Sand Casting Service

1. Үлгі жасау

А pattern is a replica of the final part, slightly oversized to account for metal shrinkage during cooling.

It is usually made from wood, пластик, немесе металл.

• Мақсат: To create the mold cavity in the sand.
• Түрлері: Split pattern (for complex parts), match-plate pattern, or cope-and-drag patterns.
• Shrinkage allowance: Typically 1–3% depending on the metal.

2. Қалыптау

The pattern is placed inside a molding box (колбра), және sand mixed with a binder (like clay or resin) is packed around it.

The mold is made in two halves:

• Cope (top half) және Drag (bottom half).
• The pattern is removed, leaving a cavity in the shape of the part.
• If required, cores are inserted into the mold to form internal features or hollow sections.

3. Негізгі жасау (If Applicable)

Cores are sand shapes inserted into the mold to form internal cavities in the casting.

• Made from core sand, which is more durable and heat-resistant.
• They must be accurately placed and often supported with chaplets (metal spacers).
• Cores are removed after casting, usually broken out and discarded.

4. Metal Melting and Pouring

Molten metal is prepared in a furnace and poured into the mold through a шырша және runner system.

• The system includes қақпалар (to direct flow), risers (to compensate for shrinkage), және vents (to let gases escape).
• Metals used: шойын, алюминий, болат, қола, т.б.
• Care is taken to avoid turbulence, gas entrapment, and inclusions during pouring.

5. Салқындату және қатаю

After pouring, the metal is allowed to cool and solidify inside the mold.

• Cooling rates affect grain structure and mechanical properties.
• Proper riser design ensures that metal shrinkage is compensated to avoid internal voids.
• The solidification time depends on part thickness and metal type.

6. Shakeout and Mold Removal

Once the metal has cooled, the sand mold is broken apart to retrieve the solid casting.

• This step is called Шығару.
• The sand can often be recycled after cooling and screening.
• The casting is rough at this point and may have residual sand or oxide layers.

7. Тазалау және әрлеу

Excess material such as sprues, risers, and flash are removed by cutting or grinding.

• The surface may be тазартылған by shot blasting, tumbling, or pickling.
• Өңдеу is performed as needed to achieve final tolerances.
• Surface treatments or coatings (мысалы, сурет, жылтырату) қолдануға болады.

Sand casting supports a wide range of ferrous and non-ferrous metals. The choice depends on the desired mechanical properties, коррозияға төзімділік, салмақ, және құны.

Ferrous Metals

These metals contain iron and are commonly used for high-strength and structural applications.

Non-Ferrous Metals

These are metals without significant iron content, typically used for corrosion resistance and weight savings.

• 1. Cost-Effective for Low to Medium Production
• 2. Wide Range of Material Compatibility
• 3. No Size Limitations
• 4. Complex Geometries Possible
• 5. Short Lead Time
• 6. Recyclable Materials
• 7. Suitable for a Variety of Surface Finishes