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Sand casting is a mold based net shape manufacturing process in which metal parts are molded by pouring molten metal into a cavity. The mold cavity is created by withdrawing a pattern from sand that has been packed around it. Since the pattern imprint forms the cavity, the pattern creates the external shape of the cast part. If the part has undercuts or hollow internal regions, these can be formed...
Typically, the sand-casting tool design and fabrication process begins when the tool builder receives the part design from the client or design engineer. In general, the part design can be communicated in variety of ways such as by a physical part, a 2D engineering drawing, a 3D computer generated solid model, or other means that sufficiently conveys the design intent needed for tooling design and...
Fast freeform fabrication, also called rapid prototyping, is the automatic manufacturing techniques using slicing and additive processes. The first techniques for fast freeform fabrication became available in the late 1980s and were used to produce models and prototype parts. With the fast freeform fabrication method, the machine reads in data from a CAD drawing, slicing the CAD model into a thin,...
Sand casting is one of several near net shape manufacturing processes. In near net shape manufacturing, multiple copies of the product are produced by imprinting the shape of the tool or die on a suitable working material. Typically, the working material starts out as a liquid, powder, or pliable material that is eventually solidified or hardened after being formed by the tool. Net shape manufacturing...
Dimensional accuracy and variability are critical factors in the casting process that must be considered at each stage of the process. Dimensional accuracy is an indication of how close a casting dimension is to design intent (the actual target value). Dimensional accuracy is often referred as a system error. The main causes for poor dimensional accuracy in sand casting are pattern equipment errors,...
Evaluation of tooling alternatives is the comprehensive mental exercise involved in selecting the most efficient way to produce a sand casting pattern. Selection of the proper tooling process can significantly effect the time, cost and accuracy of castings involved. Selection of an appropriate tooling alternative is typically performed by the tool builder. The process requires a sound understanding...
The tool path evaluation form shown in Table 7.1 is a simple form that allows a sand casting tool design professional to quickly estimate the best tooling alternative selection for a given casting geometry as a function of production volume. The form also allows the tooling professional to document the key considerations driving the selection. It should be noted that the “key tool considerations and...
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