UNIVERSITY OF ENGINEERING AND

TECHNOLOGY LAHORE, PAKISTAN

Department of Mechanical Engineering

Subject:
Manufacturing process LAB

Submitted to:

Submitted by:

AFTAB SAFDAR
MECHANICAL ENGINEERING (Section A)
2018-ME-6
E-mail: aftabsafdaruetian@gmail.com
 Assignment of Manufacturing process -Lab
Mold:

We can give shape to the metal after melting it and making it hot liquid by pouring into a
container. That container is called molds.

Pattern:

This is the design to be made and use to make cavity for the molten motel to be poured. It can
be of any material like wood or metal.

There are various types of patterns categorize as:

1) Solid pattern:
The most simple method used for giving shape to the molten metal is solid
pattern. It is without any sub-part. By this process we can make only flat
surfaces like gear blanks.

2) Split pattern:
This is also known as two pieces pattern. When it is difficult to withdraw pattern
of sand casting from mold or the in the casting depth of the part is too high then
we split the pattern into two parts. One part will be contained in cop and other
part is contained in the drag. To align together these two parts dowel pins are
 used

3) Multi cavity pattern:

When it is required to cast most complicated parts and making pattern

in more than two parts for ease in the casting process. In this pattern
we can use either two or more pattern.

This pattern has usually three parts. First is cope, second is check and
last one is drag. Dowel pins are also used here and by using clamp box is
locked.

Core:

In the manufacturing process like casting including moulding a device is used for the making
internal cavity. This is called core.
 Experiment no. 1

Mold making for solid pattern

Objective:

Making mold for solid pattern

Apparatus:

1) Molding box
2) Hammer
3) Rammer
4) Solid pattern
5) Holding pins
6) Sand with binding material
7) Sprue and riser
8) Roller
9) Cutting scale

Procedure:

1) First sand is mixed with the binding material so that it may remain fixed with in the box
2) Then I put the solid pattern whose casting is required in the drag when drag was in upside down
position.
3) One of my group mates hold it while I was pouring sand into the drag, so that the pattern might
not change its position while pouring
4) To make sand completely settle down into the drag we used hammer and rammer. Hammer
(made of wood) was used for the center and rammer (made of metal) was used for the sides.
5) We leveled it by roller and cutting scale.
6) Drag was brought to its original position.
7) We put cop on it.
8) Then one of my group mates, hold the sprue and riser at the pattern’s both ends.
9) We filled that cop with sand.
10) Then carefully sprue and riser were removed with rotating clock wise or anti clock wise.
11) Cop was removed carefully and then solid pattern was removed using holding pins creating
cavity.
12) Metal (aluminum) was melted in the gas furnace.
13) Then molten metal was poured into the cavity.
14) After sometime sand was removed.
15) Then furnish was done to get main part.

Theory
Molding box:
 This box contains removeable two parts one is cop and one is drag. Bottom part is
named as drag and top part is named as cop. Solid pattern is put into drag part. It is mostly made of
metal. Both parts are clamped.

Sand and binding material:

Cavity is usually made in the sand molds which are made from wet sand. It has
binding material in it that is usually clay. Mostly sand use for molding is green sand this is not called
green because of color but because it is wet sand.

We made choice for the sand on the basis of the metal which is to be poured. So the temperature of the
molten metal effect the sand.

Hammer:

It is use to make the sand settle down.

Rammer:
 It is use for the edges to make sand settle.

Roller:

It is used to make the surface level. For this purpose, cutting scale is also used.

Applications:
We can say that from all on the pattern this is cheapest process. On small scale production we use this
process. Flat surfaces are being casted by this process like rectangular blocks, gear box etc.

Safety precautions:

Metal is melted at very high temperature so during it pouring one should be very careful.
 Experiment no. 2

Mold for split pattern

Objective:

Make mold for split pattern.

Apparatus:

1) Molding box
2) Hammer
3) Rammer
4) Split pattern
5) Holding pins
6) Sand with binding material
7) Sprue and riser
8) Roller
9) Cutting scale

Procedure:

1) First sand is mixed with the binding material so that it may remain fixed with in the box
2) Then I put the split pattern whose casting is required in the drag when drag was in upside down
position.
3) One of my group mates hold it while I was pouring sand into the drag, so that the pattern might
not change its position while pouring
4) To make sand completely settle down into the drag we used hammer and rammer. Hammer
(made of wood) was used for the center and rammer (made of metal) was used for the sides.
5) We leveled it by roller and cutting scale.
6) Drag was brought to its original position.
7) We put cop on to it.
8) Other part of the pattern is put into it.
9) Sprue and riser are adjusted and then sand in poured into it.
10) Sprue and riser are removed carefully.
11) Cop is removed and positioned upside down.
12) Then both the parts are removed by holding pins.
13) Metal is converted into molten state by putting it into gas furnace.
14) Molten metal is then poured into cavity.
15) After sometime, sand is removed and casted part is obtained after furnishing.

Theory is same as of above.

Applications:

We can use it for weapon like AK-47.

Also used for steam valves.

 Experiment no 3

Mold making core

Objective:

Making mold with core in it.

Apparatus:

1) Molding box
2) Hammer
3) Rammer
4) Split pattern
5) Holding pins
6) Sand with binding material
7) Sprue and riser
8) Roller
9) Cutting scale
10) Core

Procedure:

1) First sand is mixed with the binding material so that it may remain fixed with in the box
2) Then I put the split pattern whose casting is required in the drag when drag was in upside down
position.
3) One of my group mates hold it while I was pouring sand into the drag, so that the pattern might
not change its position while pouring sand.
4) Core is also positioned in the drag.
 5) To make sand completely settle down into the drag we used hammer and rammer. Hammer
(made of wood) was used for the center and rammer (made of metal) was used for the sides.
6) We leveled it by roller and cutting scale.
7) Drag was brought to its original position.
8) We put cop on to it.
9) Other part of the pattern is put into it.
10) Sprue and riser are adjusted and then sand in poured into it.
11) Sprue and riser are removed carefully.
12) Cop is removed and positioned upside down.
13) Then both the parts are removed by holding pins.
14) Metal is converted into molten state by putting it into gas furnace.
15) Molten metal is then poured into cavity.

After sometime, sand is removed and casted part is obtained after furnishing.

Theory is same as above

Application:

Core is basically used for internal casting. For example, in blocks of cast engine cores can
provide multiple passages.
 Experiment no 4

Mold making for multi cavity

Objective:

Make mold for multi cavity.

Apparatus:

1) Multi cavity Molding box

2) Hammer
3) Rammer
4) Split pattern
5) Holding pins
6) Sand with binding material
7) Sprue and riser
8) Roller
9) Cutting scale

Procedure:

1) First sand is mixed with the binding material so that it may remain fixed with in the box
2) Then I put the first part of the multi pattern whose casting is required in the drag when drag was
in upside down position.
3) One of my group mates hold it while I was pouring sand into the drag, so that the pattern might
not change its position while pouring sand.
4) To make sand completely settle down into the drag we used hammer and rammer. Hammer
(made of wood) was used for the center and rammer (made of metal) was used for the sides.
5) We leveled it by roller and cutting scale.
6) Drag was brought to its original position.
7) Middle part is known as check second pattern is put into it.
8) We put cop on to it.
9) Other part of the pattern is put into it.
10) Sprue and riser are adjusted and then sand in poured into it.
11) Sprue and riser are removed carefully.
12) Cop is removed and positioned upside down.
13) Then all parts are removed by holding pins.
14) Metal is converted into molten state by putting it into gas furnace.
15) Molten metal is then poured into cavity.

After sometime, sand is removed and casted part is obtained after furnishing.

Theory is same as above

Applications:
 Some difficult and designs that are complicated are casted by this process. Mitre joints
and dowel joints are casted by this type of casting.

The pictures during experiments in lab are given below:

Pictures are in sequence:

Note: Due to having almost same procedure of all experiments pictures are inserted at the end