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Metal Casting Technologies : March 2011
Polystyrene Pattern used in LFC process. The schematic diagram of the SMMC mould is shown in Figure 1. The casting as well as the gating system is made of sheet metal and the assembly is embedded in loose unbounded sand contained in a mould box. Whereas the EPS pattern supports the loose sand before pouring, in case of the proposed SMMC process, the hollow structure made of sheet metal shaping the mould cavity supports the loose sand before pouring. During pouring, the liquid metal burns and displaces the EPS pattern in case of LFC process. However in the proposed SMMC process, the sheet metal is strong enough just before filling the mould cavity to support the loose sand in the mould. Once the filling is complete, metallostatic pressure acts outward and progressive solidification is expected to start at the mould- metal interface, which further supports the loose sand. On solidification and cooling, casting is to be taken out of the loose sand mould as usual. FEATURE STORY METAL Casting Technologies March 2011 23 Figure 1. Schematic diagram showing the basic principle of SMMC process