Which casting process is inexpensive with a versatile setup but rougher finishes and looser tolerances?

• A. Investment casting is inexpensive with a versatile setup but rougher finishes and looser tolerances.
• B. Sand casting is inexpensive with a versatile setup but rougher finishes and looser tolerances.
• C. Die casting is inexpensive with a versatile setup but rougher finishes and looser tolerances.
• D. Lost-wax casting is inexpensive with a versatile setup but rougher finishes and looser tolerances.

Answer: (B)

Understanding casting cost and quality trade-offs helps explain why sand casting fits this description. Sand casting uses simple, inexpensive sand molds and patterns, so setup is quick and tooling costs are low, making it versatile for a wide range of shapes and sizes and suitable for low to medium production runs. The trade-off is in the finish and accuracy: the mold surface formed by loose sand is rough on a microscopic level, and small shifts in the mold or solidification can lead to looser dimensional tolerances. Finishing steps like machining or grinding are often needed to achieve precise dimensions. Other methods use more expensive tooling and processes that yield smoother surfaces and tighter tolerances, but at a higher cost and with less flexibility for quick changes. Therefore, sand casting is the best match for being inexpensive with a versatile setup but rougher finishes and looser tolerances.