –
It is also called metallic spacings.

7. These are used to supportcores or cores are held upon it inside the mould cavity.
Reason to use chaplets is that cores can take care of their own weight and
overcome the metallostatic forces.
Chills –
These are metal objects which are used to increase the cooling rate of casting. It
can be said that it is used for directional solidification. It provides uniform or
desired cooling rate.
Chills are usually made of metal which have high thermal conductivity.
Types of pattern-
 Single piece pattern.
 Two-piece pattern.
 Multi piece pattern.
 Cope and drag pattern.
 Loose piece pattern.
 Sweep pattern.
 Gated pattern.
 Skeleton pattern.
 Follow board pattern.
Factors governing selection of pattern material –
 Component’s shape and size.
 Surface finish required.
 Number of components to be produced.
 Cost of pattern.
 Moulding method used.
Types of pattern allowances –
1. Shrinkage allowance-
It can be classified as – liquid shrinkage
Solidification shrinkage

8. Solid shrinkage.
2. Draft allowance-
It is provided for easy removal of pattern from mould cavity without
damaging the mould.
3. Machining allowance-
It is also termed as finish allowance. It is provided on the pattern in order
to remove some amount of material after the casting has been done. So we
get good surface finish.
4. Rapping / shake allowance-
It is negative in nature.
It is provided to make clearance between pattern and mould walls.
5. Distortion / camber allowance-
Sometypical applications like U shape, Vshapeand the objects which have
very less thickness which can distort. It keeps them in its shape,
Types of sand-
a. Green sand
b. Dry sand.
c. Facing sand.
d. Parting sand.
e. Backing sand.
Properties of moulding sand-
a. Refractoriness
b. Green strength
c. Dry strength
d. Hot strength
e. Permeability
f. Flowability
g. Adhesiveness
h. Cohesiveness
i. Toughness
j. Collapsibility

9. Additives used in moulding sand-
a. Wood flour/ saw dust
b. Starch
c. Dextrin
d. Iron oxide
e. Aluminium oxide
f. Coal dust
g. Sea coal
h. Silica flour
Sand casting defects-
a. GAS Defects-
Blow holes
Pin hole porosity.
b. Moulding material defect –
Cuts and washes
Metal penetration
Runout
Fusion
c. Pouring metal defects-
Misrun
Cold shuts
Slag inclusion
d. Metallurgical defect
Hot tear
Hot spot

10. Why we need sand casting?
a. Sand casting is used because of its capabilities of manufacturing typical
shapes and complex shapes.
b. Part size through sand casting varies up to 450 ton.
c. Multiple materials can be used.
d. Cost of production is less as compared to other manufacturing process.
e. Mass production of small items is possible easily.
f. Complex geometries can be manufactured which are not possible by other
processes.
g. Nothing is waste. Scrap can be recycled.
h. Different moulding techniques are available.
i. Non metals can also be casted.

11. 4.Advantages & disadvantages
Advantages of sand casting-
a. Molten metal can flow in any minute section.
b. Any intricate shape can be made
c. It is possible to cast almost any material ferrous or non-ferrous.
d. Casting is cooled uniformly so there is no directional properties.
e. Low tooling and equipment cost.
f. Short lead time possible.
Disadvantages of casting-
a. Poor surface finish.
b. Dimensional accuracy.
c. Defect arising out of the moisture present in casting.
d. High porosity possible.
e. Poor tolerance.
f. Secondary machining often required.
g. High labour cost.

12. 5.Future scope-
Sand casting methods has to be improved. Casting efficiency has to be
increased.
Binders used, sand used & rate of melting of metal should have optimum
quality control.
Different casting methods like die casting, gravity casting, investment casting
should be focused upon.