These castings are made using sand molds formed from “wet” sand which contains water and organic bonding compounds, typically referred to as clay. The ability to quickly make molds through automated machines makes green sand casting economical and popular for making medium to high volume castings since the automated processes allows for a lot of molds to be quickly made at an affordable cost.
Tooling Design and Tool-Making
Designing and making cope pattern plate, drag pattern plate and core box.
Core halves pasted together
Making the cores in the core box and pasting the cores together.
Packing the sand around the cope pattern plate, sprue and risers. Afterwards, remove the extra sand, pattern, sprue and risers.
Pack the sand around the drag pattern plate. Then remove the extra sand and pattern.
Setting core in the drag.
Cope and Drag Assembly
Assemble the cope on the top part of the drag then securely clamp them together.
Molten metal is poured into the sand mold.
Casting is removed from the sand mold. Shake out the core and sand from the casting.
Cut the sprues and risers off the casting.
Finished parts are heat treated to desire hardness as requested.
Remove extra residue material on the casting surface and release casting stress created during the casting process.
Castings undergo thorough testing and inspection to ensure that they meet dimension tolerances and specifications.
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