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Emax
Product Description:
Production of Gray Iron Square Washers through Sand Casting
Gray iron square washers are widely applied in industry due to their low cost, durability, and excellent vibration-damper properties. Sand casting, which is a low-cost and traditional method, remains the most preferred method of producing these components. This paper presents the basic steps involved in producing gray iron square washers using sand casting.
1. Pattern Design and Mold Preparation
A wooden or metal pattern that replicates the size of the washer (with machining and shrinkage allowances) is created. The pattern is green sand cast (a mixture of silica sand, water, and clay) in a two-part flask. Sand is packed around the pattern to form the mold cavity. Core inserts may be added if internal features are required.
2. Melting and Pouring
Gray iron (typically 2.5–4% carbon and 1–3% silicon) is melted in a cupola or electric furnace at around 1,200–1,400°C. The molten metal is poured into the mold through a gating system that causes minimal turbulence and oxidation. Gray iron's high fluidity makes it possible to fill the cavity completely.
3. Cooling and Solidification
Controlled cooling allows for the formation of flake graphite structure, which allows for gray iron's characteristic properties. The mold is not upset for 30 minutes to a few hours, depending on washer size and thickness of the walls, to ensure proper solidification.
4. Shakeout and Finishing
After cooling, the sand mold is broken (shakeout) to retrieve the casting. Excess material, such as gates and risers, is removed by cutting or grinding off. Surface imperfections are cleaned with shot blasting or grinding. Final machining achieves dimensional accuracy for critical surfaces or holes.
Advantages of the Process
Sand casting offers low-to-medium volume production flexibility and complex geometries. Green sand use is cost-effective and environmentally friendly compared to bonded sand systems. The natural lubricity of graphite flakes in gray iron minimizes tool wear during machining, further lowering production costs.
Applications
Square washers produced by this method are utilized in heavy machinery, automotive assemblies, and construction equipment, where high compressive strength and wear resistance are essential.
In conclusion, sand casting remains a reliable and economical method of manufacturing gray iron square washers, balancing performance requirements against production.
Email: nurul@emaxmetal.com
Product Description:
Production of Gray Iron Square Washers through Sand Casting
Gray iron square washers are widely applied in industry due to their low cost, durability, and excellent vibration-damper properties. Sand casting, which is a low-cost and traditional method, remains the most preferred method of producing these components. This paper presents the basic steps involved in producing gray iron square washers using sand casting.
1. Pattern Design and Mold Preparation
A wooden or metal pattern that replicates the size of the washer (with machining and shrinkage allowances) is created. The pattern is green sand cast (a mixture of silica sand, water, and clay) in a two-part flask. Sand is packed around the pattern to form the mold cavity. Core inserts may be added if internal features are required.
2. Melting and Pouring
Gray iron (typically 2.5–4% carbon and 1–3% silicon) is melted in a cupola or electric furnace at around 1,200–1,400°C. The molten metal is poured into the mold through a gating system that causes minimal turbulence and oxidation. Gray iron's high fluidity makes it possible to fill the cavity completely.
3. Cooling and Solidification
Controlled cooling allows for the formation of flake graphite structure, which allows for gray iron's characteristic properties. The mold is not upset for 30 minutes to a few hours, depending on washer size and thickness of the walls, to ensure proper solidification.
4. Shakeout and Finishing
After cooling, the sand mold is broken (shakeout) to retrieve the casting. Excess material, such as gates and risers, is removed by cutting or grinding off. Surface imperfections are cleaned with shot blasting or grinding. Final machining achieves dimensional accuracy for critical surfaces or holes.
Advantages of the Process
Sand casting offers low-to-medium volume production flexibility and complex geometries. Green sand use is cost-effective and environmentally friendly compared to bonded sand systems. The natural lubricity of graphite flakes in gray iron minimizes tool wear during machining, further lowering production costs.
Applications
Square washers produced by this method are utilized in heavy machinery, automotive assemblies, and construction equipment, where high compressive strength and wear resistance are essential.
In conclusion, sand casting remains a reliable and economical method of manufacturing gray iron square washers, balancing performance requirements against production.
Email: nurul@emaxmetal.com
