THE UNIVERSITY OF ZAMBIA

SCHOOL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
SAND CASTING OF A G-CLAMP
LAB 01
ENG 2159
MECHANICAL AND ELECTRICAL WORKSHOP TECHNOLOGY
SECOND SEMESTER ,2nd YEAR
NAME OF STUDENTS ATTENTION : M R M USA
1. CHISHALA CHISHALA 2019034603

2. PHIRI JERRY 2021490351

3. TATENTDA SIBANDA 2021432866

4. LWEENDO HAAHIMBA 2021379523

5. DANEIL NYANGU 2021386708

6. BENARD BANDA 2021379027

7. HOPE RUMBIDZAI SHABOLYO 2021478327

8. JOSEPH NYIRONGO 2021410676

9. YAVAN SAKALA 2021416054 MR KAMANA

10. RODGERS SICHILIMA 2021413861

11. PHIRI PURITY 2021478718

12. SUNGANANI CHIRWA 2020020793

13. ANTHONY SAPULENI 2021462005

14. TITUS PHIRI 2021417808

15. SHALUBALA SANTE 2021482669

16. PATRICK SAKALA 2021498751

17. ASAF SAKALA 2021480682

18. LOUIS MULENGA 2021466906

19. GIFT SHAWA 2021450911

20. TIMOTHY PETIMOYA 2021471993

21. WILLIAM PHIRI 2021391671

22. NSAMA DORCAS 2021410480

23. NAMONDA MUTANEKELWA 2022075455

24. MWILA NYONDO 2022996836

25. THOMAS NYIRENDA 2021417247

26. DALISTO BULAYA 2021387950

27. DANNY SANDAMBO 2021432092

28. INNOCENT NYIRENDA 2021394395

13th October 12, 2023 GROUP D1 FIRST SESSION

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1. ABSTRACT
This report was based on the objective of making the frame of a G-clamp using a casting process
particularly sand casting. The significance in the use of such a manufacturing process lies in the
desired shape of the machine part and its application. In essence, the frame of a G-clamp serves
as a sturdy base that allows for the secure clamping and positioning of objects, making it an
essential tool in applications such as woodworking, metalworking, and general repairs. An
explanation of what was involved lies in the definition of casting. Casting is a manufacturing
process in which a liquid material, usually a metal, is poured into a mold that contains a cavity of
the desired shape. The material is then allowed to solidify, and the solidified part, also known as
the casting, is ejected or broken out of the mold to complete the process. As a result of using
such a manufacturing process a machine part of desired shape even to the most intricate detail
was obtained. In conclusion, the use of sand casting to make the frame of the G-clamp was so
important in the sense that it married the design and application of the frame the G-clamp
accurately.
2. OBJECTIVE AND INTRODUCTION
The objective of this laboratory experiment was to use sand casting process and aluminium metal
to produce the one component of the G-clamp, that is the frame.
The engineering problem was lack of stability when working objects in the workshop. Here
workpieces might move or shift during processes like gluing, soldering, or welding. This could
lead to inaccurate results. Besides, if workpieces are not securely clamped during processes like
soldering or welding, there is an increased risk of accidents due to the high temperatures
involved. One such tool to provide a solution is the G-clamp, which plays a pivotal role in
clamping and positioning objects. The G-clamp is utilized to secure workpieces together during
processes such as gluing. It also ensures that work is held firmly to a bench or machine while
being worked on. This function is particularly crucial in maintaining the accuracy and precision
of the work. G-clamps are indispensable tools in the workshop environment and are available in
a variety of sizes to accommodate different tasks.
3. THEORY AND EXPERIMENTAL METHODS
THEORY
Casting is a manufacturing process in which a liquid material, usually a metal, is poured into a
mold that contains a cavity of the desired shape. The material is then allowed to solidify, and the
solidified part, also known as the casting, is ejected or broken out of the mold to complete the
process. A specific type of casting, sand casting, involves forming a mold from a sand mixture
and pouring molten liquid metal into the cavity. After cooling and solidification, the casting is
separated from the mold. This process involves six steps: placing a pattern in sand to create a

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mold, incorporating a gating system, filling the mold cavity with molten metal, allowing the
metal to cool, breaking away the sand mold, and removing the casting.
There are two main types of sand used for molding. Green sand is a mixture of silica sand, clay,
moisture and other additives. The air set method uses dry sand bonded to materials other than
clay, using a fast-curing adhesive. These different types of sand are used depending on the
specific requirements of the casting process.
Formulas for top gating system

𝑣 = √2𝑔ℎ𝑡
𝐴𝑚 × ℎ𝑚
𝑡𝑝 =
𝑣 × 𝐴𝑔

Where

 tp is the pouring time

 Am is the area of the mold
 hm is the height of the mold and,
 v is the velocity of at the gate and area is the area of the gate

EXPERIMENTAL METHOD
1. Mold Creation: The pattern of the G-clamp frame was placed in a specially prepared
green sand to create a mold. Green sand, a mixture of sand, clay, and water, was
typically contained in a system of frames or mold boxes known as a flask. The mold
cavities and gate system were created by compacting the green sand around the pattern.
This process was usually done by hand with a ramming tool that compacted the green
sand around the pattern.

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 Figure 1.1 Green Sand

Figure 1.2 Casting Flask

2. Pattern Removal: After the green sand had been compacted, the pattern was carefully
removed to avoid damaging the mold cavity. This was a delicate process as any damage
to the mold could have resulted in defects in the final casting.

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 Figure 1.3 Pattern for G-clamp frame

Figure 1.4 Bellow

3. Casting: Molten aluminium was then poured into the mold cavity through a gating
system. The gating system included a pour cup (where the molten metal entered), sprue
(vertical passage), runner (horizontal passage), and gates (entry points into the mold

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 cavity). The design of this system ensured a smooth flow of metal and helped prevent
defects.

Figure 1.5 Furnace for melting aluminium.

4. Cooling and Mold Removal: After pouring, the aluminium was allowed to cool and
solidify into the shape of the mold. This cooling time varied depending on the size and
complexity of the casting. Once solidified, the green sand mold was broken away, often
with water jets or mechanical means, and the casting of the G-clamp frame was removed.

It should be noted that aluminium shrinks as it cools, so allowances for shrinkage had to be made
when designing both the pattern and gating system.
After the casting of the G-clamp was made at the foundry, it was then taken to undergo the
following procedure to obtain the desired shape and surface finish:
1. Trimming Unwanted Extensions: The first step was to remove the unwanted extensions
like runners, sprues, and gates that resulted from the sand-casting process. The G-clamp
frame was secured in a bench vice and a saw was used to carefully cut off these
extensions.

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 Figure 1.6 Sprue, runner and gate
2. Securing the G-clamp: After trimming, the G-clamp frame was re-secured in the bench
vice. Care was taken to ensure it was held firmly but not too tightly to avoid deforming or
damaging the frame.

Figure 1.7 Bench vice

3. Filing the Frame: A file was then used to remove any large burrs or irregularities on the
surface of the G-clamp frame. The filing was done in one direction with a steady rhythm
to ensure an even surface.

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 Figure 1.8 Files
4. Sanding the Frame: After filing, sandpaper was used to smooth out the surface further.
The process started with a coarser grit sandpaper (like 80 or 100 grit) and gradually
moved to finer grits (like 220 or 320 grit). This process, known as ‘progressive sanding’,
helped achieve a smoother finish.

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 Figure 1.9 Sand paper
5. Checking Smoothness: The smoothness of the frame was periodically checked by
running fingers over it (care was taken not to cut oneself on any sharp edges). Any rough
spots felt were gone over again with the sandpaper.
6. Cleaning the Frame: Once satisfied with the smoothness, any dust or debris from the
frame was cleaned off using a damp cloth.
7. Inspecting the Frame: Finally, the frame was inspected under good light to ensure that it
was uniformly smooth and free of any scratches or marks.

Figure 1.10 Finished G-clamp frame

Safety gear such as gloves and safety glasses were worn throughout these tasks to protect from
potential injury.
Discussion and results
This section involves careful and thorough analysis of the casting product, to check if it fits the
desired specifications (i.e. size and shape) and to look for any possible defects. There are
varieties of different things that may introduce different types of defects in the casting product,
and these will be discussed. It should be noted that different types of defects might be
introduced at different stages during the casting process.
General casting defects

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 Defect type Cause Remedy
(classification)
1 Gas porosity Bubbles created within the  Control the moisture in
casting after the cooling step as the sand mold and
a result of too much moisture ensure mold sand is dry
and bad vent se up. (they are in and permeable.
three types, that is; pinholes,
blowholes and open holes ).
2 shrinkage Occur as a result of uneven  Ensure the riser system
solidification of molten fluid. is designed to
(They are in two types, close compensate for
shrinkage and open shrinkage). solidification
This may be due to faulty contraction.
gating system or when the
pouring temperature is too  Ensure gating system is
high. designed to control
metal flow rate, must
be smooth and
constant, must be able
to control temperature
in the mold to cavity to
cool the meat steadily.

3 Molding material Resulting from molding  Design a proper gating

material and mold design(these system.
defects can either be cuts or
washes)  Enhance the strength of
sand mold.

 Add binders in the

facing and core stand.
5 pouring Results from improper molten  Optimization of the
pouring process into the mold pouring system.
cavity.( are mainly in three
types, namely; cold shut,  Proper pouring
misruns and slag inclusion) technique.

6 metallurgical Come about as a result of  Proper mold design to

problems in casting metal. enhance collapsibility
(They are in two type, that is.
Tears and hot spots)  Soft rammed sand
mold.

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The following are the final results of sand casting
Before surface finish after surface

The surface finish of the casting typically had a rough appearance immediate ly after it was taken
out of the mold. This was because the casting material, when in a molten state, solidified against
the surface of the mold cavity, resulting in a somewhat grainy surface. Since aluminum was used
the cast had a silver grey appearance. There were traces of molding sand on the surface of the
casting immediately after its removal from the mold. This sand residue was present in recessed
areas and needed to be removed during post-casting cleaning processes. Because of our mold
design, there were sharp edges or parting lines on the casting where the mold halves came
together. These needed to be removed or smoothed in subsequent finishing process. gating
system with sprue, risers and gates was used in the mold, there was excess material (known as
gating material) connected to the casting, which needed to be removed. Vernier calipers were

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also used to assess the surface finish of the cast G-clamp. By measuring features like surface
roughness or variations in thickness, the quality of the casting was evaluated.

5. CONCLUSION
The experiment was successful, even though there were some defects in the frame of the G-
clamp. This experiment provided valuable experience and helped students understand the
importance of the casting process in manufacturing machine parts. Sand casting, the process used
in this experiment, served as an effective introduction to practical casting techniques.
Furthermore, the choice of aluminum for the frame of the G-clamp proved to be excellent due to
its beneficial properties such as light weight, good corrosion resistance, and high strength-to-
weight ratio. For future studies, it would be worthwhile to explore other casting processes that
could be both affordable and capable of producing high-quality castings for machine parts at the
University of Zambia. One such alternative could be investment casting. Although more
expensive than sand casting, investment casting can produce parts with high dimensional
accuracy and excellent surface finish across a wide range of metals. The superior quality might
justify the higher cost, especially in a lab setting where precision is often crucial.
6. REFERNCES
1. https://link.springer.com/chapter/10.1007/978-1-349-01179-7_7
2. https://www.xometry.com/resources/casting/sand-casting/
3. https://link.springer.com/chapter/10.1007/978-1-349-01179-7_7
4. https://link.springer.com/article/10.1007/s40962-018-0229-0
5. https://www.studocu.com/my/document/university-of- malaysia-of-pahang/mechanical-
engineering/sandcasting-sand-casting-report-for- manufacturing- lab/6298580
6. https://www.studocu.com/row/document/university-of-engineering-and-technology-
lahore/manufacturing-process/sand-casting-lab-report/11241661
7. https://www.wiltronics.com.au/wiltronics-knowledge-base/the-functions-of- g-clamps/
7. APPENDICES
DATA TABLE
G CLAMP FLAME PARTS THEORETICAL ACTUAL
MEASUREMENT/ mm MEASUREMENT/ mm
1 82 79.3
2 19 18
3 25 22

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 4 150 145

SAMPLE CALCULATIONS
POURING TIME CALCULATION

𝑉𝑜𝑙𝑢𝑚𝑒 = 209 239.2 mm³

𝑔 = 9.81𝑚/𝑠 2
𝐴𝑚 = 2268.73 mm²
h = 79.3m

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PERCENTAGE ERRORS
|𝑀𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑣𝑎𝑙𝑢𝑒 − 𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑣𝑎𝑙𝑢𝑒|
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟 = × 100%
𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑣𝑎𝑙𝑢𝑒
|79.3 − 82|
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟 𝑓𝑜𝑟 𝑝𝑎𝑟𝑡 1 = × 100% = 3.29%
82
|18 − 19|
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟 𝑓𝑜𝑟 𝑝𝑎𝑟𝑡 2 = × 100% = 5.26%
19
|25 − 22|
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟 𝑓𝑜𝑟 𝑝𝑎𝑟𝑡 3 = × 100% = 12%
25
|145 − 150|
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟 𝑓𝑜𝑟 𝑝𝑎𝑟𝑡 4 = × 100% = 3.33%
150

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