MALNAD COLLEGE OF ENGINEERING

HASSAN, 573201
DEPARTMENT OF MECHANICAL ENGINEERING

“MECHANISATION OF FOUNDRY”

BY
A N ROHAN – 4MC20ME001
DARSHAN B S – 4MC20ME020
DARSHAN H J – 4MC20ME022
DHRUVANTH S J – 4MC20ME028

Department of Mechanical Engineering, MCE HASSAN

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 CONTENT

• INTRODUCTION
• NEED FOR MODERNIZATION AND MECHNIZATION
• TYPES OF CONVEYORS USED
• SAND PREPRATION EQUIPMENT
• MOULDING PROCESSES
• TYPES OF CORES

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 INTRODUCTION

Mechanisation of foundries is necessary, where permitted, (depending on the quantity and type of
production) in order to improve the working conditions in foundry, increased production and quality of
casting lowering down the cost, elimination of laborious manual operations like preparation of sand,
moulds and various other material handling operations.
Mechanisation can be applied to preparation of sand moulds, cores, transporting sand, moulds and
molten metal etc. It is best suited where a repetitive work and mass production of small size parts is
involved.
Materials handling mechanisation increases efficiency, saves lot of man-hours, keeps production costs low,
promotes safety of personnel and reduces damage. The material (sand, flasks, patterns, etc.) are moved
automatically at a fast speed.
Heavy-lifting and laborious operations are done by machines. Given floor space is utilised in optimal way,
dust nuisance is minimised, and castings with closer dimensional tolerances and with fewer defects are
produced.
Mechanical equipment for sand preparation comprises of magnetic separator, gyratory riddle, rotary
sand kicker, sand Muller, sand aerator, reclamation units.Use of fume and dust extraction equipment is
essential in mechanised foundries at screens, chipping or fettling benches, knock out belts, turning point
etc.

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NEED FOR MODERNISATION AND MECHANISATION
• To change picture of foundry from dark, dirty place dotted with mounds of sand, coal, ashes and
metal. Atmosphere filled with smoke ; and enclosure where workers breath noxious fumes.
• To improve working conditions in the shop ensuring a safe healthy and happy life for worker.
• To meet the ever-changing needs of customers.
• To reduce production cost and material handling cost.
• The efficiency of a manufacturing system is dependent upon the ability to move tho
parts/materials effectively, timely and rapidly.
ADVANTAGES
• Increased production from a given floor area andhigher productivity.
• Higher degree of accuracy, closer tolerances andbetter surface finish.
• Minimum casting defects.
• Reduced number of labours. Elimination of timeconsuming manual operations such as mixing
and preparing sands, preparing moulds and handling various foundry materials.
• Better working conditions and improved job satisfaction.
• Reduced cost of production and higher profits.
DISADVANTAGES
• It is not adaptable for small jobbing foundries.
• Rise to unemployment.
• Gradual disappearance of skillful art of hand moulding.

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 TYPES OF CONVEYORS USED IN
1. HANDLING SAND
• BELT CONVEYOR:

• BUCKET ELEVATOR

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 • APRON CONVEYOR:

• FLIGHT CONVEYOR • CRANE

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 2. HANDLING MOULD
• ROLLER CONVEYOR
- It has two beams fixed on trestles of suitable heightand supporting latterly
arranged rollers above.
- It may be either of the gravity or power driven type.
• PALLET OR CAR TYPE CONVEYOR.
- It has pallets made of cast iron or steel plates mountedon wheels which
can roll along narrow-gauge track.

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• SAND PREPARATION EQUIPMENT
1.MAGNETIC SEPARATOR
The moulding sand coming from shake out station must be freed of iron particles and foreign
matter before being put to reuse.
• The magnetic separator consists of magnetized pulley over whichflat rubber or canvas belt
rolls.
• As the belt rolls over pulley, the sand and non-magnetic particlesfall freely.
• The ferrous objects on other hand tend to cling the belt due to magnetization effect
and drop off only when the belt has leftthe pulley.
• The pulley may be permanent magnet type or electromagnettype carrying DC
magnetizing coils.
2. RIDDLE
After separation of iron pieces, the sand usuallypassed through screen or
riddle.
• There are two types of riddles available
(i) Operated by compressed air
(ii) Operated by electric motors

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 3. MULLER
• The function of muller is to condition the moulding sandfor reuse.
• Mulling is process of distributing the ingredientsinto homogeneous
Mixture.
4. AERATOR
• After the sand is conditioned in muller, it is sent to an aerator where sand grains are
separated and each grain is made to flow freely and smoothly.
• The capacity of moulding sand to flow freely aroundthe pattern and get packed
is termed as flowability.
• Mechanical aerating accomplished by an impeller orrotating paddles whirling the sand at
high speed towards the inner wall of casting. The rotating paddle consists of set of rods
each having number of combing fingers arranged radially.

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 MOULDING PROCESSES
According to method of preparation
• Hand Moulding.
• Machine Moulding.
• Floor moulding.
• Bench moulding.
FLOOR MOULDING
• Open sand moulding:
Eg: Weights, manhole covers, drain covers.
• One box moulding:

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BENCH MOULDING
It is preferred for small sized castings
Two box casting:
• It makes use of pair of moulding boxes, upper partbeing called cope and lower part is drag.
• The two parts are fitted with suitable clamping and locating arrangement.
• The clamping required to prevent the cope from lifting due to the pressure of molten
metal.
• The locating device is essential for the two partsto maintain proper alignment
all the times.
Three box moulding.
• Sometimes it is difficult to prepare mould with two boxes, then the mould can be made
in three boxes.

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Machine Moulding

1) Hand operated moulding machines

One or more operation such as ramming, pattern drawing are performed by machine which is
manually operated either by a hand lever or pedal control.

2) Power operated moulding machine

• The power operated moulding machines makes use of hydraulic or pneumatic action to
perform variousoperations during moulding processes.
• Three principle methods are employed to for ramming the sand.
➢ Squeezing
➢ Jolting
➢ Slinging

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Hand operated moulding Power operated moulding machine
machines

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 Types of Cores
1. BALANCED CORE
• The cores used in foundries are named according to their shapeand
position in the mould.

2. Cover Core
• When entire pattern is rammed in the drag and the core is
• required to be suspended from the top of mould a “cover core” may be employed.

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Department of Mechanical Engineering, MCE HASSAN
3. Hanging Core
• If the core hangs from the cope and does not have any support at the
bottom in drag, it is referred to as hanging core.

4. Wing core
• Wing core may be used when a hole or recess is to be obtained in the casting either
above or below the parting line.
• This type of core is necessitated when it is not possible to place the pattern in the mould
such that the recess can be cored directly.

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5. Ram up core
• Sometimes, the core is set with the pattern in the mould before the mould is rammed.
Such a core is called “ram up core”.

6. Kiss Core
• When the pattern is not provided with core prints and no seat is available as a rest of the core ,
the core is held in position between the cope and drag simply by the pressure of the cope. Such
core are termed “Kiss core”.
• They are excellent when number of holes required are required in casting and where dimensional
accuracy with regard to the relative location of holes is not important.

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Department of Mechanical Engineering, MCE HASSAN
 THANK YOU

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