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Found Ary
Found Ary
Found Ary
By
Instructor at
Wah British Institute of technology, Taxila
What is a Foundry?
A foundry is:
a factory that pours molten metal into molds,
producing cast metal objects.
Casting is one of the oldest industrial processes
There are different casting processes.
The focus here is: GREEN SAND CASTING
Some
typical cast
metal
objects:
Aluminum
pots
Engine blocks,
axles
Turbine blades
in jet engines
SAND-CASTING
Basic materials & equipment for green sand-casting
Pattern
a copy of the shape
you want to produce,
made of wood, plastic
or metal
Sand,
mixed with clay binder &
water (so it will hold its
shape) plus coal dust to
improve surface finish
Container of molten
filled from furnace
metal
Rammer
tool to compact the sand; often a
pressing machine is used
SAND-CASTING
A very basic summary of the sand casting process. . .
First of all,
mix the sand.
THEN
MOLDING:
Sand placed
into bottom mold
form &
compacted
MOLDING:
Pattern placed into mold
SAND-CASTING
MOLDING: Add
the top mold
form
RISER: A tube or
pipe provides a
path to exhaust
gases
RUNNER: A tube or
pipe provides a
path to pour the
metal in
SAND-CASTING
5
MOLDING: Take
the top mold off
and remove
pattern & pipe
Pouring
hole
SAND-CASTING
8
7
CASTING:
Pour the metal (container is
filled from furnace immediately
before you are ready to pour)
SAND-CASTING
A copy of the pattern
has now been made
in metal
9
CLEANING. Sand is
cleaned off the part
SAND-CASTING
Sand-casting is simple
in concept, but
demanding in
execution. It is a
process essential to
making basic and
advanced products. . .
it is also hazardous
and energy-intensive!
Casting Terminology
Parting line
Patterns
What is pattern?
Approximate duplicate of product
Patterns are made in the shape of the casting
Pattern Materials: Wood, Plastic or metal.
One piece or multiple piece pattern
Types of Patterns
Types of patterns used in sand casting:
(a) solid pattern
(b) split pattern
(c) matchpalate pattern
(d) cope and drag pattern
Pattern Making
Split Pattern
Pattern Allowances
Shrinkage Allowance
Patterns are made larger than the casting to compensate
contraction of the liquid while freezing.
For internal cavities the allowances should be negative.
Machining Allowance
Allowance required to remove the rough cast surface. 2 to 25 mm
(0.1 to 1)
Draft Allowance
To facilitate ease of removal, usually to 2 deg.
Shrinkage allowance
Normal shrinkage: Cast iron 0.83 to 1.3%
Aluminum - 1.3%
Cores
Casting Process
1
Mould
Dolly
5
Sprue
Pins
10
11
12
13