Course Title: Manufacturing Process-1

Course Code: ME-220

Sequence of Manufacturing process

The process cycle for sand casting of cam shaft consisted of six main stages, which are explained below.

Mold-making: 
In manufacturing of camshaft, firstly we created the mold for the camshaft by sand casting process. Sand mold
was formed by packing sand into each half of the mold. The sand was packed around the pattern, which was a
replica of the external shape of the casting. Any internal features of the casting that cannot be formed by the
pattern were formed by separate cores which were made of sand prior to the formation of the mold. Also, the
parting powder was applied to the surfaces of the mold cavity in order to facilitate removal of the casting.

FIGURE: Parting Powder FIGURE: Mold Making

Clamping:
  Once the mold was made, now it was prepared for the molten metal to be poured. The surface of the mold
cavity was first sprayed with parting powder to facilitate the removal of the casting. Then, the cores were
positioned and the mold halves were closed and securely clamped together.

Pouring:  The molten metal was maintained at a set temperature in a furnace. After the mold was clamped,
the molten metal was ladled from its holding container in the furnace and poured into the mold. The pouring
was performed manually by us.

FIGURE: Pouring through ladle

Course Title: Manufacturing Process-1
Course Code: ME-220

Cooling:  The molten metal that was previously poured into the mold began to cool and solidify as it enters
the cavity. When the entire cavity was filled and the molten metal was solidified, the final shape of the casting
was formed. The mold was not opened until the cooling time had elapsed.

FIGURE: Solidification Process

Removal:
After the predetermined solidification time had passed, now the sand mold was simply broken,
and the casting was removed. This step which was sometimes called shakeout was performed by a vibrating
machine that shake the sand and the casting out of the flask. When the casting was removed, the casting had
some sand and oxide layers adhered to the surface. We used wire brush to remove remaining sand, especially
from internal surfaces.

FIGURE: Product after breaking the mold

Course Title: Manufacturing Process-1
Course Code: ME-220
Trimming: During the cooling, the material from the channels in the mold was solidified to the part. This
excess material was trimmed from the casting manually via sawing. The time required to trim the excess
material was estimated from the size of the casting's envelope. The scrap material that results from this
trimming was reusable.