EnginSoft shows essential advantages of sand casting as one of the fastest and most cost-effective casting methods adopted in the production of metal prototypes.

Sand Casting is an excellent solution for low to medium runs of parts that do not require precise shape repeatability, as well as being the only solution for very large objects which cannot be produced with other mass production casting techniques.

Sand is an excellent low cost cast material because it is refractory and chemically inert. Sand casting is also ideal for the production of very complex components requiring sand cores (cold box or shell sand) for the most intricate details and having internal areas with variations in thickness.

Green sand, which is new or regenerated sand mixed with natural or synthetic binders, is the most commonly used material for making aluminum expendable molds. Green sand molds get their name from the fact that they are still moist when the molten metal is poured into them. The process of aluminum sand casting using green sand and the gravity filling method can be summarized as follows:

Aluminum sand casting defects to look out for are residual oxide film, inclusion, core erosion, gas holes and shrinkage porosity.

Sand cast aluminum components are widely used in the automotive and transportation industries including aerospace. Parts commonly produced with sand casting include the power-train, supports, suspensions, casings, gears and many others.

A simulation model that optimizes the process and layout of sand casting requires a complete fluid-dynamics simulation, including the change of a laminar flow of molten metal to an undesired turbulent flow. The model should also account for the natural air permeability of the mold, allowing gases and steam created by the casting process to easily escape, thanks to the good permeability of sand molds and cores. Some typical process parameters and their corresponding outcomes to be included in the model are:

Using engineering simulation to optimize the sand casting process for aluminum and light alloys, we can lead foundries to “zero defect” manufacturing resulting in the dimensional conformity of the objects produced. Engineering simulation can help with:

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