Sand mold casting technology is a casting method that takes sand as the main molding material to prepare the mold. Sand casting is the most traditional casting method.

Due to its characteristics (not limited by the shape, size, complexity, and alloy type of parts, short production cycle, and low cost), sand casting is still the most widely used casting method in casting production, especially single piece or small batch castings!

The technological process of traditional sand mold casting includes the following steps: sand mixing, mold making, core making, modeling, pouring, sanding, grinding, inspection, and so on.

1. In the sand mixing stage, molding sand and core sand are prepared for molding. Generally, the sand mixer is used to put in the old drawing an appropriate amount of clay for mixing.

2. In the mold-making stage, molds and core boxes are made according to the part drawings. Generally, wood molds can be used for single pieces, plastic molds or metal molds (commonly known as iron molds or steel molds) can be made for mass production, and molding plates can be made for mass castings. Now molds are made by engraving machines, so the production cycle is greatly shortened. Generally, it takes 2-10 days to make molds.

3. Molding (core making) stage: including molding (forming the cavity of the casting with molding sand), core making (forming the internal shape of the casting), mold matching (putting the clay core into the cavity and closing the upper and lower sandboxes). Modeling is the key link in casting.

4. Smelting stage: prepare the chemical composition according to the required metal composition, select the appropriate melting furnace to melt the alloy material, and form a qualified liquid metal (including qualified composition and qualified temperature). A cupola or electric furnace is generally used for smelting (due to environmental protection requirements, the cupola is now basically banned and the electric furnace is used).

5. Pouring stage: use a molten iron ladle to inject molten iron melted in the electric furnace into the formed mold. When pouring molten iron, pay attention to the pouring speed to fill the whole mold cavity with molten iron. In addition, pouring molten iron is dangerous, and you need to pay attention to safety!

6. Cleaning stage: after pouring, after the molten metal solidifies, take a hammer to remove the gate and shake off the sand of the casting, and then use a sand blasting machine to sandblast, so that the surface of the casting will appear very clean! Casting blanks that are not strictly required can leave the factory after inspection.

7. Casting processing. For some castings with special requirements or castings that cannot meet the requirements, simple processing may be required. Generally, grinding wheels or grinders are used for machining and grinding to remove burrs and make castings more smooth.

8. Casting inspection. The casting inspection is generally in the process of cleaning or processing, and the unqualified ones are generally found and picked out. However, some castings have specific requirements and need to be checked again. For example, some castings need a 5cm shaft to be inserted into the center hole, so you need to take a 5cm shaft and try it on.

Summary

After the above 8 steps, the castings are formed. For castings requiring high precision, machining is required, because they do not belong to the scope of casting, so they are no longer described here. With the progress of casting technology, traditional sand casting is either improved or replaced by other casting methods. Continuous innovation is the eternal theme, and it is the internal quality and foundation that a foundry must have!

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