UNIVERSITY INSTITUTE OF ENGINEERING

Bachelor of Engineering (Mechanical Engineering)

Manufacturing Techniques (MET-204)
By: Dr. Harsimran Singh Sodhi
Lecture no. 7

CASTING PROCESS DISCOVER . LEARN . EMPOWER

 Topics Covered

1. Characteristics required in moulding materials.

2. Various molding equipment

 Various Characteristics Required in Molding Materials

• Refractoriness

• Permeability

• Green Strength

• Dry Strength

• Hot Strength

• Collapsibility
 Moulding Sand Composition

• Base sand

• Binder

• Moisture
 2.11 Various Molding Equipments
Shovel Riddle Rammers

Fig 1: a. Shovel b. Riddle c. Rammers

Trowels Strike-Off Bar

Vent Wire

d. Rammers e. Strike off Bar f. Vent Wire

(image Source:yourarticlelibrary.com)
 2.11 Various Molding Equipments
Lifter Swab
Slick

g. Lifter h. Slick i. Swab

Bellow Sprue Cutter

Gate Cutter

m. Sprue Cutter
j. Bellow k. Gate Cutter

(image Source:yourarticlelibrary.com)
 2.11 Various Molding Equipments
Methods of moulding

• Bench molding
• Molding done on bench of suitable height
• Floor molding
• Molding is done on foundry floor
• Foundry floor acts as drag
• Used for medium sized and large castings
• Pit Molding
• Molding is done in pit instead of flask
• Machine molding
Molding machine performs which are normally performed by hand i.e. ramming , rolling ,
forming of gate , removal of pattern
• Sweep molding
• Molding is done by sweep pattern
 2.11 Various
Important CAMS Molding Equipments
Moulding Machines

Jolt machine
• Used for ramming of sand in the mould
• It consists of cylinder & piston on top of which a table is attached
• Flask & pattern with sand over it is placed on the table
• These machines ram the sand harder at pattern face with decreasing hardness towards
back of mould
 2.11CAMS
Important Various Molding Equipments
Squeezing machine
• Ramming of sand is also done by squeezing machine.
• A plate slightly smaller than inside dimensions of molding flask is fitted into the flask.
• Uniform pressure is applied on the plate.
• Sand nearest to plate is rammed hardest and softest near the pattern surface.
 2.11CAMS
Important Various Molding Equipments

Jolt – Squeeze machine

• Combination of jolt and squeezing machine

• It over comes draw back of both the machines
• It produces uniform hardness throughout the mould
• The flask is assembled with match plate between cope and drag
• Sand is rammed into drag by jolting action
• Now assembly is turned over
• Then cop is filled with sand and pressure plate is placed on top of flask
• Now sand is rammed by squeezing
 2.12 Core

A core is a shape/ form, used in casting and molding processes to produce internal
cavities. The core is normally a disposable item that is destroyed to get it out of the
piece
 2.12 Core

Requirements of Core

1.Green Strength: In the green condition there must be adequate strength for handling.
2. In the hardened state it must be strong enough to handle the forces of casting; therefore the compression
strength should be 0.69 to 2.07 MPa.
3. Permeability must be very high to allow for the escape of gases.
4. Collapsibility: As the casting or molding cools the core must be weak enough to break down as the
material shrinks. Moreover, they must be easy to remove during shakeout.
5. Good refractoriness is required as the core is usually surrounded by hot metal during casting or molding.
6. A smooth surface finish.
7. Minimum generation of gases during metal pouring.
2.13 Functions of Cores
Functions of Cores

1. For making internal cavities

2. May form a part of green sand mold
3. For providing external undercuts.
4. To improve mold surface
5. To achieve deep recess in castings
6. To strengthen molds
7. To form gating system of large castings
 2.14 Characteristics of Cores materials

1. Sufficient strength to support itself and to get handled without breaking.

2. High permeability
3. Smooth surface
4. High refractoriness
5. High collapsibility
 2.14 Characteristics of Cores materials

Core Materials:-
1. Granular Refractory materials: silica sand, zircon, olivine, carbon etc.
2. Core Binders: Core oil (vegetable, mineral oil), starch, dextrin, molasses, wood
flour, fire clay, bentonite, Portland cement etc.
3. Water:- 2-7 %
4. Additives
2.15 Core Preparation

Core Preparation

1. Core Sand Preparation

2. Making the cores
3. Baking the Cores
4. Finishing of cores
5. Setting the cores
 2.15 Core Preparation
Chaplets
Chaplets are used to support the cores which tend to sag or sink. These are normally rigid metal
pieces. If chaplets are not used , then cores will be displaced and we will get defective casting

a) Core held in place in the mold cavity by chaplets, (b) possible chaplet design, (c) casting with internal
cavity
2.15 Core Preparation
Different type of chaplets
 2.16 Types of Cores:-

Types of Cores :-

Cores may be categorized according to :

1. State of condition of core – Green sand or dry sand core
2. Nature of Core materials employed- Oil bonded core, Resin bonded cores, Sodium silicate cores
3.Shape and Position of core :-
A. Horizontal core
B. Vertical core
C. Hanging or cover core
D. Balanced Core
E. Drop/stop off core
F. Ram up core
 2.16 Types of Cores:-

According to the position of core in mould

Horizontal core
• This is place horizontally in mould
• This is most commonly used
• It is supported in mould at both ends formed by pattern
• This is usually positioned along parting line
 2.16 Types of Cores:-
Vertical core
• This is place vertically in mould
• Two ends of core rest on core seats in cope and drag
• The maximum portion of core is supported in the drag
2.16 Types of Cores:-
Balance core
• This is used for producing blind holes in the casting
• This is basically horizontal core supported at one end
• Second end remains free in mould
2.16 Types of Cores:-
Hanging core
• This core hangs vertically in the mould
• This has no support in bottom
•This type of core usually requires a hole through the upper part to permit the metal to reach the
mould.
THANK YOU