Experiment No.

1
Muller Mixer

AIM:To Study Muller Mixer

THEORY:

Mixing of sand is an important part of sand preparation. This ensures distribution of

components and a lump-free consistency. To minimize cost the binder should be distributed as a
thin film around each sand grain. Efficient mulling performs this very function.

In the case of clay binder, distribution of clay and water is commonly accomplished by
the gentle squeezing action of roller which progressively expose more clay flakes to the
absorption of water.

MULLER:

It is a mechanical device used to mix sand, binder and moisture thoroughly. Mixing can also
be carried out by hand using shovels. Mullers must be used for synthetic sand mixing but natural
sands can be hand mulled. A mullerkneads, shears and slices through the sand by means of
revolving wheels or rollers.

The mixing plant is provided with facilities for storage of constituents including new and
reclaimed sands bonding materials and special additions. In many plants, provisions exists for
feeding bulk materials directly into the mixer in measured quantities without intermediate
handling and for the direct metering of water additions. The water content of new sand is
normally low enough for intermediate use but sands intended for use with chemical binder often
require preliminary drying.

A) SPEED MULLER–This type of muller uses lighter, thinner and rubber covered wheels
spinning rapidly over and through the moulding sand. It is a high speed muller used in
mechanical foundries. Wheels rotate in horizontal planes with their axes vertical. The
sand is stirred vigorously against the vertical sides of the rubber lined mixing chamber.
Sands is then circulated by ploughs. Sometimes an air blast may be provided for forced
cooling of the sand being processed. The intensive mulling action enables sand
preparation or mixing in about 60 to 90 seconds.
B) SIMPSON BATCH MIXER–It uses thick rimmed, heavy metal wheels rotating at slow
speeds over the tempered moulding sand mixture. The two wheels along with two plows
roll and rotate in a circular path about horizontal axis. Wheels either rest on the sand or
 remain about 5mm above the base of the rotating pan. Wheels may be attached to vertical
shaft or mounted rigedly with the ritating pan. Plows stir the sand and bring it under the
wheels, while wheels mix the sand with a squeezing action. After mixing the sand, it may
be taken out from a drop door at the bottom of muller. Such mullers can be provided with
auto loading skips and discharge directly into the sand distribution system. Mixing times
are in the range of 3 to 6 mins.

Mulling Characteristics:
Based on observations it has been agreed that mulling cycle times less than 90 seconds
are inadequate for ideal parameter control in sand preparation. Thus, mulling times should only
be counted after all ingredients have been added, including water.

As milling time proceeds, the mixture becomes more uniform with respect to physical
and mechanical properties. In most foundries, the extent of mulling is established on an arbitary
time or mulling energy basis, as a function of sand capacity demand. Mulling action causes
“complete disorder so that mulled products are uniformly mixed when it is sampled and tested”.

In the batch mixing of sand, properties increase progressively as the ideal distribution of
binder is approached, the relation of strength to mulling time follows the relation shown in the
figure. Excessive mulling time however leads to frictional heating and subsequent loss of
moisture in standing.

Laboratory Muller Mixer