Sand Casting

Sand casting is a process in which molten metal is poured into a non-reusable, compacted sand mold and held until solidification occurs.

The sand mold is composed of sand mixed with small amount of binding materials. A channel called a pouring basin is provided at the top of the mold. Molten metal runs into the mold cavity.

Possible Sand Casting Shapes

Many 3D shapes - often used on larger parts. Wide variety of geometries and different sized parts. Generally parts are not highly intricate.

Sand Casting Guidelines

• Keep wall thickness uniform.
• Fillet sharp corners.
• Ribs reduce distortion caused by thermal contradiction.

Example Sand Casting Parts

Engine blocks, gear blanks, crankshafts, brake drums etc.

Advantages of Sand Casting

Low cost for medium to large size parts.

Specifications for Sand Casting

• Material - Most metals: aluminum, brass, cast iron, cast steel.
• Alternative machines - Mill 3-Axis, Casting, Die Pressure.
• Tooling - Requires custom tooling - mold.
• Reducing costs - Minimize size and material volume.

Sand Casting Notes

Produces a parting line on the work piece. Produces rough textured surfaces. Pattern - approximate duplicate of real part. Parting line - location where the two mold halves meet. Core - shape inserted into the mold to produce the internal features of the part.