Introduction to Basic Manufacturing Process Lab
(ME29201)
Core Making Process
Department of Mechanical Engineering
IIT Kharagpur
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Cores in Casting and Moulding processes
• Core is a device used in casting and moulding processes to produce internal
cavities and is commonly used in sand moulding. The core is normally
disposable that is destroyed to get it out of the casting.
Mould for a sand casting [1]
https://www.youtube.com/watch?v=cjebklLgrf8
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Types of Cores
Different types of core as per the
shape and position of the core.
• Horizontal Core
• Vertical core
• Balance Core
• Hanging Core
• Drop Core
• Kiss Core Different types of cores [2]
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Preparation of Sand Cores
• Cores are made of sand, clay (binder) and moisture. The mixture of sand, clay
and moisture is thoroughly mixed and then it is compacted in the core box.
• On compaction, the sand mixture attains the shape of the cavity in the core box.
• In order to prevent the core from breaking/ crumbling (during handling)
reinforcement of cores is done by inserting metallic wires in them.
• The moisture in the core has to driven off. The core is next placed in an oven and
heated to 154˚C for about 2 hours to drive out the moisture in the core sand.
• On drying the core attains strength.
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Core Boxes
Core boxes are used for making cores. A core boxes can be wooden or metallic
type of pattern and can be made either single or in two parts.
Some of the common types of core boxes are illustrated as follows:
a) Half core box: In this method two identical halves of a symmetrical core is
prepared.
Half core box [3]
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Core Boxes (cont..)
b) Dump core box: A dump core box is used to prepare complete core in it.
Dump core box [3]
c) Split core box: Split core boxes are made in two parts. They form the
complete core by only one ramming.
Split core box [3]
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Sand Casting - Cores
• The prepared core of desired dimension is placed inside the mould.
• These cores are supported by some supporting portions/extensions which is
termed as core prints.
Core, Core prints and Chaplets [3]
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Function (Purpose) of Cores
• The cores are used to form the
internal cavities.
• Cores are used to form a part of a
green sand mould.
• Cores are used to strengthen the
mould.
• Cores can be used as a part of the
gating system
Core made up of sand [4]
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Essential Characteristics of Cores (Sand)
A good core must posses following features:
• High permeability to allow an easy escape of gases.
• High refractoriness to withstand high temperature of molten metals.
• Smooth surface
• High collapsibility (Friability) i.e. easy to disintegrate
• Sufficient strength to support itself
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References
1. www.substech.com
2. https://prezi.com/bioc6wqu0vwe/types-of-cores/
3. https://www.engineersgallery.com/core-and-core-box/
4. http://4mechtech.blogspot.com/2014/08/core-and-core-prints.html
5. https://www.reliance-foundry.com/blog/coremaking-sand-casting
6. https://www.harrisoncastings.com/capabilities/sand-core-making/
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