--- title: "Sand casting steps and mould parts" subject: "Manufacturing and Production Processes" chapter: 4 key: "semester_4/manufacturing_and_production_processes:sand-casting-process-steps-mould-components" source: https://www.bctengineer.com/q/semester_4/manufacturing_and_production_processes/sand-casting-process-steps-mould-components site: BCT Engineering --- # Sand casting steps and mould parts Manufacturing and Production Processes · Chapter 4: Solidification Process and Powder Metallurgy - Asked in: year not given, 6 marks - Video: [SAND CASTING LESSON FOR BEGINNERS - STEP-BY-STEP - (A 3rd HAND) - MSFN](https://www.youtube.com/watch?v=XlRK_SMWX7Y) — Makin Sumthin From Nuthin - Answer checked by Claude Opus 5.5 (high effort) on 2026-10-14 - Page: https://www.bctengineer.com/q/semester_4/manufacturing_and_production_processes/sand-casting-process-steps-mould-components - Whole chapter: https://www.bctengineer.com/md/semester_4/manufacturing_and_production_processes/chapter-4 ## Question Describe the steps of the sand casting process with a neat sketch of a mould showing its parts. State the advantages and limitations of sand casting. ## Short answer Steps: pattern making, core making, moulding (cope and drag rammed around pattern), core setting, melting and pouring, solidification, shakeout and fettling. Mould parts: pouring basin, sprue, runner, gate, riser, cavity, core, vents. Advantages: any metal, complex shapes, low tooling cost. Limitations: rough surface, wide tolerances, machining needed. ## Answer **Sand casting** is a process in which molten metal is poured into a cavity formed in compacted sand and allowed to solidify; the sand mould is then broken to take out the casting. #### Steps 1. **Pattern making** - a pattern slightly larger than the part (allowances added) is made of wood, metal or plastic. 2. **Core making** - cores of sand bonded with resin or oil are made to form internal cavities. 3. **Moulding** - the pattern is placed in the drag and moulding sand is rammed around it; the cope is then rammed on top, the pattern is withdrawn, and the gating system is cut. 4. **Core setting and closing** - cores are placed in the cavity on core prints, and the cope and drag are clamped together. 5. **Melting and pouring** - metal is melted (cupola, induction or arc furnace) and poured through the sprue. 6. **Solidification and cooling.** 7. **Shakeout and fettling** - the casting is removed, gates and risers are cut off, sand is cleaned off and flash is ground. 8. **Heat treatment and inspection.** #### Mould sketch ```text pouring basin riser \ / +----+ +--------\ /-------------------| |-----+ | COPE | | sprue | | | <- cope | | | +---------+----+--+ | | | | | mould cavity | | |=========| |==runner==gate==[ core ]====|==| <- parting line | |__| | | | | DRAG +-----------------+ | <- drag +--------------------------------------------+ (vents are pierced through the cope sand) ``` Parts: pouring basin, sprue, runner, gate, riser, cavity, core, cope, drag, parting line, vents. #### Advantages - Almost any metal can be cast, including high melting point alloys. - Sizes range from grams to many tonnes, and complex shapes are possible. - Low tooling cost; suitable for both small and large batches. #### Limitations - Poor surface finish (Ra about 12-25 micrometre) and wide tolerances (about plus or minus 1 mm). - A machining allowance is required. - Defects such as porosity and sand inclusions are common; the process is labour intensive and slow for high volumes. ## Check yourself The answer's key points as multiple-choice questions, with the correct option and why. 1. Why is the pattern made slightly larger than the part? A. To make it easier to handle B. To include allowances such as shrinkage and machining C. To allow for shake only D. To reduce sand usage Answer: B. Allowances are added to the pattern so the final casting reaches the required size. (Key point: Pattern size) 2. In the mould, which parts form the metal-feeding path? A. Cope and drag B. Pouring basin, sprue, runner and gate C. Core prints and vents D. Parting line and riser Answer: B. Metal enters through the pouring basin and sprue, then runner and gate to the cavity; the riser feeds shrinkage. (Key point: Mould parts) 3. What are cores used for in sand casting? A. Forming internal cavities B. Forming the outside shape C. Cooling the casting D. Supporting the cope Answer: A. Sand cores, held on core prints, form internal cavities. (Key point: Role of cores) 4. Which is a limitation of sand casting? A. Cannot cast high melting point alloys B. Poor surface finish and wide tolerances, with machining allowance needed C. Very high tooling cost D. Limited to small parts Answer: B. Ra is about 12-25 um with tolerance about +/-1 mm; sand casting has low tooling cost and handles many metals and sizes. (Key point: Limitations) ## Related in Manufacturing and Production Processes - [Solidification, shrinkage and casting defects](https://www.bctengineer.com/question.md?key=semester_4%2Fmanufacturing_and_production_processes%3Asolidification-shrinkage-casting-defects) — Manufacturing and Production Processes, chapter 4 - [Powder metallurgy process and applications](https://www.bctengineer.com/question.md?key=semester_4%2Fmanufacturing_and_production_processes%3Apowder-metallurgy-process-steps) — Manufacturing and Production Processes, chapter 4 - [Chvorinov's rule and riser design](https://www.bctengineer.com/question.md?key=semester_4%2Fmanufacturing_and_production_processes%3Achvorinov-rule-riser-design) — Manufacturing and Production Processes, chapter 4 ## Related in other subjects - [Steps in the design and synthesis process](https://www.bctengineer.com/question.md?key=semester_6%2Fmachine_design_i%3Adesign-process-steps) — Machine Design I, chapter 1 - [JPEG compression process steps](https://www.bctengineer.com/question.md?key=semester_8%2Fmultimedia_system%3Ajpeg-compression-steps) — Multimedia System, chapter 5, asked 3× - [Capital budgeting needs, steps, process](https://www.bctengineer.com/question.md?key=semester_7%2Fproject_engineering%3Acapital-budgeting-needs-steps-process) — Project Engineering, chapter 6 - [Casting versus forging design considerations](https://www.bctengineer.com/question.md?key=semester_7%2Fmachine_design_ii%3Acasting-forging-design-differences) — Machine Design II, chapter 3