Conventional Manufacturing

Process 20ME33
Module 01 Class 06
Presented and Delivered by:
Vinayaka GP
Assistant Professor
Department of Mechanical Engineering
Vidyavardhaka College of Engineering, Mysuru
Ph. No:9880553655; Email: vinay91gp@vvce.ac.in
 Other Sands 2

Though moulding sands are the prime mould materials used in a foundry, there are a number
of other materials which are also used for a number of specific properties:
1. Facing Sand:
This sand is used next to the pattern to obtain cleaner and smoother casting surfaces.
Generally, sea coal or coal dust (finely divided bituminous coal of 2 to 8%) is mixed
with the system sand to improve the mouldability and surface finish.
2. Mould Wash:
Purely carbonaceous materials such as sea coal, finely powdered graphite or
proprietary compounds are also applied on to the mould cavity after the pattern is
withdrawn. This is called the mould wash and is done by spraying, swabbing or
painting in the form of a wet paste. These are used essentially for the following reasons:
a. To prevent metal penetration into the sand grains and thus ensuring a good casting
finish.
b. To avoid mould‑metal interaction and prevent sand fusion.

Vinayaka G P, Asst. Professor , ME Department, VVCE, Mysuru

 Other Sands 3

3. Backing Sand:
This is normally the reconditioned foundry sand and is used for ramming the bulk of the
moulding flask. The moulding flask is completely filled with backing sand after the pattern
is covered with a thin layer of facing sand. Since the casting is not affected to any great
extent by the backing sand, it usually contains the burnt facing sand, moulding sand and
clay.
4. Parting Sand
This is the material which is sprinkled on the pattern and to the parting surfaces of the
mould halves before they are prepared to prevent the adherence of the moulding sand. This
helps in easy withdrawal of the pattern and easier separation of the cope and drag flasks at
parting surface. It is essentially a non–sticky material such as washed silica grains.

Vinayaka G P, Asst. Professor , ME Department, VVCE, Mysuru

 Properties of a Casting Mould 4

In order to produce sound castings, moulds are required to have some specific properties, it includes:

1. It must be strong enough to withstand the temperature and weight of the molten metal.

2. It must resist the erosive action of the flowing hot metal.

3. It should generate minimum amount of gases as a result of the temperature of the molten metal.

4. It should have good venting capacity to allow the generated gases to completely.

Vinayaka G P, Asst. Professor , ME Department, VVCE, Mysuru

 Types of Sand Mould 5

Moulds that are used for sand casting may broadly be classified as

1. Green sand mould

2. Dry sand mould

3. Skin dried mould

4. Loam Sand mould

5. CO2 mould

Vinayaka G P, Asst. Professor , ME Department, VVCE, Mysuru

 Green Sand Mould 6

Green Sand Moulds:

• Green sand is the moulding sand which has been freshly prepared from silica grains,
clay and moisture.
• The molten metal is poured immediately and the castings are taken out.
• They are adapted for rapid production whereas the moulding flasks are released quickly.
• Require less floor space as no storage is involved.
• Least expensive.
• Hot tearing of the castings is less in green sand moulds.
• Mould erosion is common in these types of moulds.
• The permeability of these moulds should be properly controlled otherwise blow holes
and gas inclusions are likely to form.

Vinayaka G P, Asst. Professor , ME Department, VVCE, Mysuru

 Dry Sand Mould 7

Dry Sand Moulds:

• These are the green sand moulds which are completely dried by keeping in an oven
from 150 to 350°C for 8 to 48 hours depending on the binders in the moulding sand.
• These moulds generally have higher strengths than the green sand mould and are
preferred because they are less likely to be damaged during handling.
• Generally used for medium to large castings.
• Better surface finish and dimensional accuracy can be achieved by dry sand mould.
• Main disadvantages are the likely distortion of the mould caused during the baking
process.
• Susceptibility to hot tearing of castings on longer production cycles.
• More expensive than green sand mould.

Vinayaka G P, Asst. Professor , ME Department, VVCE, Mysuru

 Skin Dried Mould 8

Skin Dried Moulds:

• Though the dry sand mould is preferable for large moulds because of the expense
involved, a compromise is achieved by drying only the skin of the mould cavity with
which the molten metal comes into contact, instead of the full mould.
• The skin is normally dried to a depth of 15 to 25 mm, using either torches or by simply
allowing them to dry in atmosphere.
• Pouring of metal should be completed immediately after the drying process such that
moisture from the undried portion would not penetrate the dried skin.
• Usually adopted in Pit moulding, where the pit is normally formed in the foundry floor
with sand. This pit acts as a drag where the cavity is formed.

Vinayaka G P, Asst. Professor , ME Department, VVCE, Mysuru

 Loam Sand Mould 9

Loam Sand Moulds:

• Loam sand contains many ingredients like fine sand particles, finely ground refractories, clay,
graphite and fibre reinforcements.
• Loam soils generally have better drainage than clay soils.
• They retain water easily. Organic matter such as chopped straw is added to the sand to provide
good ventilation.
• Loam moulds are generally employed for making large castings without using the expensive
full patterns and moulding flasks.
• They use skeleton patterns and sweeps to reduce the cost of patterns.
• Objects such as large cylinders, chemical pans, large gears, round bottoms, kettles and other
machining parts are produced in loam moulding.
• Big moulds are constructed using brick framework that will be lined with loam sand and dried.
• Sweeps, etc. are used for getting the requisite profile of the casting.

Vinayaka G P, Asst. Professor , ME Department, VVCE, Mysuru

 CO2 Mould 10

Carbon dioxide Moulds:

• The method which is widely used in making cores and occasionally for moulds is to use
sodium silicate (water glass, SiO2:Na2O) as a binder.
• This is essentially a quick process of core or mould preparation.
• The mould is prepared with a mixture of sodium silicate and sand which is treated with
carbon dioxide for two to three minutes such that a dry compressive strength of over 1.4
MPa is arrived at.
• The carbon dioxide is expected to form a weak acid which hydrolyses the sodium silicate
resulting in amorphous silica forming the bond.
• introduction of CO2 gas starts the reaction by forming hydrated sodium carbonate (Na2CO3 +
H2O).
• This gelling reaction increases the viscosity of the binder till it becomes solid. The
compressive strength of the bond increases with standing time due to dehydration.

Vinayaka G P, Asst. Professor , ME Department, VVCE, Mysuru