Manufacturing Process: Sand Casting

These flashcards cover the key terms and concepts discussed in the lecture on the sand casting process, providing definitions for important vocabulary related to the manufacturing process.

Sand Casting

A manufacturing process that involves pouring molten metal into a mold to create metal parts.

Mold Materials

Materials used to create molds, which can be metallic or non-metallic, such as cast iron or molding sands.

Natural Sand

Sand sourced from natural deposits, requiring additives and water for molding.

Synthetic Sand

Sand prepared by mixing clay-free sand with clay binder, water, and additives.

Chemically Coated Sand

Sand grains coated with hydrocarbon resin as a binder to prevent molten metal from reaching the sand.

Binder

A substance used to hold sand grains together in mold making.

Green Sand Molds

Molds made of sand, clay, and water, used in a damp condition for casting.

Dry Sand Molds

Molds made similarly to green sand molds but with added flour and baked for greater strength.

CO₂ Molds

Molds created by mixing sand with sodium silicate and treating them with CO₂ gas for fast hardening.

Resin-Bonded Sand Molds

Molds made with sand mixed with thermosetting resins for enhanced strength.

Permeability

The ability of sand to allow air to pass through, important for gas escape during the casting process.

Strength of Sand

The ability of sand grains to stay together, preventing mold collapse during metal pouring.

Refractoriness

The ability of sand to withstand high temperatures without softening or fusing.

Plasticity

The ability of sand to flow around the pattern and fill the mold evenly.

Collapsibility

The ability of sand to decrease in volume under compressive forces during metal cooling.

Adhesiveness

The ability of sand to stick to the mold box without falling out during handling.

Moisture Content Test

A test that measures the amount of moisture in molding sand.

Clay Content Test

A test that determines the amount of clay present in a sand sample.

Permeability Test

A test that measures the ability of sand to allow air to flow through it.

Fineness Test

A test that assesses the grain size and distribution of molding sand.

Strength Test

A test evaluating the holding power of binders in different types of molding sand.

Hardness Test

A test that determines the ramming density of sand on the mold surface.

Hand-Molding Process

A manual method of creating molds, suitable for small-scale production.

Machine-Molding Process

An automated method for producing large quantities of molds and castings.

Right Sand Composition

An optimal mixture of sand, clay, and other components that ensures effective molding.

Cores

Refractory materials used to form cavities in castings, made from sand or metal.

Chaplets

Small metal supports used to hold cores in position within large or complex castings.

Cold Curing CO₂ Process

A method for fabricating cores that uses sodium silicate and CO₂ gas to enhance strength.

Furan System

A no-bake core system that uses furan resins to harden at room temperature.

Machine Types

Various machines classified based on sand compaction methods, such as squeeze molding machines.

Jolt Machine

A machine that achieves sand compaction by dropping the flask against a fixed stop.

Squeeze Molding Process

A method that uses compressed air to compact sand in molds.

Resin System

A mold making system using thermosetting resins to bind sand.

Mold Hardness

A measurement of how solidly the sand is compacted in the mold.

Equipment for Molding Sand Testing

Tools used to assess properties of molding sand to ensure quality in castings.

Surface Finish

The smoothness of the surface of the castings, influenced by the type of sand and mold process.

Dimensional Accuracy

The precision of the mold and final product dimensions achieved through proper mold making.