Sand Casting Service

1. Membuat Corak

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

It is usually made from wood, plastik, atau logam.

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

2. Pembuatan acuan

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

The mold is made in two halves:

• Cope (top half) dan 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. Pembuatan Teras (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 sprue dan runner system.

• The system includes pintu (to direct flow), risers (to compensate for shrinkage), dan vents (to let gases escape).
• Metals used: besi tuang, aluminium, keluli, gangsa, dll.
• Care is taken to avoid turbulence, gas entrapment, and inclusions during pouring.

5. Penyejukan dan Pemejalan

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 shakeout.
• 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. Pembersihan dan Kemasan

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

• The surface may be dibersihkan by shot blasting, tumbling, or pickling.
• Pemesinan is performed as needed to achieve final tolerances.
• Surface treatments or coatings (cth., lukisan, menggilap) boleh digunakan.

Sand casting supports a wide range of ferrous and non-ferrous metals. The choice depends on the desired mechanical properties, rintangan kakisan, berat badan, dan kos.

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