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Explore Lifting the Gear: How a Foundry Worker Frees a Casting from Its Sand Mold with 42,086 views, 73 likes, and 2 comments. Experience the impact of this video content that has captured audience attention.

**Gear and Sand: The Mechanics of Foundry Demolding** In a foundry, molten metal is poured into a sand mold. When the metal cools and solidifies, the casting must be removed—a process called demolding or shakeout. The worker breaks the sand mold apart and lifts the casting out. The casting is still rough, with sand clinging to its surface, and it will be cleaned and machined later. The work is heavy and hot, and the casting can weigh 50 to 500 pounds. - **Casting Type**: A gray iron or steel gear, 12 to 24 inches in diameter. - **Mold Type**: A sand mold, packed in a flask or a pit. - **Demolding**: The sand is broken away, and the casting is lifted out. - **Casting Weight**: The gear weighs 50 to 500 pounds, depending on its size. - **Cleaning**: The casting is shot-blasted or ground to remove sand and scale. - **Machining**: The gear’s teeth and bore are machined to final dimensions. - **Safety**: Workers wear gloves, boots, and eye protection; the casting can be hot and heavy. - **Sand Reuse**: The used sand is collected, cooled, and reconditioned for the next mold. When the gear is free, the worker sets it on a pallet and inspects it for defects. The mold is broken up, and the sand is recycled. This is not a task that will appear in a machining manual; it is the rough, hands-on work of a foundry. And as the sun sets over the shop, the worker knows that the gear he freed today will turn in a machine—thanks to a mold, a lift, and a steady hand.

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