Lab Session # 1

To study lab layout and introduction of casting tools.

Lab layout:

Door

Sand Mold
Mold
mixture Racks
Rack
Pneumatic machine
press
machine

Riddle
machine
Working
Table

Mechanical
forging
machine

Working
Air Table
compressor

Door
Casting Tools:

Molding Box:

A molding box, also known as a mold box or flask, is an essential component in the sand casting
process. It is used to contain and shape the sand during the molding process. The molding box is
typically made of metal and is comprised of two halves: The Cope and The Drag.

 Cope:
The top half of the molding box is called the cope .It is placed over the pattern and filled
with sand to create the top part of the mold.

 Drag:
The bottom half of the molding box is known as the drag. It is placed beneath the pattern and
filled with sand to form the bottom part of the mold.

 Parting Line:
The parting line is the division between the cope and drag halves of the mold.

 Alignment Pins:
Alignment pins are used to ensure proper alignment between the cope and drag when
assembling the mold.

 Mold Cavity:
The space enclosed by the cope and drag, where the molten metal will be poured to create the
casting, is called the mold cavity.
Molding Board:

A molding board typically refers to a board or a flat surface used in the molding process. The
molding board is an integral part of the pattern-making and mold assembly stages. The molding
board serves as the surface on which the pattern is laid out.

Green Sand:

Green sand is a type of foundry sand used in the sand casting process. It is named "green"
because it is used in a wet, uncured state, not because of its color. is composed of a mixture of
sand, clay, water, and sometimes other additives. Green sand is commonly used in the molding
process for sand casting. It is packed around a pattern to create a mold cavity, and after the
metal has been poured and solidified, the green sand mold is broken apart to retrieve the
casting.
Molasses:

Molasses is known for its sweetness and distinctive taste, and it comes in different varieties
such as light, dark, and blackstrap, each with varying levels of sweetness and depth of flavor.

Clay powder:

Clay powder is a fine, dry substance composed of naturally occurring clay minerals. Clays are
hydrous aluminum phyllosilicate minerals formed from the weathering of rocks over time. The
mixture of clay and sand forms a mold that can withstand the heat and pressure of molten
metal.

Rammer:

A tool used for compacting or ramming sand into a molding flask to create a mold cavity. The
ramming process is a critical step in preparing the sand mold for receiving molten metal during
the casting process.
Hand Rammer:

Hand rammers are manually operated tools that are handheld and used by foundry workers to
compact sand around the pattern.

1. Wooden Rammer:
A wooden rammer, also known as a wooden mallet or ramming tool, is a type of hand-operated
tool used in sand casting for compacting and ramming sand around a pattern in a molding flask
2. Iron Rammer:
Iron rammer is a tool used for compacting and ramming sand around a pattern in a molding
flask. It is a more robust and durable alternative to wooden rammers and it is typically made of
iron or another strong and sturdy metal.

Gate:

It is used to give path to the molten metal to pass easily into the cavity.

Sprue:

Sprue Pins are used to create the runner and riser in the sand mold. Sprue pins are set a
distance from the pattern to allow sufficient space to cut gates into the mold. The pattern and
sprue pins are coated with parting powder prior to covering with sand and ramming firm.
Strike-Off Bar:

A tool to strike or level the surface of the sand within the molding flask. This process is
important for creating a flat and even surface on which to place patterns or create mold cavity.

Roller:

A roller is a tool used in the sand casting to level surface of the sand over the cope and drag
section of the molding flask and to make their surface smooth and flat.

Vent Wires:
A vent wire is used to form vents or holes in the rammed sand to provide easy escape of gasses
or steam formed during pouring of molten metal.

Lifter:

Lifters are components used to create and support the cores within a sand mold. Cores are internal
structures made of sand that create voids or complex shapes in the final casting.

Ladle:

A ladle is used to pour molten metal into molds to produce the casting, in ladle molten metals is
placed which is then set to liquification at high temperature. Ladles used in foundries are often
made of materials that can withstand high temperatures, such as refractory materials, and they
are designed to safely handle molten metals.
.

Lifting Tong:

Tongs are the types of tools used to grip and lift the objects instead of holding them directly
with hands. There are many forms of tongs adapted to their specific use.
Electric Furnace:

An electric furnace is a heating device that generates heat by using electrical energy. It is
commonly used in various industries for processes such as metal smelting, heat treatment, and
in residential or commercial settings for heating purposes.

Slag Remover Bar:

A slag remover bar is a tool used in metalworking and foundry operations to remove slag, a
byproduct formed during the smelting and refining of metals. Slag is a non-metallic residue that
floats on the surface of molten metal and consists of impurities, oxides, and other undesired
elements. The slag remover bar is specifically designed to skim, stir, and remove this unwanted
material from the surface of the molten metal.

Types of pattern:

 Single piece pattern:

It is the simplest form of a pattern made without any joints, partings or loose pieces in its
construction is called the solid or single piece pattern. It is inexpensive and generally used for
large castings of simple shapes.

 Split pattern:

Split pattern consists of two pieces; one half of the pattern rests in the drag (lower part of the
molding box) and the other half in the cope (upper part of the molding box).Split patterns. The
split patterns are commonly used for the casting of steam valve bodies, small pulleys, wheels
and
cylinders etc.
 Core:

A core pattern refers to a pattern that is used to create a core – a removable interior part of the
casting mold that shapes the internal features of the final casting. Cores are used when the
desired shape of the casting includes internal cavities, voids, or complex geometries that cannot
be achieved by molding the entire part in a single piece.

 Multicavity Pattern:

The multicavity pattern refers to a pattern design that allows for the creation of multiple copies
or cavities of the same part in a single mold. The use of multicavity patterns can significantly
increase the efficiency of the casting process by producing multiple parts in a single casting
cycle. This is particularly useful for high-volume production where mass production of identical
parts is required.
Safety precautions:

Working in a foundry lab involves various potential hazards related to the handling of molten
metal, hot surfaces, and heavy machinery. Implementing safety precautions is crucial to prevent
accidents, injuries, and ensure a secure working environment. Here are important safety
precautions for a foundry lab:

 Personal Protective Equipment (PPE):

Wear appropriate PPE, including heat-resistant clothing, safety glasses, face shields, heat-
resistant gloves, and closed-toe shoes. The specific PPE requirements may vary depending on
the tasks being performed.

 Training:

Provide comprehensive training for all personnel on foundry operations, equipment usage, and
emergency procedures. Ensure that employees are aware of the potential hazards and know
how to mitigate risks.

 Foundry Ventilation:

Ensure proper ventilation to control fumes, gases, and dust generated during the foundry
processes. Use exhaust systems and personal respiratory protection when necessary.

 Molten Metal Handling:

Exercise extreme caution when handling molten metal. Use proper ladles, crucibles, and
pouring techniques to minimize splashes. Keep a safe distance from molten metal sources.

 Mold and Core Handling:

Be cautious when handling molds and cores, especially when they contain hot metal or have
recently been poured. Use lifting equipment and proper techniques to prevent strain injuries.
 Heat Sources:

Clearly mark and isolate hot surfaces, such as furnace exteriors and molten metal containers, to
prevent accidental contact. Use caution when working near heat sources, and wear heat-
resistant gloves.

 Emergency Procedures:

Establish and communicate emergency procedures, including the location of emergency stops,
first aid kits, eye wash stations, and fire extinguishers. Conduct regular drills to ensure everyone
is familiar with these procedures.

 Tool Inspection:

Regularly inspect and maintain tools and equipment. Ensure that shovels, rammers, tongs, and
other tools are in good condition to prevent accidents.

 Respiratory Protection:

Provide and use appropriate respiratory protection if there is a risk of inhaling harmful fumes or
dust. Conduct regular fit testing for respiratory protective equipment.

 Supervision:

Ensure that there is adequate supervision, especially for individuals who are less experienced or
undergoing training.

 Post Warning Signs:

Clearly post warning signs indicating potential hazards and required safety precautions in
prominent locations.
Always follow the specific safety guidelines provided by the lab or institution, and consult with
safety professionals to address any specific risks associated with foundry operations. Regular
safety training, awareness, and a commitment to maintaining a safe work environment are
crucial in a foundry lab.