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h Sand Casting ______________ Also visit: Casting Processes Sand Casting, also known by the name of Green Sand Molding – is the most commonly used casting platform throughout the entire Casting Industry. In Sand Casting there is a top, a bottom, and a middle to a mold. The pattern, or impression device, sits in the middle of the mold, and later is surrounded with sand .
The Cope and Drag & How it all Works The top and the bottom of the pieces of the mold form the Flask. The Flask Assembly, the top and bottom, "holds the whole thing together". Cope and Drag = The Flask The upper or topmost section of the mold (flask) is called the Cope. The bottom of the mold (flask) is called the Drag. The impression device, in the middle, is called the Pattern or by some the Tool. The sand around the pattern is called the, Holding Medium. The completed assembly, of the Cope, of the Drag, of the Pattern / encased in the Holding Medium, all fastened together, awaiting the molten material is called the Mold . Summary ( Cope + Drag ) = Flask Flask (cope and drag) + Pattern + Holding Medium = Mold
Below examples are from Wynn Danzur's X-RAY Visioning
Above is a drawing of how a sand casting works.
Above is how a sand cast part looks like inside the holding medium. The silver areas are the sprues, gates, risers, and pouring cup. The red areas are the desired cast parts.
Above is another drawing of how a sand casting works. Note that all the familiar parts are being mentioned again.
How it all Works 1. The mold maker uses the pattern to make the impression in the sand. First he does the bottom, then he does the top. 2. He then sets the pattern aside, to use in making the next mold. This is repeated for as many of the cast parts that have been ordered. Metal Casting is labor intensive. 3. At that point, the molder closes the cope and drag, leaving the pattern void inside, forming the mold. 4. What the mold maker wants is the void left from the impression of the pattern, in middle of the sand, inside the mold. This is going to be the Cast Part. 5. So he fills that void with a molten material, which could be aluminum, gray iron, steel, etc., 6. The cast parts are the red areas you see in the second drawing. 7. The Molds are left to cool, then the molds are shook out; sand and castings separated. Sand is filtered, cleaned, materials added, and it is used again.
NOTE> What has just been explained, are the basic, universal casting components, which can be applied to all casting processes. Die Casting, Investment Casting, Permanent Mold, etc., all use the same Principle of Cope and Drag with a Pattern. In these other processes, when you study how they work, the Concept of Cope and Drag will become apparent.
Go to this Section for more detail Casting Processes
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