Introduction of Sand Casting Process- An Overview

Yash Choundiye1 , Vishal Choundiye2 , Vinod Chaudhari3 123Student of Second Year B Tech, Department of Mechanical Engineering, Deogiri Institute of Engineering and Management Studies.

Abstract - DISAMATIC is associate automatic assembly line used for quick manufacturing of flaskless sand moulds for inexperienced sand casting. This methodology is typicallyaccustomed mass manufacture of metal castings for the automotive and machine business. Sand castingsmethodologyis susceptible to get some defects resulting in high rejection rates. An industrial plant that produces within ball rejection istaken under consideration to be ancient whereas the qualitythese days is anticipated to evolve per million defects. So management of defects has become a vital issue for the industrial plant industry. Sand castings methodology is susceptible to many defects resulting in high rejection rates. An industrial plant that produces within ball rejectionistakenunder consideration to be ancient whereas the quality these days is anticipated to evolve per million defects. So management of defects has become a vital issue for the industrial plant trade. The purpose of this paper is to optimizethe sand casting methodology parameters of the castings store bought in many industries

Key Words: Sand casting, Pattern, Molten metal, Sands,Sand molds, Sand casting operation.

1. INTRODUCTION

Sand casting is traditional methodology of producing that usedsandas a refractorymedium toextendthestandardofthe casting. Sandcasting involves melting metalandpouringit into a mould cavity shaped by impression of the pattern. This patternissortofanequivalentdimensionsasofthe ultimatesizedmodel.Asmalltoleranceisgivenbyenlargingtoaccount forshrinkageandmachiningallowanceswithinthefinalcasting.Itsformresemblestheformofthespecifiedproduct.During thiscavity,themoltenmetalispouredandallowingthemetaltocooluntilitsolidifies.Thiscoagulatedonehalfpartistaken outofthemould,andcleansedthenfinishedbymachiningprocessestocreateitappropriatetobeused.Herethesandused isnamedgreensand.Itscompositionincludes90%basesand,7%binderand3%clay.

2. Literature review

SunilChaudhari,HemantThakkar[1]theyfoundthevarioussimulationtechniquesand softwareare the benefit forindustry. It provides number of advantages such as high quality of surface, reduce different types of defects. Ifcastingusing some technologicalwayminimizethedefectincasting.

SagarMBaligidad,NKrishnamurthy[2]classifiedtheadvantagesofrapidprototypingusedinthesandcasting processfor gettingmoredimensionalandsurfacefinish.Therapidprototypinggetlessleadtimetomanufacturingproduct.

LalNarayanPandey, [3] Using taguchi methodto reducethedefects occurs insand casting process. Taguchimethodsthat factorwhichwillbereducedifferentdefects.

Bhushan Shankar Kamble [4] it reviews that in some small foundry had not standardized process for sand casting. The systematicworkwillbebenefitsofimprovingthequalityofproduct.

Sameer Rafiq Shah [5] Sublime sand casting method is generally used in different types of manufacturing for making machinepartslikegear,helicalspring,torsionspring,conicalspring.

Manikanda Prasath K, Vignesh S [6] the sand casting have application and advantages would be remarkably elevate. The sandcastingprocesswillbethefirstpreferredthanotherprocessincasting.

ManpreetDubey,AbhishekSharma[7]thepaperisreviewthatisfullyanalyzedthattheprocessofsandcastingwiththeir applicationandbackground.Theadvancementsaremakingmajorroleinincreasetheproductionrate.

Nishant Hawaldar, Jing Zhang [8] they classified differencebetween conventional sand casting process and 3D printed mouldsandcastingprocess.Forreducetheleadtimeandwastageofmaterials.

International Research Journal of Engineering and Technology (IRJET) e ISSN:2395 0056 Volume: 09 Issue: 06 | June 2022 www.irjet.net p ISSN:2395 0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page404

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International Research Journal of Engineering and Technology (IRJET) e ISSN:2395 0056

CindySithole,KasongoNyembwe [9]thesandcastingitis importantforindustrytomakinga largeproduction.By using sixsigmamethodologiestheindustrywillbereducedefectsinsandcasting.

I Rajkumar, N Rajini [10] the feeding system is use to minimize the unrest through proper location of parts. By simulationreducetheleadtimerequiredtosandcastingprocess.

WossenuAli[11] byanalysisthedifferentdefectsthe mainreasonsforthisuseprevioussandandhigh percentageof clay content.

AniketNargundkar,ApoorvaShasri[12]thepaperisreviewsthatusingofdifferentcombinationofsandswiththeirdifferent propertiesforimprovingthequalityofproduct.

VishwasMehta,AtharvaKulkarni,RohanMahale[13]byusing3Dmodelandvisualsimulationincastingfillingprocessthey makehighaccuracyandvisibilityoccursinthesandcastingprocess.

SDhanush,SBalaganesh[14]itfoundthesinglemethod/techniqueisnotsufficientfordifferenttypesofparts,objects,and products.Byusingdifferenttechniquewereducethedefectsoccursinsandcasting.

SPrashanth,Dr.T.Sathish,Dr.R.Venkatesh[15]byperformingdifferentexperimentstheyfoundthemoisturecontaininsand willmakemajorroleofcastingdefects.

3. Process of sand casting

3.1 Sand Preparation =Preparesandandcoresandformolding,generallyusingasandmixertomixtheusedsandandthe rightamountofclay.

Fig 1 Sand mixer

3.2 Pattern making = Molds and core boxes are made according to the part delineations. Generally, we can use rustic moldsforsinglecorridorproduct,plasticoressence moldsformassproduct,andpatternplatesforlargecastings.Currently, moldsaremadebydrawingmachines,sotheproductcycleisdockedsignificantly,anditcouldtake2to10daysformold. Fig-2 Pattern Making

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3.3 Molding = sand molding, core making, and mold fittingare the main features in the molding. Sand molding means forming the depression for the casting from the molding sand. Core making refers to the product of the cores, whichare usedtoformtheinternalshapeofthecasting.Moldfittingistheassemblyoftheupperandlowersandboxesafterthecores hasbeenplacedinsidethecavity.Moldingisapivotalpartofthecastingprocess.

Fig-3 Molding

3.4 Melting= the chemical composition needs to match theneeded essence. A suitable furnace is named to melt the amalgamation material to form a good liquid essence (pieceand temperature of the molten essence must misbehave). Meltingadoptscupolasorelectricfurnaces(duetoenvironmentalconditions,cupolashavesubstantiallygotoutlawed.

3.5 Molten Essence Pouring=themoltenessencefromtheelectricfurnaceispouredintotheearthusingaspoon.Thespeed ofpouringiscriticaltoinsurethatthemoltenironfillstheentiredepression.It'salsodangeroustopourtheiron,sobecareful.

Fig-5 Molten metal

3.6 Sand Removal=afterthemoltenessencesolidifies,takeahammertoremovethesprueandshakeoffthebeachfromthe castings.Thecastingsarealsoblastedwithasandblastertogiveacleansurface.Thecastingblanksarereadytoleavetheplant afterexamination.

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Fig 4 Furnace

Fig-6 Sand removal

3.7 Grinding =forcastingswithspecialconditions,orwherethefaceofthecastingblankscannotbeovertoanticipation,simple grinding .And grinding is generally done with a grinding wheel or grinder to remove churrs and give the casting a better finish.

3.8 Inspection=generally,duringthecleaningandgrindingphases,non conformingcastingshavebeenpickedout.Butstill, final examination is needed. And for castings with assembly conditions, we need to make a set of tools or through stop needlesforreviewtoinsurenoproblemswiththeassembly.[6][8][9]

Fig 8 Inspection

4. Types of sand molds

Sandmoldsarecharacterizedbythetypeofsandthatcomprisethemandbythemethodusedtoproducethem.Thereare threebasictypesofsandmolds.

4.1 Green sand =themostcommonmoldmaterialisgreenmoldingsand,anadmixtureofsand,clay,andwater.Theterm” green”referstothefactthatthesandinthemoldis moistordampwhilethemetalispouredintoit.Green sandmoldingis theleastprecioussystemofmakingmolds,andthesandisreclaimedfluentlyforafterreuse.Intheskin driedsystem,the moldsurfaces aredried, eitherbystoringthemoldinairorbydryingitwithfirebugs.Becauseoftheiradvancedstrength, thesemoldsaregenerallyusedforlargecastings.[5]

4.2 Cold box molds =inthecold boxmoldprocess,variousorganicandinorganicbindersareblendedintothesandtobond thegrains chemically for lesser strength. These moldsare more dimensionally accurate than green sand molds, but are

International Research Journal of Engineering and Technology (IRJET) e ISSN:2395 0056

Fig 7 Grinding

International Research Journal of Engineering and Technology (IRJET) e ISSN:2395 0056

more precious to make. In the singe mold process, asynthetic liquid resin is mixed with the sand, and the admixture hardensatroomtemperature.Becausetheclingofthe moldinthisandinthecold- boxprocesstakesplace withoutheat, they’recalledcold-settingprocesses.[7]

4.3 No break molds =No bake molds could be a casting method that involves the utilization of chemical binders to bond themoldingsand.Sandissenttothemoldfillerstationinpreparedforfillofthemold.Amixerisemployedtomixthesand with the chemical binder and catalyst. Because thesand exits the mixer, the binder begins the action of hardening. This techniqueofmildewfillerisusedforevery1/2themold(copeanddrag).Everymoldisadditionally compactedtocreatea robustandthickmold.[13]

5. Defects

Various defects can develop during manufacturing, depending on factors such as raw material quality, mold design and controlofmachiningparameters.Whilesomedefectsonlyaffecttheappearance,otherscanhaveamajornegativeimpacton thestructuralintegrityofpartsmade.

5.1 Misruns =Misrunisakindofcastingillnessthathappenswhilstthemetallicisnotworthytofillthemouldmelancholy andconsequentlyleavestheunfilledelementwithinsidethemouldmelancholy.[1]

Causes:

i. The molten metallic might also additionally havedecreasefluidity.

ii. Thetemperatureofmoltenmetallicislow.

iii. Pouringvelocityisslow.

iv. Crosssegmentofthemouldmelancholyisthin.

Remedies:

i. Thepouringtemperaturehastobeexcessive.

ii. Gatingmachinehastobemodified.

5.2 Inclusions = When the metallic is melted, the flux is brought to it so that you can take away the unwanted contaminationsandoxidesfoundinthemetals.Duringthetimeoftapping,thesedimenthavetobeassetseliminatedelseif itmixeswithmoltenessence,additionallyitreasonsadisfigurementreferredtoasinclusions.Alsotherearevariousdifferent motivesthatareaccountableforsedimentconformation.Thesereasonsarereferredtobelow.[10]

Causes:

i. Indecorousgatingmachine.

ii. Improper pouring of molten metallic and softrammingandcoresandqualityandindecorousflux.

Remedies:

i. ModifyingthegatingmachineandpouringmethodandUsetherightflux.

ii. Properrammingofsandhastobefinished.

iii. Superiorsandhastobeused.

5.3 Cold shut =Whenthequantitiesofthemoltenessenceinfluxtogether,thereisalossofemulsionamongthembecause ofunseasonablesolidification.Thisdisfigurementincastingisreferredtoasbloodlessshut.[4]

Causes:

i. This illness might also additionally do because oflossoffluidityofmoltenmetallic.

ii. Faultydesignanddecreasepouringtemperatureofessence.

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Remedies:

i. Designofthegatingmachinehastobeamended.

ii. Maintaining the superior pouring temperature ofmoltenmetallic.

5.4 Shrinkage hollow space =Thisillnessisinducedbecauseofmelancholywithinsidetheshellwithinsidethecasting thatisbecauseofsolidificationlossthatrestrictstheamountofliquidmetallictobehadwithinsidethefinalareatoconcrete. [11]

Causes:

i. Thishappensbecauseofafaultygatingmachine.

ii. Alsobecauseofincorrectchilling.

Remedies:

i. Gatingmachinehastoberefined.

ii. Chillingmachinehastobemodified.

5.5 Blow holes =Blowholesarelikesmallcavitiesinacasting.Theholesthatseematthefloorofthemetalliccastingare calledopenblowholes.Whiletheholeswhichdowithinsidethemetalliccastingaretermedasblowholes.

Causes:

i. Thisillnesshappensbecauseofinessentialmoisturecontentmaterialwithinsidethemoldingsand.

ii. Ithappensbecauseoflowpermeabilityofseashoreandexcessivefirst rategrainsand.

iii. Excessivebindersadditionallyreasonthisillnessincastingandimproperbakedcoresadditionallycausethisillness.

Remedies:

i. MoisturecontentmaterialhastoberegulatedandCoreshavetobebakedproperly.

ii. Coresandmouldshavetobeventedproperly.

iii. Bindershavetobeusedwithinsidethepreferredamount.

5.6 Porosity =theporosityisapinholeskindillnessvisiblewithinsidethecasting.Thisillnessislikewisereferredtoasfuel lineporosityashydrogenfuellineisaccountableforthisdefect.Generallythegasescontinuetobeabsorbedthroughthemolten metallic.[14]

Causes:

i. This illness happens because of low permeability ofthe molding sand in addition to excessive moisturecontent materialgiftwithinsidethesand.

ii. Gases dissolved in molten metallic also are responsible and excessive pouring temperature is accountable for porosity.

iii. Thisillnessmightalsoadditionallydobecauseofdecreaseamountoffluxutilizedinmoltenmetallic.

Remedies:

i. Increasetheshareofflux.

International Research Journal of Engineering and Technology (IRJET) e ISSN:2395 0056

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ii. Properventinghavetobefinishedandmoisturecontentmaterialofthemoldingsandhavetobereduced.

5.7 Swells = Sometimes because of excessive stress of themolten metallic, the mould will amplify slightly.Because ofthis thedimensionsofhollowspacewillincreaseandsotheverylastcastingcanbebulgyatthatpoint.Thisillnessisreferredto asswells.[15]

Causes:

i. Softrammingreasonsthisillnessandlowelectricityofsandcores.

ii. Moldisnotsupportedcorrectly.

Remedies:

i. Harderramminghastobefinished.

ii. Strength of mould and sand cores has to beincreased.

iii. Properaidhastobeprovidedtothemould.

6. Conclusions

Inmoment’sglobalcompletion,it’simportantforfoundriestoconcentrateonprocessenhancementtoincreasecompetitive advantage. Competitiveadvantageforsandcastingfoundriesmeansadvancedproductprocess,betteredplantconservation processes, bettered product quality andproper operation of resources, especially scarce resources.Process knowledge could be truly critical for sand casting foundries to palliate its limitations compared to other substance manufacturing ways. This paper aimedat defining process knowledge of the sand casting. Thus sand casting process is useful to manufacture intricate, irregular and tough shaped casting products. And thecastingssoproducedhave high dimensional delicacy, good surface finish, no residual stresses and superior mechanical properties. All inall, it can be concluded that sand casting is one of the most important methodologies to produce the metallic corridor and structures, still, a better understandingandtherebyawell conditionedcontrolofsandcastingisstillrequired.

REFERENCES

[1]Sunil Chaudhari, Hemant Thakkar, Review on analysis offoundry defects for quality improvement of sand casting, Internationaljournalofengineeringresearchandapplications,volume 4,issue march2014.

[2] SagarMBaligidad,NKrishnamurthy,etal,Sandcasting conventionalandrapidprototypingmanufacturingapproaches, Internationaljournalofresearchinengineeringandtechnology,volume 3,June2014.

[3] LalNarayanPandey,Sandcastingabasicreview,Internationaljournalofinnovativeresearchintechnology,December 2015.

[4] Bhushan Shankar Kamble, Analysis of different sand casting defects in a medium scale foundry industry a review, Internationaljournalofinnovativeresearchinscienceengineeringandtechnology,volume 5,issue 2,February2016.

[5] SameerRafiqShah,Designofasandcastingmethod usingpatternmadeofsublimematerialsforcastingintricateshapes, Internationaljournalofengineeringresearchandapplications,volume 6,February2016.

[6] Manikanda Prasath K, Vignesh S, A review of advanced casting techniques, Research journal of engineering and technology,volume 8,issue 4,2017.

[7] Manpreet Dubey, Abhishek Sharma, A review paper on sand casting and its recent development, Pramana research journal,volume 8,issue 3,2018.

[8] Nishant Hawaldar, Jing Zhang, A comparative study of fabrication of sand casting mold using additive manufacturing andconventionalprocess,theinternationaljournalofadvancedmanufacturingtechnology,April2018.

International Research Journal of Engineering and Technology (IRJET) e ISSN:2395 0056

[9]Cindy Sithole, Kasongo Nyembwe, Process knowledge forimproving quality in sand casting foundries, International conferenceonasustainablematerialprocessingandmanufacturing,2019.

[10]I Rajkumar, N Rajini, Effectiveness of feeding system for enhanced product quality in sand casting industries, Internationaljournalofrecenttechnologyandengineering,volume 8,December2019

[11] Wossenu Ali, Defect analysis for sand casting process, International research journal of engineering and technology, volume 7,issue 1,2020.

[12] AniketNargundkar,ApoorvaShasri,Optimizationofsandusageformetalcastingprocessasustainablemanufacturing approach,Internationaljournalofscientific&technology,volume 9,issue 2,February2020.

[13]VishwasMehta,AtharvaKulkarni,RohanMahale,Gatingsystem design and material for the sand casting of a sprocket, Internationalresearchjournalofengineeringandtechnology,volume 7,issue 10,2020.

[14] SDhanush,SBalaganesh,Areviewondefectminimizationinsandcasting,Naturalvolatiles&essentialoils,2021.

[15]S Prashanth, Dr.T.Sathish, Dr.R.Venkatesh, Experimentalinvestigation on sand casting process and optimizing process parameters,Journalofpositiveschoolpsychology,volume 6,

2022.

BIOGRAPHY

Yash Choundiye Pursuing the Bachelor of Technology Degree [Mechanical] From Deogiri Institute of EngineeringandManagementStudies,Aurangabad,Maharashtra,India.

Vishal Choundiye Pursuingthe Bachelor of Technology Degree [Mechanical] From Deogiri Institute of EngineeringandManagementStudies,Aurangabad,Maharashtra,India.

Vinod Chaudhari PursuingtheBachelorofTechnology Degree [Mechanical] From Deogiri Institute of Engineering and Management Studies, Aurangabad, Maharashtra, India .

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