CPM Industries' Blog

Advantages of Sand Casting & Die Casting

Posted by Gavin Mason

Sand Casting vs. Die Casting 

Talking with our Sales Manager the other day, I discovered that one of the more popular questions he gets asked by potential customers is "when should we use sand casting vs. die casting?" The answer to that question is actually fairly easy and depends 100% on what the customer is looking for. 

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Tags: Casting Design, sand casting, pattern, die casting, casting, casting, machining, cnc machining, casting process, castings, pattern equipment, diecasting, sand casting vs. die casting

New Committee Focuses on Metalcasting

Posted by Gavin Mason

AFS Creates a New Committee

The American Foundry Society (AFS) has created a new committee, within their engineering department, to focus on metalcasting facilities. The goal is to create an understanding of quality business and manufacturing principles to improve these metalcasting facilities. 

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Tags: Casting Design, Casting Knowledge, casting, Metalcasting, AFS, American Foundry Society, engineer

Take Your New Casting and Cut It Up

Posted by Gavin Mason

Casting Tip

Creating a metal casting is a highly detailed and intricate process and has so many different variables that no two castings are the same. When the variables are not controlled tightly enough that is when the differences occur, usually in the form of defects. Even castings produced from the same pattern have their differences, those differences may be hard to spot but they are there. The difference from casting to casting may be so small that you can only spot the difference under a microscope, making it crucial to control the variables as much as possible. 

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Tags: Casting Design, CPM Industries, Patterns for Sand Castings, pattern, metal casting, casting, casting, Metalcasting, fracturing, casting porosity, cross section, chemical testing

Does Your Casting Have a Sweet Tooth?

Posted by Gavin Mason

Simple Sugar may Solve Complex Problem 

The foundry and metal casting industry is a multi-billion dollar industry with foundries of all shapes and sizes located throughout the world. Metal castings can be dated back to before the Roman empire and were used to develop weapons and tools as well as being critical in the development of human civilization. The most common method of casting is known as sand casting and involves using sand to hold the shape of a part. Once the sand is in the shape of the part to be casted, molten metal is poured into the sand mold forming the final part. If you are like me, the first time I heard of this process my first question was, "so how does the sand stay in place with molten metal being poured into it?" 

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Tags: Casting Design, Aluminum Castings, Sand Casting Design Improvements, Aluminum Sand Casting, Green Sand Casting Method, Prototype Sand Castings, Quality Control of Sand Casting, sand casting, Magnesium Sand Casting, casting

Cast vs. Billet

Posted by Gavin Mason

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Tags: Casting Design, Aluminum Castings, Aluminum Sand Casting, CPM Industries, casting, CNC, Aluminum Hog-Outs, Billet

2013 CastExpo

Posted by Gavin Mason

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Tags: Casting Design, casting, Castexpo

3 Types of Cores used in Sand Castings (Part 2)

Posted by Tim Carlstedt

      Back for more?! In the second of an installment about Core Knowledge, we will be discussing a few more common names and terms associated with Loose Pieces.  Loose pieces are used by Pattern Makers to create attributes that cannot be created normally without modification.  The types of loose pieces that we will discuss today are the Attached Pieces, Drawbacks, and Pick-Out Pieces. (P.S If you haven't read part 1 yet, then go check it out first)

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Tags: Casting Design, Green Sand Casting Method, Casting Knowledge, Pattern/Foundry Tooling

3 Types of Cores Used to Make Sand Castings

Posted by Tim Carlstedt

How are hollow passage ways or special features put into a casting?


Through the Use of Cores that are Placed into the Mold Box!! 

In this part 1 of 2, we will discuss the common names and terms for Cores and Coreboxes that are used in the horizontal green sand casting method.  At CPM Industries, we often use Cylinder Cores, Balanced Cores and Dovetail Cores with Patterns to create the necessary passageways to meet the component's characteristics.  The article below discusses three types of cores that are placed on the parting line of the casting.

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Tags: Ductile Iron Castings, Casting Design, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Sand Casting Design Improvements, CPM Industries, Green Sand Casting Method, Casting Knowledge, Pattern/Foundry Tooling

3 Tips to Reduce Machined Sand Casting Cost

Posted by Tim Carlstedt

We often get asked by engineers, "What can I do to REDUCE THE COST of MACHINING A SAND CASTING?" 

   So, I put together 3 QUICK CONSIDERATIONS FOR REDUCING MACHINING COSTS.  These are ideas that all engineers should keep in mind while designing their component.  This can save money in engineering/programming time, labor time (Fixturing & Set-Ups), and machining time.  While every design is different, therefore these are just some general ideas that may not always be applicable.  The below tips can be applied for Prototype Aluminum Castings, Ductile Iron Castings, Gray Iron Castings, and any other Machined Sand Castings that you can think of! 

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Tags: Casting Design, Secondary Machining, Finished Sand Castings, Machined Sand Castings

Sand Casting vs. Investment Casting

Posted by Tim Carlstedt

What are the advantages and disadvantages between the Green Sand Casting Method and the Investment Casting Method?

This is a common question for the metal casting industry and CPM wanted to shed some light on the subject.  In this entry, we will first look at a comparision of the two different methods, followed by a explanation of the table, then lastly another table highlighting the advantages and disadvantages of each method in comparison.

 

Comparison of Green Sand Casting vs. Investment Casting

 

Green Sand Casting Method

Investment Casting Method

Relative Cost in Quantity

Low

Highest

Relative Cost for Small Number

Lowest

Medium

Permissible Weight of Casting

Unlimited up to approx. 1 ton

Ozs to 100 lbs.

Thinnest Section Castable (Inches)

1/10

1/16

Typical Dimensional Tolerance (Inches)

.012

.01

Relative Surface Finish

Fair to Good

Very Good

Relative Mechanical Properties

Good

Fair

Relative Ease of Casting Complex Design

Fair to Good

Best

Relative Ease of Changing Design in Production

Best

Fair

Typical Base Tolerances

+/- .040 – 1.00 in

+/- .003 - .008 in

Typical Surface Finish

150 – 350 RMS

63 – 125 RMS

Minimum Wall Thickness

.140 - .250 in

.094 - .187 in

Typical Tooling Cost

$800 to $5,000

$3,000 to $10,000

Well, WHAT DOES THAT MEAN TO ME?!

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Tags: Ductile Iron Castings, Ductile Iron Sand Casting, Casting Design, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Casting Knowledge, Secondary Machining, Finished Surfaces, Prototype Sand Castings, Pattern/Foundry Tooling, Patterns for Sand Castings, Cast Iron (Gray) Sand Casting, Investment Casting Method

Balance Core use in Sand Casting Pattern

Posted by Tim Carlstedt

This post is in response to several searches performed by our readers that wanted to know what a "Balance Core" is and how it is used in a sand casting.  Since we do have an House Pattern Shopat CPM Industries, I thought it would be appropraite to explain this particular type of core and it's importance in Pattern/Foundry Tooling for Sand Castings. 

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Tags: Casting Design, CPM Industries, Green Sand Casting Method, Pattern/Foundry Tooling

Ductile Iron Sand Casting Machinabilty Facts

Posted by Tim Carlstedt

“Tim, what characteristics of the different Ductile Irons Alloys effect each Alloy's Machinability?”


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Tags: Ductile Iron Castings, Ductile Iron Sand Casting, Casting Design, CPM Industries, Green Sand Casting Method, Casting Knowledge

Sand Casting vs. Other Casting Methods

Posted by Tim Carlstedt

    There are several methods that are used to produce a casting.  But what are the general differences and characteristics of the Methods?  Here is a table that represent that highlights the key differences between the Green Sand, Precision Molding, and Chemically Bonded Molding casting methods. 

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Tags: Ductile Iron Castings, Ductile Iron Sand Casting, Casting Design, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Casting Knowledge, Cast Iron (Gray) Sand Casting, Magnesium Sand Casting

A CPM Example: From CAD Model to Finished Aluminum Sand Casting

Posted by Tim Carlstedt

A Look into CPM's Turn-Key Capabilities for an Finished Aluminum Sand Casting!

    We were recently asked to show an example of a Turn-Key Cast Component that we have made here at CPM Industries.  So, why not share it with the world!  What does Turn-Key mean to us?  This means that the project will go from Engineering Assistance, Pattern Tooling, Casting, and Secondary Machining.  We also perform any other additional testings that may be required.

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Tags: Casting Design, Aluminum Castings, Aluminum Sand Casting, Casting Wall Thickness, CPM Industries, Secondary Machining, Finished Surfaces, Pattern/Foundry Tooling

Aluminum Plaster Casting? What is that?

Posted by Tim Carlstedt

  Recently, I was asked to describe what Plaster Casting was and the benefits of using this method.  What a perfect topic!  At CPM, we provide Aluminum Plaster Castings primarily to Simulated Die Casting in Short Runs of 15-30 for Prototyping and Testing Operations. For runs of 1 or 2 parts, then it is often best to go with a Rapid Prototyping such as a SLA.

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Tags: Casting Design, Aluminum Castings, Aluminum Sand Casting, Simulated Die Casting, Plaster Casting Method, CPM Industries, Casting Knowledge, Prototype Sand Castings, Pattern/Foundry Tooling

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