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A new casting method, called the press casting process, has been developed by our group in recent years. In this process, the ladle first pours molten metal into the lower (drag) mold. After pouring, the upper (cope) mold is lowered to press the metal into the cavity. This process has enabled us to enhance the production yield rate from 70% to over 95%, because a sprue cup and runner are not required in the casting plan [1]. In the casting process, mol‐ ten metal must be precisely and quickly poured into the lower mold. Weight controls of the pouring process have been proposed in very interesting recent studies by Noda et al. [2]. However, in the pressing part of the casting process, casting defects can be caused by the pattern of pressing velocity. For example, the brake drum shown in Fig. 1 was produced with the press casting method. Since the molten metal was pressed at high speed, the prod‐ uct had a rough surface. This type of surface defect in which molten metal seeps through sand particles of the greensand mold and then solidifies, is called Metal Penetration. Metal penetration is most likely caused by the high pressure that molten metal generates, and it necessitates an additional step of surface finishing at the least. Thus, the product quality must be stabilized by the suppression of excess pressure in the high-speed press. For shortcycle-time of production, a high-speed pressing control that considers the fluid pressure in the mold is needed. Pressure control techniques have been proposed for different casting methods [3-4]. In the injection molding process, the pressure control problem has been suc‐ cessfully resolved by computer simulation analysis using optimization technique by Hu et al. [5] and Terashima et al. [6]. Furthermore, a model based on PID gain selection has been proposed for pressure control in the filling process. Although the pressure in the mold must be detected in order to control the process adequately using feedback control, it is difficult

Sand Mold Press Casting with Metal Pressure Control System