TUANKU SVED SIRAJUDDIN

DEPARTMENT OF MECHANICAL ENGINEERING

Report Title FOUNDRY

DJJ20042: MECHANICAL WORKSHOP

PRACTICE 2

WORKSHOP REPORT

Students Name : Muhammad hazwan bin ahmad sobri

Lut Iskandar bin jamaludin

Matrix No : 18DKM21F1030
18DKM21F1015

Class : DKM 3C
Session : I: 2022-2023
Programme : Diploma in Mechanical Engineering
Lecturer Name :
Total ( /40)

Mark
1. TITLE

FOUNDRY (PATTERN MAKING)

2. OBJECTIVE
a. at the end of the session, we was able to follow the safety procedures in the foundry
workshop.
b. at the end of the session, we were also able to design and make simple mold patterns.
c. finally, we will be able to keep the workshop clean and safe.

3. EQUIPMENT AND TOOLS

a. Pattern Materials
i. Wood
b. Pattern-making tools
i. Ruler
ii. Compass
c. Pattern-making machines
i. Wood turning lathe
ii. Circular saw
iii. Sander machine
d. Jointing material
i. Wood glue.
4. Safety precaution
a. Get permission from the lecture before starting.

b. Follow all the instructions that have been given.

c. Do not use equipment unless you have been instructed.

d. Proper personal protection must be worn during workshop practice.

e. Work area and equipment are to be thoroughly cleaned after use.

f. If last to leave the workshop, make sure all equipment is turned off.
5.0 PROCEDURES
Before going into the steps in pattern making, several things to be prepared and considered:
a) To ensure the sand mould is easy to make, this pattern should be made in a single
pattern.
b) The pattern should be divided into 2 sections, i.e. Flange Top and Flange Base.
c) The parting line for this pattern is located on the base/bottom of the Flange Base.
d) Both parts are combined using white glue.
e) The draft or taper has been set on the pattern.
f) The holes of the casting will be produced through the sand core produce by core box.
g) The core box is provided (Note: Ignore fabrication of the core box and core print).
h) The casting bolt holes shall be drilled using a 12 mm diameter drill bit.
i) Material for pattern: Jelutong wood
I. 1 piece (120 x 120 x 20 mm) (Part 1: Flange base)
II. 1 piece (60 x 60 x 40 mm) (Part 2: Flange top)

j) Tool and equipment:

I. Geometri set
II. Hand tool
III. Wood working machine
IV. Shrinkage rule for aluminium alloy: 13/1000 (mm/m)

k) Adhesive: White glue

l) Duration: 8 hours
1) Organizes and plan the task a) Prepare 2 pieces of jelutong wood according to the
dimension as below:
I. 1 piece (120 x 120 x 20 mm) (Part 1: Flange
base)
II. 1 piece (60 x 60 x 40 mm) (Part 2: Flange top)
* Note: Wear mask and goggle in all the process.

Part 1: Flange base

ii. Part 2: Flange top

b) Use a circular cutting saw / band saw to cut the

jelutong wood.
c) Remove / sand over the wood pieces in various
surfaces with #100 grit.
d) Then using a wood disc sander machine / planner
machine to grind / sand the surfaces.
e) Remember, "Turn On" the dust collector to collect
the duct generate from the sanding process.

*Note: Make sure dust collector is working.

f) Regularly check the accurate 900 angles (squares) and

straight edges for the wood pieces by "L" Square.
i. Part 1: Flange base
 900 (4 ANGLES)

120,00

ii. Part 2: Flange top

60,00

900 (4 ANGLES)

g) Sketches the required thickness of wood pieces.

h) Use a drawing compasses / divider to sketch the thickness and
 leave a clear line on the surface.
i) Continuous sand the wood surfaces until the thickness

is reached. i.e.:

I. Part 1: Flange base - 15 mm.

II. Part 2: Flange top - 35 mm.
j) Remember, make sure the thickness is large enough and allow to the
further pattern marking process.
k) Avoid over cut the pattern thickness. (Tolerance: ± 1 mm).

THICKNESS 15 MM
i. Part 1: Flange base

ii. Part 2: Flange top

THICKNES : 35 MM
2) Plan sketching and marking on the
pattern
a) Mark the centre point of the wood pieces at the both
sides.
b) Sketches the diameter of the patterns on the both sides
i.e.,
I. Part 1: Flange base
 Top side with Ø 110 mm.
 Bottom side with Ø 111.05 mm.

"11,05

ii. Part 2: Flange top

 Ø 45.96 mm,
 Ø 50 mm.

Ø45,96
3) Cut and construct the pattern a) Mark the 4 angles of wood pieces with 45 degrees.
b) Remember, sketches as close as possible over the
diameter line of the pattern.
i. Part 1: Flange base

ø111t05
Ø110
POO

ii. Part 2: Flange top

Ø45,96

øsgoo

c) Cut the angles of wood pieces with band saw.

d) Sand and grind the surface of the wood pieces in
vertical direction with #100 grit.
 i. Part 1: Flange base

ii. Part 2: Flange top

e) Sand and grind the surface draft angle on the wood pieces.

i. Part 1: Flange base

ii. Part 2: Flange top

090

f) Align the require draft angle at disc table.

g) Trial to sand and grind the surface draft until reach
the final require dimension.

i. Part 1: Flange base

110,00

111,05

ii. Part 2: Flange top

45,96

50,00
6) RESULT

No Task Result

7.1 Practical task (pattern)

7) Discussion

In the process, some problems arise. For example, our wood is packed with
several holes from previous nail drills. This caused our wood to break a little while
turning. It causes our results to be uneven.

8) Conclusion

In conclusion, we were able to achieve the objectives we wanted to achieve at

the beginning. Although there is a little difference because the wood we use has a hole
in the inside.