WORKSHEET REPORT

DJF21012 – FOUNDRY WORKSHOP

SAND CASTING
GROUP MEMBERS :
NAME: REG .
NO.
BIL NAME MATRIX NO
1 NOOR SAKINAH BT KAMAL 16DTP20F1006
MARKS:
A B C D E F

LECTURER NAME :
BIL NAME
1 PUAN MARZIANA BINTI HASHIM
2 PUAN ZAFARIDA BINTI KADIR
CLASS : DTP2A
SUBMISSION DATE : 31 AUGUST 2021
1.0 OBJECTIVE

Afoundryis afactorythat producesmetal castings. Metals are cast into shapes by melting
them into a liquid, pouring the metal into a mold, and removing themold material after the
metal has solidified as it cools. The most common metals processed are aluminium and
cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are
also used to produce castings in foundries. In this process, parts of desired shapes and
sizes can be formed.

 To get a hands-on experience on metal casting through the process of sand

casting.
 To deploy the knowledge of metal casting into making useful products through the
process of sand casting.
 To use a new, indirect composite tooling technique to produce molds for the lost-
foam pattern making process.
 Identify the capabilities of the lost foam casting process
2.0 INTRODUCTION
Casting is a solidification process, which means the solidification phenomenon controls
mostof the properties of the casting. Moreover, most of the casting defects
occur duringsolidification, such as gas porosity and solidification shrinkage. Solidification
occurs in two steps: nucleation and crystal growth. In the nucleation stage;solid particles
form within the liquid. When these particles form their internal energy is lowerthan the
surrounded liquid, which creates an energy interface between the two. The formationof the
surface at this interface requires energy, so as nucleation occurs the material actuallyunder
cools, that is it cools below its freezing temperature, because of the extra
energyrequired forming the interface surfaces. It then recoalescence’s, or heats
back up to itsfreezing temperature, for the crystal growth stage. Note that nucleation
occurs on a pre-existing solid surface, because not as much energy is required for a partial
interface surface,as is for a complete spherical interface surface. This can be
advantageous because fine-grained castings possess better properties than coarse-grained
castings. A fine grain structurecan be induced by grain refinement or inoculation, which is the
process of adding impuritiesto induce nucleation. All of the nucleations represent a crystal,
which grows as the heat offusion is extracted from the liquid until there is no liquid left. The
direction, rate, and type ofgrowth can be controlled to maximize the properties of the casting.
Directional solidificationis when the material solidifies at one end and proceeds to solidify to
the other end; this is themost ideal type of grain growth because it allows liquid material to
compensate for shrinkage.
In a nutshell, casting processes involve the use of molten material, usually metal. This molten
material is then poured into a mould cavity that takes the form of the finished part. The
molten material then cools, with heat generally being extracted via the mould, until it
solidifies into the desired shape.

SAND CASTING
A sand casting or a sand molded casting is a cast part produced by forming a mold from
asand mixture and then pouring molten liquid metal into the cavity in the mold. The mold
isthen cooled until the metal has solidified. In the last stage the casting is separated from
themold. There are six steps in this process:
1. Place a pattern in sand to create a mold.
2. Incorporate a gating system.
3. Remove the pattern.
4. Fill the mold cavity with molten metal.
5. Allow the metal to cool.
6. Break away the sand mold and remove the casting.
3.0 TOOL / EQUIPMENTS

i. Safety Apparel / Wear

TOOLS & EQUIPMENT FIGURE

Eye glass and face shield

 Eye protection is protective gear for the
eyes, and sometimes face, designed to
reduce the risk of injury.

 Examples of risks requiring eye protection

can include: impact from particles or debris,
light or radiation, wind blast, heat, sea
spray or impact from some type of ball or
puck used in sports.
Heat resistant glove
 Safety Gloves are highly heat resistant
gloves that are ideal for protection when
melting and casting metals.

Knee leggings
 To protect the feet from being exposed to
hot objects.

Bib type apron

 To protect yourself from hot aluminum
splashes.
 To protect you from getting spills and stains
on your clothes.
 Safety boot
 It prevents from getting foot injuries due to
slippery surface.
 Protection against falling or rolling objects

ii. Metal Melting and Casting

TOOL / EQUIPMENT FIGURE

Crucible furnace
 A crucible furnace is a simple and very
old type of melting unit commonly used
in foundry.
 The crucible furnace typically uses a
refectory crucible with contains a metal
charge.
 The actual crucible is a container that
can withstand very high temperatures
and is therefore used to melt materials
such as metals.
Crucible
 A crucible is a pot that is used to keep
metals for melting in a furnace.
 Furnace crucibles are designed to
withstand the highest temperatures
encountered in the metal casting works.
 The crucible should essentially be made
of materials with a much higher melting
point than that of the materials to be
melted.
Crucible rest or stool
 It can be made from any material that
withstands temperatures high enough to
melt or otherwise alter its contents.
Metal pick-up tongs
 To grip and lift objects instead of
holding them directly with hands.

Combined dross lifter and skimming ladle

 For easy and efficient removal of dross
and dirt from all types of molten metal.
 Taking molten metal samples and for
skimming slag from induction furnaces
and ladles.
 For obtaining samples for
spectrographic analysis, test bars and
thermal analysis samples.
Crucible lifting tongs
 To grasp a hot crucible, flasks,
evaporating dishes, or even small
beakers.
 Used to grip the hot crucible and lifting
crucible with full of molten metal from
top of the furnace

Ladle carrier
 Used to manually transfer or extract
small to large amounts of molten metal,
either in a laboratory or aluminium
foundry environment.
Metals: Aluminum ingots/brass ingots/grey
iron ingots
 Used for housings where the stiffness of
the component is more important than
its tensile strength.
4.0 Safety Precautions

Safety Apparel /Wear

i. Astronauts wear special clothing for protection must wear when handling molten metal.
ii. This safety apparel must be worn during metal melting to protect from heat, burns and
splashed molten metal.

There are some of the common safety equipment that have found to be useful in :
i. Wear leather work boots, preferably with steel toes.
ii. Wear trousers, not shorts and long sleeve shirt or welder's vest.
iii. Wear loose-fitting leather clothes, or at least clothes made of a material, which is fairly
flame resistant.
iv. Welder's gloves or other leather gloves with long gauntlets up the arm have proved to be
of immense help.
v. Safety glasses are an absolute minimum. It is wise to wear a full-face shield as well.
vi. Long-handled pliers (or tongs) and three foot 1/4" rod. The pliers are designed for adding
things to the crucible and adjusting coals, etc. The rod is used for mixing the contents of
crucible and move dross to the side just before pouring.
5.0 Procedures

Sand Molding

1. Place the drag pattern with parting surface down the bottom (ram-up) board. .[Figure a]

2. Sprinkle the facing sand carefully around the pattern so that the pattern does not stick with
molding sand.

3. Fill the drag with loose molding sand

4. Ram the sand uniformly in the molding box around the pattern.

5. Strike off the excess sand to bring it at the same level of the flask height. This completes
the drag.
 Figure 2.3: Making a mold

6. Sprinkle parting sand on top of the drag and roll over the drag. Then, place the tackle
pattern on the drag streak (and align using a dowel pin) .After that, place the lid (flask) on top
of the drag that has been hit.Finally, sprinkle parting sand all over the cover pattern.

7.Erect Sprue and riser pins to form suitable sized cavities for pouring molten metal.[Figure
c]

8. Fill the cope with sand and ram

9. Strike off the excess sand from the top of the cope
10. Remove sprue and riser pins
11. Vent the cope with a vent wire
12. Sprinkle parting sand over the top of the cope surface
13. Roll over the cope on the bottom board.
14. Rap and remove both the cope and drag patterns.
15. Repair the mold if necessary.
16. Cut the gate connecting the sprue basin with the mold cavity.
17. Close the mold by inverting cope over drag.
18. Clamp cope with drag and the mold is ready for pouring (if necessary).

Sand casting
1. Pre-heat the furnace
2. Place the crucible stool and crucible in the furnace
3. Lift the crucible lid open
4. After a few minutes, place the metal/alloy ingots or scrap into the crucible. Place only ¾
fill the crucible.
5. When metal/alloy start to melt cover it with a suitable melting flux. Take out metal/ alloy
slag.
6. Lift out the crucible from the furnace using crucible lifting tong or scope the molten metal.
7. Pouring the molten metal into the mold.
8. Let the mold in room temperature until the molten metal solidified.
6.0 Results
7.0 Discussion
1. The advantages and disadvantages of Sand Casting
Disadvantages
1. Low strength – Low material
strength due to high porosity
compared to a machined part
2. Poor surface finish – Due to internal
sand mould wall surface texture.
3. Low dimensional accuracy
– Because of shrinking and the
surface finish dimensional accuracy is
very poor.
4. Post processing – Secondary
machining operation often required if
tighter tolerance needed to interface
with other mating parts
5. Defects unavoidable – Like any
other metallurgical process, defects
or quality variations such as
shrinkage, porosity, pouring metal def
ects, surface defects are unavoidable
Advantages
1. Wider material choice – Virtually all
types of engineering alloys can be cast
as long as it can be melted.
2. Short lead time – Short lead time
compared to others and hence ideal
for short production runs.
3. Design flexibility – The size and
weight of parts can range from few
millimetre & grams to meters & many
tons. The size and weight of the cast
are only limited by the restriction
imposed by molten metal handling
and supply.
4. Low cost tooling – Tooling and
equipment costs are low compared to
some other metal manufacturing
processes. Hence making it one of the
cheapest method to achieve near net
shape components
5. High complexity shapes – No other
process offers the same range of
possibilities for the shaping of complex
features than casting that can produce
near net shape components.
2. The purposes of casting process

Casting processes have been known for thousands of years, and have been widely
used for sculpture (especially in bronze), jewelry in precious metals, and weapons and
tools. Highly engineered castings are found in 90 percent of durable goods, including
cars, trucks, aerospace, trains, mining and construction equipment, oil wells,
appliances, pipes, hydrants, wind turbines, nuclear plants, medical devices, defense
products, toys, and more. Casting is a manufacturing process in which a liquid
material is usually poured into a mold, which contains a hollow cavity of the desired
shape, and then allowed to solidify. The solidified part is also known as a casting,
which is ejected or broken out of the mold to complete the process. Casting materials
are usually metals or various time setting materials that cure after mixing two or more
components together; examples are epoxy, concrete, plaster and clay. Casting is most
often used for making complex shapes that would be otherwise difficult or
uneconomical to make by other methods. Heavy equipment like machine tool beds,
ships' propellers. can be cast easily in the required size, rather than fabricating by
joining several small pieces
8.0 Conclusion and Discussion

Sand casting is one of the most wide-spread processes in manufacturing. Its

economicviability, technological simplicity and overall naturalness make obvious the reasons
of itspopularity. However, sand casting is not the silver bullet of manufacturing. The
overhead, themediocre quality of the castings, and the potential hazards of metal casting are
some of thereasons why it isn’t so.
The molding operation aboard ship depends primarily on the molder and ability on certain
people. A molding technique based on careful attention to the various details involved in
making a mold. As a conclusion this experiment should have the following qualities to a
degree suitable for the purpose intended:

1. Refractoriness to withstand the casting heat. This is obtained by selection

material and proper processing.
2. Strength to withstand handling and casting forces. This is obtained by the use of
the proper amount of binders and by good internal structural supports.
3. Collapsibility to permit breakdown during contraction of the casting and ease of
cleaning. By avoiding the use of sands bonded too strongly and by hollowing out
the center or filling it with coke, cinders, gravel, or weak sand, this quality may be
obtained.
4. Smooth strong surface to provide a good casting finish, internal cleanliness, and
ease of cleaning. This quality is obtained by the use of an adequately bonded
refractory sand, uniformly hard rammed, baked immediately after being made,
and used shortly after baki.ng.
5. Low gas content to prevent unsoundness in the casting. This quality is obtained
by using the minimum of organic binding materials, baking well, and venting
thoroughly. All of the above features are essential in core making and are
regularly obtained only by good core practice

Molding consists of all operations necessary to prepare a mold for receiving molten metal.
Molding usually involves placing a molding aggregate around a pattern held with a
supporting frame, withdrawing the pattern to leave the mold cavity, setting the cores in the
mold cavity and finishing and closing the mold. The preparation of molten metal for casting
is referred to simply as melting. Melting is usually done in a specifically designated area of
the foundry, and the molten metal is transferred to the pouring area where the molds are
filled. In a nutshell, the principles and terminology underlying the sand casting process has
been investigated. Overall, this experiment has been done well and all the understanding
and knowledge about molding preparation and pouring are obtained.
9.0 References

 S.K Yadav. (2006). Workshop Practice, 1st. Ed. Discovery Publishing House.

 Additional

 Serope Kalpakjian and Steve Schmid (July 27, 2007). Manufacturing Processes
for engineering materials (5th Edition). Prentice Hall.

 Charles A. Harper. (August 11, 2006). Handbook of Plastic Processes. Wiley-Inter

science; 1 edition.

 Dell Allen and Robert Todd. (Jan. 1, 1994). Manufacturing Processes Reference
Guide. Industrial Press, Inc.

 Robert A. Malloy (1994). Plastic Part Design for Injection Moulding; an

Introduction, Hanser Gardner Publications, Inc, Cincinati.