Experimental investigation to produce thin-walled sand casting using combination of casting simulation and additive manufacturing techniques

Sand casting process is used by man from olden days to manufacture metallic components. Due to various problems of sand, mold and filling, the process is considered not suitable to produce small intricate castings having thin geometries. Only huge castings are preferred and sophisticated components are completely ruled out of the process. However, the cost-effectiveness of the process is very attractive. The present work is taken up to investigate the possibility of sand mold casting process to produce intricate components having thin sections like automobile cylinder head castings. The project uses additive layer manufacturing technique for pattern development and computer-aided casting simulation technique to analyze mold filling and solidification aspects. Simulations are performed by varying pouring temperature and gating system design which also reduces shop floor trials and lead time. Based on simulation results, experiments are design and conducted using three types of sand, namely air-set sand, dry sand, and sodium-silicate sand. The produced castings are tested for various parameters and found successful. Results obtained from simulation are validated experimentally proving the methodology adopted is very helpful in producing intricate castings economically.