Sand casting is a basic low-cost process, and it lends itself to economical production in large quantities with practically no limit to the size, shape, or complexity of the part produced.
In sand casting, the casting is made by pouring molten metal into sand molds. A
pattern, constructed of metal or wood, is used to form the cavity into which the molten metal is poured. Recesses or holes in the casting are produced by sand cores introduced into the mold. The designer should make an effort to visualize the pattern and casting in the mold. In this way the problems of core setting, pattern removal, draft, and solidification can be studied. Castings to be used as test bars of cast iron are cast separately and properties may vary.
Steel castings are the most difficult of all to produce, because steel has the highest melting temperature of all materials normally used for casting. This high temperature aggravates all casting problems.
The following rules will be found quite useful in the design of any sand casting:
1 All sections should be designed with a uniform thickness.
2 The casting should be designed so as to produce a gradual change from section to section where this is necessary.
3 Adjoining sections should be designed with generous fillets or radii.
4 A complicated part should be designed as two or more simple castings to be assembled by fasteners or by welding.
Steel, gray iron, brass, bronze, and aluminum are most often used in castings. The minimum wall thickness for any of these materials is about 5 mm, though with particular care, thinner sections can be obtained with some materials.
Mechanical Engineering
McGraw−Hill Primis
ISBN: 0−390−76487−6
Text:
Shigley’s Mechanical Engineering Design,
Eighth Edition
Budynas−Nisbett
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