Manufacturing Process Investigation

Manufacturing Process Investigation
Assignment 1b
Topic: Sand Casting
Name:
MG6044 – Manufacturing Processes and Production 2019

SECTION 1
A brief executive summary of manufacturing processes:
Manufacturing is a word derived from Latin, manu factus which means ‘made by hand”.
Manufacturing is involved with the process of making products. Often these manufactured
products may be used to make other products.
(Kang, 2016) pointed out four different modes of manufacturing
1. Moulding – The most common type of moulding is casting, in which the material is
heated till it becomes a liquid, then filling it into a mould. Once the liquid solidifies,
the mould is removed, giving you the desired shape. There are four other kinds of
moulding are as follows:
a. injection moulding,
b. centrifugal moulding
c. blow moulding,
d. pressure die casting,
2. Machining – as stated by (Rao.P.N., 2013), also known as Subtractive manufacturing
in which tools are used to form or shape solid materials, specifically
metals. The final product is made by removing material from the bulk
with the use of tools .
3. Joining – At some point of time one has to join 1 or more products together. Such
processes include mechanical fastening, welding, adhesive bonding, soldering,
brazing, and diffusion bonding
4. Forming and shearing – In these processes the part is primarily deformed by various
processes like forging, drawing, Rolling, extrusion, sheet forming, and moulding.
Figure 1: Different types of metal forming processes

In this report we shall discuss about Sand casting which comes under moulding techniques.
Sand casting is the oldest manufacturing method know to mankind. And it has been used to
make products since ages.
(Banchhor, 2014) stated the main reason it is still used today is because of its simplicity, low
cost etc. Sand casting falls under expandable mould type, since once the shape is made it
can be changed unlike permanent mould types, that is where is differs from other
processes.
Sand casting is a very common casting process used in production. The upside of utilizing
sand to make components of metal is that sand is exceptionally impervious to high
temperatures practically all metal casting materials can be sant casted. Sand castings can vary
in size from exceptionally little to very large. At present day a few products made in industry
by sand casting process are engine bloacks, machine bases, barrel heads, pump lodgings, and
valves.
(Groover, 2016) explained the procedure of sand casting in detail, on a perfect floor we will set
the drag box then we will put the pattern in the drag box. We will fill the box with the
sand and press or ram the sand into a mould of the shape of the pattern. We place the cope
box on top of the drag box and fill it with the sand and pressed again after putting all the taper
riser and vent patterns. Now, we lift the cope box and remove the patter and risers. We place
the cope box back and seal it. Next we pour the molten metal in the mould cavity.
Sand casting procedure