EXPERIMENT 2: MOLD PREPARATION AND SAND CASTING
(SPLIT PATTERN)
Objectives
1. To prepare a sand mold using the two-piece (Split) pattern with core.
2. To perform sand casting operation using molten aluminum.
3. To observe shrinkage and surface appearance on the cast item.
Background
Also known as sand molding casting, sand casting is a casting-based manufacturing process that
involves the use of a sand mold. It’s used to create metal products and components in a variety of
sizes and shapes. To put its popularity into perspective, statistics show over half of all metal
castings about 60% are produced using sand casting.
Tools and Equipment
1. Molding sand
2. Parting sand
3. Binder
4. Water
5. Single piece solid pattern
6. Vernier Calliper / Ruler
7. Molding board
8. Molding boxes / wooden flask
9. Riser and sprue pins
10. Vent rod
11. Wire brush
12. Rammer
13. Ladle
14. Hammer
15. Electric Furnace
16. Aluminium Block/Wax
Precautions
1. Make sure during molding process, the foundry area has good ventilation
2. Keep in distance when molten metal is poured to the mold
Procedure
1. Sieve the used silica sand by using riddle.
2. Mix the sieved sand with 6.5-8.5% of water, 12-18% of clay and 3% of coal dust. This
molding sand is known as green sand.
3. Place a flat board known as a molding board on the floor and ensure the board's surface is
even.
4. The bottom half of the flask or the drag is kept upside down, then place the lower half of
the pattern on the molding board at the center of the board as shown in Figure 1.1.
Figure 1.1: Drag
5. The pattern must be entirely in the drag and there should have enough clearance between the
pattern and the walls of the flask (50 – 100 mm).
6. Sprinkle with dry parting sand or facing sand on the pattern’s surface and the molding board.
This is to provide non-sticky layer between the molding sand with the pattern and the molding
board.
7. The freshly molding sand is then sifted or riddled into the drag and tamped or packed firmly in
layers about the pattern (up to 30-50 mm thickness).
8. Fill the drag with the molding sand and ram using rammer accordingly to compact the sand as
shown in Figure 1.1.
9. After the drag has been completely filled with sand and compacted, the bottom of the drag is
screeded or scraped off to provide a smooth surface on which to rest.
10. Carefully turn the drag and place it on the bottom board.
11. Fix rapping plates to the pattern with draw screw and carefully pull out the pattern by shaking
it slowly. Dust the pattern with parting sand and place it again in the mold cavity.
12. Mate the cope (upper part of the molding flask) on the drag through the closing pin (Figure
1.2).
Figure 1.2: Cope on top of drag with sprue and riser pin
13. Place the upper part of the pattern on the lower part and fix sprue pin and riser pin in the cope
beside the pattern on the surface of the molding sand as shown in Figure 1.2.
14. Similarly, the pattern is dusted with parting sand and the molding sand is riddled around the
pattern, cope and riser.
15. Pack the molding sand to fill the cope and screed the excessive molding sand to make the
upper part of the flask to be levelled.
16. Once filled and levelled, remove the sprue and riser tubes. Cup off the upper part of the by
using slick to shape the pouring basin. Carefully clear all the unneeded molding sand with air
gun.
17. Remove the cope from the drag.
18. Draw runner path from the pattern to sprue and riser (Figure 1.3) and cup off the sand to make
choke (well) and runner drain (depth 10-15 mm) as shown in Figure 1.4.
Figure 1.3: Runner path
Figure 1.4: Cupping off the sand to produce the choke (well)
19. Make the core as shown in Figure 1.5
Figure 1.5: Core Making
20. Place the core on the core print carefully.
21. Place the cope on the drag. The mold is now ready for the pour.
22. Melt the metal/wax in an induction furnace and scrap the slag produced.
23. The molten metal is poured to a ladle (Figure 1.6) and poured slowly and evenly into the
pouring basin until it is seen in the risers. Then allow it to solidify.
24. After the metal has solidified, separate the cope and drag and shake the sand from around the
casting.
25. The solidified casting will have the sprue, runners, riser and core still attached; these
must be removed by sawing.
Report The Following (to be included in the report):
1. Write down 3 advantages of sand casting process.
2. What kind of furnace is used to melt the metal?
3. The melting and pouring temperature of Aluminium?
4. Describe the surface texture of the cast Aluminium and identify defects (if any).
5. Total solidification time. (show calculation)
