Sand Casting process steps
Raw Material incoming inspection
Pattern making & inspection
Core making & inspection
Metal melting
– Electric Arc furnace
Pouring
– Curing time of 1hr
Shake out (differentiate sand and casted part)
Runner & gates removing (de gating)
Sand blasting (sand) / shot blasting ?(shots, steel balls)
Deburring / parting line grinding or matching
Sand blasting (sand) / shot blasting ?(shots, steel balls)
Painting
Manual inspection
Dispatch
Sand Casting process steps
Raw Material incoming inspection
– Spectro analysis ( by etching gas in to metal we can check the material Properties)
Raw Materials preparation for melting
Based on Above testing methods we can find the base material properties which can be
used for following grades
– Grey Cast iron (FG-180, 200, 220, 240,260, 300, 400)
– Ductile cast iron (SG-400/12, 400/18)
Then based on your product Material specification we need to add Alloys to base
metals while melting (EX:- Carbon, Silicon, Manganese, Sulphur, Zinc, Copper and
etc….)
Sand Casting Process
• Sand Mixing by sand mixture machine (New sand 5% + return sand 95%+
bentonite clay+ water) They will mix all this materials then they will do below
listed tests for sand cake.
Sample Checking (sand properties)
– Strength (By applying pressure , we need to check where it is breaking)
– Permeability (how well gases pass through the sand)
– Thermal Stability ( Heat withstand stability)
– Collapsibility (How much load is required to break this sand cake)
– Reusability (They will heat the sand cake in Owen How much % we can reuse)
Casting Process Flow
Sand Mixing
Pattern Mold / Core Metal
Preparation Solidification
Making Pouring
Melting
Flashes Sand Flask
Cleaning De-Gating
Grinding Removal
Inspection Painting Packing Dispatch
Core Making Process
Co2 Core Making – Hand core making (by using co2 gas @ 7%)
– Core Material – sand 100%
– Bonding – catalyst 3%
– Only one time use of this sand
– After core making 2days we can store this for production
– It is 2 part agent (2 materials used)
Machine core making – Cold box core making (by using Amine gas @0.8%)
– Core Material – sand 100%
– Bonding – oil A (1%) & Oil B (1%) with Amine Gas
– Only one time use of this sand
– After core making 15 days we can store this for production
– It is 3 part agent (3 materials used)
Shell Moulding core making – Very fine finish and less wall thickness
– Core Material – Phenolic Resin sand 100%
– Bonding – Ready to Use sand
– Only one time use of this sand
– After core making 30 days we can store this for production
Green sand Moulding process
o Sand Filling
o Sand Squeezing
o Sand Ramming
o Pouring Cup & Venting
o Core Fixing , Chillers placing
o Mold Cleaning
o Cope & Drag Closing
o Clamping
Melting
Electric Arc Furnace ( furnace liners cost 15,000 inr – Liners life 1ton capacity x 30 times)
– 1 Ton melting cycle time – 1hrs
– Melting cost per kg – 11 to 12 inr
Pouring
Metal pouring – 6 to 7kgs per second
Ladle is used for pouring of material (They will do Magnesium treatment while taking
molten metal to ladle
After pouring - line inspection
Raw Material Pouring – After casting line inspection
– Image analyser (Micro structure Ex. Elite company material structure image)
– Tensile Strength checking (by creating sample Test piece , by pulling)
Imp Parameters cost calc– Sand casting
o Melting cost per kg – 11 to 12 INR
o Metal Melting furnace time – 1 Ton/ 1 hr
o Shot blasting – 1Ton weight part / 2.5kgs balls (steel balls – per kg 55 INR)
o 1 Ton sand mixing time Automated – 3mins
o Sand preparation /kg – 6.5 to 7.5 INR
o Sand Casting
o Green sand moulding per kg – 70 to 75 INR (Machine moulding)
o No bake process
o Manual nobake process (below 1 ton) - 90 to 95 INR(above 10ton manual 70 to 75INR / kg)
o Automate nobake process - 120 to 130 INR
Casting cost/kg including = Raw Material cost + Process cost + Indirect cost
