Casting is a process with many interlacing systems and parts: production, material reclamation, packaging, and so on. There are many moments during these processes in which castings can get damaged. But casting damage can easily be prevented by using the right sand casting equipment, and by having the correct safety and maintenance strategies in place.
The importance of high-quality, clean equipment
Castings are shaped by molds often using sand and bonding agents. Molds alone have many factors that influence how the casting will be shaped and formed. If any part of the process is not well constructed, it can cause damage to a casting. For example, if the gating system that brings the molten metal to the mold cavity is faulty, it can affect the integrity of a mold and can be hazardous if molten metal escapes the sprue. Or, if a core is made from poor molding sand, it can be difficult to extract the pattern from the mold.
Using heavy-duty, high-quality equipment reduces the risk of safety hazards and damage. Frequent and consistent maintenance for sand casting equipment makes production and reclamation run more smoothly and efficiently.
The role poor-quality sand plays in damaged castings
In the casting process, sand is mixed with clay to form a bonding agent around a pattern of a product. Once a mold is split apart and the pattern removed, the mold halves are put back together to be filled with molten metal. After the metal cools, the mold is opened and the sand is removed after the casting is taken out. This sand can be reclaimed and reused multiple times. However, if sand is reconditioned at an excessively hot temperature, it can be difficult to control as the physical properties of sand grains can change during the casting process.
A controlled cooling system can cool sand efficiently, with minimal damage to the sand grains. Returned sand is less likely to be conditioned at an overly high temperature. Quality of reconditioned sand will be higher and more consistent, making for better castings and preventing damage to future pieces.
The effective shakeout of castings from sand
As a purpose-built manufacturer, General Kinematics has dedicated equipment to serve in each casting process. Read the brief descriptions below or follow the links to find the best shakeout solution for your application.
- VIBRA-CLAIM® Shakeout / Attrition Mill – Reclaims no-bake sand at a volume of 5-25 molds per hour.
- Two-Mass High-Energy Shakeout – Ideal for small to large volume casting process. Two-Mass technology allows the use of variable frequency drives to vary the amount of G-Force applied to break down the sand.
- VIBRA-DRUM® Sand & Casting Conditioner – High production casting and sand reclamation. The VIBRA-DRUM® can be fitted with a water addition system to cool castings to 175 degrees Fahrenheit.
- DUCTA-SERIES™ Rotary Drums – For castings with a less critical finish, DUCTA-SERIES™ Rotary Drums provide sprue and casting cleaning for ductile iron operations.
Streamline your castings and maximize your profits, by preventing damage. The foundry experts at General Kinematics have worked in the industry for over fifty years. This wealth of knowledge is applied to every vibratory and rotary unit we engineer and manufacture and ensures your capital investment will prove a return on investment. Contact the Foundry and Metalcasting expert in your region. Preventing casting damage with better equipment