Industry Overview
Sand casting is one of the most widely used metal casting techniques and provides an efficient method for producing a broad range of shapes and components from different materials. The process involves preparing an expendable sand mold, melting the required metal, pouring it into the mold cavity, allowing it to solidify, and then removing and finishing the casting. Patternmaking, core making, molding, clamping, melting and pouring, cooling, removal, trimming, cleaning, and quality control are key stages of the process.
Steel can be melted in electric-arc furnaces, allowing suitable metal scrap from risers and runners to be recycled. Cast iron production may also involve cupola furnaces. Proper design of sprues, runners, risers, chills, and cores helps control metal flow, solidification, shrinkage, and casting quality. Pattern materials such as wood, plastics, aluminum, fiberglass, and cast iron are selected according to production requirements. The industry also incorporates inspection methods and equipment to identify casting defects and maintain product quality.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 25 MT/Day |
| Land & Building (96000 sq.ft.) | Rs. 3.87 Cr |
| Plant & Machinery | Rs. 3.24 Cr |
| Working Capital for 2 Months | Rs. 5.23 Cr |
| Total Capital Investment | Rs. 13 Cr |
| Rate of Return | 23% |
| Break Even Point | 60% |
Content Index
- INTRODUCTION
- SAND CASTING
- BASIC REQUIREMENTS FOR METAL CASTING
- AUTOMATED SAND CASTING IN FOUNDRIES
- CAST IRON
- TYPES OF CAST IRON
- THE VARIOUS TYPES OF CAST IRON IN USE ARE DISCUSSED AS FOLLOWS
- EFFECT OF IMPURITIES ON CAST IRON
- USES & APPLICATIONS
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- MANUFACTURING PROCESS
- (A) PIG IRON
- (B) FERRO-ALLOYS
- (C) COKE
- (D) CAST IRON SCRAP
- (2) SAND CASTING
- ADVANTAGES OF SAND CASTING:
- DISADVANTAGES OF SAND CASTING:
- (A) PATTERNMAKING
- (B) CORE MAKING
- (C) MOLDING
- (D) CLAMPING
- (E) MELTING & POURING
- (F) COOLING
- (G) REMOVAL
- (H) TRIMMING
- (I) CLEANING
- (J) QUALITY CONTROL
- CASTING DEFECTS:
- DEFECTS RELATED WITH SAND MOLDS:
- INSPECTION METHODS:
- CUPOLA FURNACE
- STRUCTURE OF CUPOLA FURNACE:
- (I) SHELL:
- (II) FOUNDATION:
- (III) CHARGING DOOR:
- (IV) CHARGING PLATFORM:
- (V) AIR BLOWER:
- (VI) TUYERES:
- (VII) VOLUME METER:
- (VIII) TAP HOLE (MOLTEN METAL HOLE):
- (IX) SLAG HOLE:
- (X) CHIMNEY:
- OPERATION OF CUPOLA FURNACE:
- (I) PREPARATION OF CUPOLA:
- (II) FIRING OF CUPOLA:
- (III) CHARGING THE CUPOLA:
- (IV) SOAKING OF IRON:
- (V) STARTING THE AIR BLAST:
- (VI) CLOSING THE CUPOLA:
- ZONES OF CUPOLA FURNACE:
- THE FOLLOWING ARE THE SIX IMPORTANT ZONES:
- (I) WELL OR CRUCIBLE ZONE:
- (II) COMBINATION ZONE:
- (III) REDUCING ZONE:
- (IV) MELTING ZONE:
- (V) PREHEATING ZONE:
- (VI) STACK ZONE:
- CAPACITY OF CUPOLA FURNACE:
- ADVANTAGES OF CUPOLA FURNACE:
- LIMITATIONS OF CUPOLA FURNACE:
- MARKET POSITION
- GENERAL ECONOMIC SCENARIO
- FORECASTS OF GROWTH BY LEADING INSTITUTIONS:
- MAJOR FOUNDRY CLUSTERS:
- MANPOWER:
- AUTO SECTOR:
- TOTAL PRODUCTION OF TRACTORS IN INDIA:
- GLOBAL SCENARIO:
- ROLE IN MANUFACTURING SECTOR:
- PRODUCTION IN MILLION TONES:
- EXPORTS IMPORT TRENDS:
- SECTORWISE CONSUMPTION OF CASTING
- IFMET 2018: INDIAN FOUNDRY INDUSTRY EXPECTS US 3 BN INVESTMENT
- THE BRIGHT FUTURE OF CASTING IN INDIA
- 1. THE ‘MAKE IN INDIA’ CAMPAIGN
- 2. FOCUSING ON STRUCTURAL CHANGE SINCE 2015
- 3. THE BOOMING GROWTH OF THE AUTO INDUSTRY
- 4. MISCELLANEOUS OPPORTUNITIES
- METAL CASTING MARKET
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF CAST IRON CASTING
- SUPPLIERS OF RAW MATERIALS
- PIG IRON
- CAST IRON SCRAP
- FERRO SILICON
- FERRO MANGANESE
- SUPPLIERS OF COKE
- FIRE CLAY
- BENTONITE POWDER
- COAL DUST
- FIRE BRICKS
- SOAP STONE
- GRAPHITE POWDER
- SILICA SAND
- SUPPLIERS OF LIME STONE
- SUPPLIERS OF PLANT AND MACHINERIES
- COUPLA FURNACE
- ALUMINIUM PATTERNS
- INTENSIVE SAND MIXTURE AND MULLER
- SAND SIEVING MACHINE
- SQUEEZE MOLDING MACHINE
- SHAKEOUT MACHINE
- CORE SHOOTER MACHINE
- DRYING OVEN
- FOUNDRY TOOLS
- MOLDING BOXES
- METAL TESTING MACHINE
- PRECISION MEASURING TOOLS
- NDT INSPECTION EQUIPMENT
- DRILLING, LATHE, TAPING MACHINES
- GRINDING MACHINE
- EOT CRANE
- POWER TRANSFORMER
- ELECTRICAL PANEL
- ELECTRIC MOTOR
- COOLING TOWER
- EFFLUENT TREATMENT PLANT (ETP PLANT)
- AIR POLLUTION CONTROL EQUIPMENTS
- AIR CONDITIONING EQUIPMENTS
- AIR COMPRESSORS
- PLATFORM WEIGHING MACHINE
- MATERIAL HANDLING EQUIPMENTS
- FIRE FIGHTING EQUIPMENTS
- SHOT BLASTING MACHINE
- JIGS AND FIXTURE
- SUBMERSIBLE WATER PUMP
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Sand casting is a metal manufacturing process in which molten metal is poured into a cavity formed in a sand mold and allowed to solidify. The mold is generally expendable, meaning a new mold is prepared for each casting operation. The process can produce a wide variety of shapes and components and is suitable for several metals. Important stages include patternmaking, core making, molding, melting and pouring, cooling, removal, trimming, cleaning, and quality control.
The basic requirements for metal casting include a mold cavity, a suitable melting process, an effective pouring technique, controlled solidification, casting removal, and finishing allowances. Pattern and core design are also important because they determine the shape and internal features of the final component. Proper control of metal flow, cooling, shrinkage, and mold integrity helps reduce defects and supports consistent casting quality.
Patterns are used to create the mold cavity corresponding to the required casting shape. A pattern is generally made as a full-sized model of the component, with appropriate allowances for metal shrinkage and machining. Common pattern materials include wood, plastics, aluminum, fiberglass, cast iron, and other metals. Material selection depends on factors such as the number of castings required, durability, manufacturing cost, and dimensional requirements.
A riser supplies additional molten metal to the casting as the metal contracts during solidification. This function helps compensate for shrinkage and reduces the likelihood of shrinkage cavities within the finished casting. Riser design is therefore an important part of mold and gating-system engineering. Proper positioning and sizing help ensure that the casting solidifies in a controlled manner and that adequate molten metal remains available to compensate for volume reduction.
A cupola furnace is a foundry furnace used for melting metal, particularly cast iron, for casting operations. Its operation involves preparing and firing the furnace, charging the required materials, soaking the iron, starting the air blast, and subsequently closing the furnace. A cupola contains functional zones such as the well or crucible zone, combination zone, reducing zone, melting zone, preheating zone, and stack zone. Furnace capacity, operating conditions, and material selection influence its performance.
Common sand-casting defects include shrinkage cavities, microporosity, cracks, inclusions, and defects associated with sand molds or improper metal flow. Defects can result from unsuitable mold conditions, incorrect gating or riser design, uncontrolled solidification, trapped gases, or inadequate process control. Chills can help regulate cooling, while appropriate riser design supports feeding during solidification. Inspection methods and quality-control procedures are used to identify defects and verify that castings meet required specifications.
A sand casting plant may require equipment for molding, core making, melting, material handling, finishing, inspection, and environmental control. The report identifies equipment such as a cupola furnace, aluminum patterns, intensive sand mixture and muller, sand sieving machine, squeeze molding machine, shakeout machine, core shooter machine, drying oven, molding boxes, metal testing machine, NDT inspection equipment, grinding machine, EOT crane, shot blasting machine, and material handling equipment. Supporting utilities and pollution-control systems may also be required.
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