Title

Sand Testing Preparation (GFN) (Foundry)

Objective
To determine the sand grain size and calculates the Grain Fineness
Number (GFN) for moulding material of sand casting.

Introduction (Background and Theory)

Casting and Molding Processes
Molding processes can be divided into four main categories: sand casting
processes; permanent mold process, ceramic processes; and rapid
prototyping. While determining the best process for the product to suit
needs, there are several factors to be considered:
Surface quality
Dimensional accuracy
Type of pattern/core-box equipment
Cost of making the mold
Effect of selected casting process on design of the casting
Among these casting processes, sand casting method has been used
extensively in industry; therefore sand casting process will be the main
issue of laboratory experiments during whole semester.

Figure 1 : Typical Foundry Process Flow

Sand Casting Processes

A mold is produced by shaping a refractory material to form a cavity of a
desired shape in which the molten metal is poured. The mold cavity must
retain its shape until the metal has solidified and the product is removed.
There are variety of different refractory materials as casting sands
including silica, olivine, chromite and zircon sands.
The mold made of one or combination of these sands must:
Have sufficient strength to sustain the weight of the molten metal
Be stripped away from casting cleanly and easily after it has
sufficiently cooled
Be inexpensive, because large amounts of sand are used in a
casting facility.
Size and size distribution
The size and size distribution of sand grain is one of the most important
factors for a healthy casting process. The size of the sand grains affects
the quality of the casting. The grain fineness of molding sand is measured
using a simple sieve analysis test. Grain Fineness Number (GFN) is a
measure of the average size of the grains in sand. Likewise, AFS Grain
Fineness Number (AFS-GFN), introduced by American Foundry Society, is a
measure of grain fineness of a sand system. AFS-GFN is used to verify the
molding sand to be staying within specification for the castings being
produced to avoid potential casting problems. Too fine grains may cause
low permeability, results in gas defects; too coarse may create high
permeability which leads to metal penetration into mold, and affects
surface roughness of the casting. The ideal GFN depends on the type of
metal poured, pouring temperatures, heavy or light casting and required
surface roughness.
The size distribution of sand grains is also related to the quality of the
sand system. Porosity is directly related to permeability which is the ability

of the mold to permit gas escape through the mold. If sand grains of the
mold are having nearly same size, the porosity is maximized. This may
lead to poor surface quality and metal penetration into the mold.
Therefore one should decide on an optimum size distribution to avoid such
defects.
Formula below used to calculate Grain Size Fineness;
GFN =

F
100
C

Apparatus
Num

Diagram

Name

.
1.

Green Sand

2.

Sieve Shaker

3.

Digital Scale
Balance

Num

Diagram

Name

.
4.

Sieve

5.

Steel Bowl

Industrial Apparatus

Num
.
1.

Diagram

Description
High

Capacity

Sieve

Shakers

A061-96

Activated

by

impulses

using

action

electromagnetic
triple

(vertical,

vibrating

lateral

and

rotational) they are recommended

to perform sieving tests where high
precision

and

performance

are

important.
Simple and sturdy construction can
hold up to 10 sieves and they are

suitable for wet sieving test

The sieving time from 1 to 999

minutes
Power supply are 230V 50/60Hz
1ph 450/750W

2.

Sieve Shaker Part No. 206650

The Sieve Shaker has a uniform

mechanical action comprising both
a horizontal circular motion and a
vertical tapping motion that allows
particles to stratify and seek critical
openings,

ensuring

accurate,

repeatable results.
Test sieve size is 8 in. diameter
(20.3cm). A maximum of six 2 in.
high (5.1cm) or thirteen 1 in. high
(2.5cm) sieves can be used for
testing

at

one

time.

Shaker

features vertically mounted 1/4hp

motor and has a built-in 99-minute
digital timer/clock accurate to 0.1

second.
Recommended

for

testing

applications requiring analysis of

particles from 5 in. (12.7cm) to 20
microns wide (635 mesh)

Experimental Procedures
a) The sieves was cleaned by turning the sieve face down and
striking the rim evenly on the table.
b) The sand sample is weighed to 100 grams.
c) The sieve is then stacked together by putting the biggest mesh
size on top until the smallest sieve on the bottom (35, 45, 60, 70,
and 80,100,120,170,230) and next with the sieve pan at the last
one.
d) The stack of sieves is then put on top of the Sieve Shaker
Octagon 2000 machine.
e) The silica sand was put into the sieve.

f) For a period of 10 minutes the sieve was shaken continuously.

g) After shaking for 10 minutes, the top sieve is taken apart and left
over sand on the sieve was wiped using a brass brush and carefully
weighed. The weight then recorded in column C.
h) The step in (g) was repeated until the last over sand in the sieve
was weighed and the value is recorded.
i) Using the Grain Fineness Number (GFN) formula at the below we
could calculate the Grain Fineness Number (GFN)
GFN =

F
100
C

Results And Data Analysis

NO

A
Sieve no

B
Opening
()

C
Sand
mass(g)

D
Sample
%

E
AFS
multiplier

1
2
3

35
45
60

500
355
250

0.00
0.00
29.00

0.00
0.00
29.59

10
20
30

4
5
6
7
8

70
80
100
120
170

212
180
150
125
90

17.00
9.00
15.00
12.00
9.00

17.35
9.18
15.31
12.24
9.18

40
50
70
100
145

F
AFS
Product
(C X E)
0.00
0.00
870.00
680.00
450.00
1050.00
1200.00
1305.00

9
230
63
10
Pan
Pan
Total accumulated sand mass
(g)
Original Mass of Sample before
Sieving (g)

GFN =

4.00
3.00

4.08
3.06

200
300

C=
98.00

800.00
900.00
F=
7255.00

100

F
7255.00
100 =
100 =74.03<100( course)
C
98.00

Discussion
In this experiment, we have to measure grain size and calculates grain
fineness number (GFN)., We have followed the procedures given on the
manual lab and recorded the data in the respective table and sample of
calculations in order to measure and calculate the grain. From the
experiment, the value of GFN we obtained for the sand silica sand in the
sieve analysis is 74.02 which is the silica sand has type of course grain.
So, it can be simply said that it is a good quality of sand.

The total accumulated mass of the sand mass (g) is 98.00. This is to
be expected from the beginning due some sand have trap at each sieves
and not 100% pass. From the original mass we were weighed before the
sieve testing, there was a little bit decrease in the mass weight where the
original sand mass on sieve shaking was 100g. This occur due to the some
errors like not wipe all the left over sand in each sieve. In addition, the
digital balancing scale also one of the factor that cause error where it is
not perform in proper condition. The reading value always change and not
fixed. However the data still accepted since the error are not too much.
For this experiment, there are several precaution we must take to avoid
and prevent errors from occurring. The screen on the sieves should be
clean carefully in order to avoid any grain sands still stuck in the sieves.
The stack of sieves on the Sieve Shaker must be locked tidily to avoid
them from moving away or fall over during shaking process. We also must
clean the area around digital scale balance to get accurate readings and
avoid the environmental effects. Student also can use a softer bristle
brush to gently wipe the screen.
i) Explain briefly what is GFN?
The definition Grain Fineness Number or also known as (GFN) is a
system developed by AFS for rapidly expressing the average grain size of
given sand. It approximates the number of meshes per inch of that sieve
that would just pass the sample if its grains of uniform size. It is
approximately proportional to the surface area per unit of weight of sand,
exclusive of clay.

ii) Based on GFN value and the distribution obtained, suggest the
suitability of the sand for castings.

To get the perfect match and sand casting suitability, there are
several factor and qualities that can be used as a reference. Firstly, there
is refractoriness, bond strength, permeability, collapsibility, grain fineness
and size and lastly grain shape and roundness. The most suitable sand for
casting should have good strength. It is important to avoid the mould from
broken during the process. It also has high refractoriness to withstand the
high temperature of the molten metal.
The sand also must have good permeability. The sand must be
porous so that the gases generated are allowed to escape. Size of the
sand and its shape its depend on the materials and casting process. The
small size provided better surface finish but the large grain size is more
permeable. The sand should have good thermal conductivity, so that the
heat from casting is quickly transferred. From the experiment, we could
say that our sand sample is good to use for casting as it have a balance
amount of porosity and permeability to be used for small cast operation
and it will also have a good surface quality.

Conclusion
From the experiment, we can found that the value of GFN of the
silica sand specimen by using the sieve analysis is 74.03. Hence, the sand
sample used in the experiment has the most suitable coarse number
value not too low of value and not too high value. As too low will had poor
surface quality in casting and too fine will make it less permeability.
However some error did occur during the experiment as the total
accumulates sand mass is differ from the original mass which is 98.00
gram while the original mass is 100g. To minimize the error we need to
take extra precaution in order to get the accurate data in this experiment
and avoid errors. As a conclusion the objective of this experiment was
achieved and successfully.

Recommendation
There is a couple of things and procedure than can be improved by
modifying certain steps or we may even remove it. Firstly, the cleaning
process of the screen on the sieves should be done carefully in order to
remove all grain sands. It also imperative to avoid contact the sieves
screen with the fingers. In the cleaning process, we should also gently
brush the sieves to make sure the sieves are not damage. In the shaking
process, the stack of sieves on the Sieve Shaker must be locked tidily to
avoid them from moving away during. Then, we have to make sure the left
over sand in each sieve is transferred to the container use in weighing
process. Lastly, the area around digital scale balance should also be
cleaned to get accurate readings and this would avoid the environmental
effects.
References
Books
1. Serope Kalpakjian, Steven R. Schmid, Manufacturing Technology and Fundamental,
5th Edition, Prentice Hall, 2004.
2. M. Y. b. H. M. al-Rangi, Manufacturing Process, Malaysia, 2009
3. Rao, Manufacturing Technology Vol-I 3E, Volume 1, Tata McGraw-Hill Education,
2009
Internet
1. http://wiki.answers.com/Q/What_is_the_important_about_grain_fineness_number_for_sa
nd_casting.
[Accessed On 27 October 2015]

2. http://www.atilim.edu.tr/~kazim.tur/mate401/Dosyalar-LAB/MATE
%20401-Lab-Exp.01-AFS%20grain%20fineness%20number.pdf
[Accessed On 27 October 2015]