MODULE -1

FOUNDRY PROCESS

Ramesh K Nayak, Mechanical Engineering, KIIT University

Courses of Studies: Pattern making, pattern materials, allowances, types of pattern, sand casting types, sand cast, moulding procedure, types of sand, gates and riser (basic design considerations) essential properties of moulding

sand,core making, types of cores. Essential qualities, core mixtures and

binder sand testing, Mould and core hardness test, fineness test, clay content test, permeability test, moisture content test, sand conditioning.

Basic idea about cupolas and other melting furnaces. Melting and
pouring procedures for cast Iron, Steel and nonferrous castings. Cleaning ofcasting and defects in casting, die casting. Precision investment casting, shell moulds, centrifugal casting processes,permanent moulds casting, dies casting.

CASTING
The solidified metal, which is taken out of the mould is called Casting. A plant where the casting are made is called a Foundry. The Foundry is derived from Latin word fundere meaning melting and pouring

Ramesh K Nayak, Mechanical Engineering, KIIT University

Various Features of a sand mold

Pouring basin(cup) Open riser Vent

Core Sand

Sprue

Flask

Cope

Blind Riser

Sand

Parting line

choke
Drag Mold Cavity Runner Sand

Ramesh K Nayak, Mechanical Engineering, KIIT University

NOMENCLATURE

Fig-1

Fig-2

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Flow Chart for Sand Casting Process

1. Make the pattern ( Pattern may be metal/wood/plastic)

2. Prepare the mould and necessary core

3. Clamp the core properly with proper placing of cores

4. Melt the metal/alloys

5. Pour the molten metal into the molud

6. Allow the molten metal to cool and solidify

(Typically to 1 Hr).
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7. Remove the casting from the mould is called shake out

8. Clean and finish the casting ( Fettling)

9. Test and inspect the casting

10. Remove the defects if any and possible

( Salvaging the Casting)

11. Stress relieve the casting by heat-tratment

12. Again inspect the Casting

13. Now the Casting is ready to use
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Casting
Advantages
Net Shape or Near-Net Shape Process Advantages:
Product is finished right out of mold. High complexity with few steps (usually) Casting can be used to create complex pan geometries, including both external and internal shapes No machining waste

Casting process can be performed on any metal that can be heated to the liquid

Disadvantages:
Expensive and time-consuming patterns/molds/dies
Solidification issues: shrinkage, porosity, low strength, brittleness Some methods require many steps (e.g., Investment casting)
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Classification of Casting Process

1. Expandable Mould Casting ( sand/refractory mould Casting) 2. Permanent Mould casting ( Gravity die/high/low pressure die casting) 3. Semi-permanent Mould Casting ( Graphite mould Casting)

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Open riser Vent Core Sand

Pouring basin(cup)

Flask Cope Blind Riser Sand Parting line choke Drag Runner Ramesh K Nayak, Mechanical Engineering, gate KIIT University Mold Cavity Sand 13

 A core is made up sand that is inserted into the mold to produce internal features of a casting, such as holes

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WHAT WE NEED FOR SAND CASTING ? 1. Pattern for desire shape of the casting 2. Mould Box 3. Core Box 4. Sand and binders 5. Sand mixing equipments 6. Melting furnaces 7. Ladles 8. Man power 9. Knock out 10.Fettling 11.Inspection 12.Supply
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Basic materials & equipment for 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

Top and bottom mold forms (made of metal, open at top and bottom)

Rammer (tool to compact the sand;

often a pressing machine is used)

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Basic summary of the sand casting process. . .

First of all, mix the sand.

THEN

MOLDING:
Sand placed into bottom mold form & compacted

2 MOLDING:
Pattern placed into mold

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3 MOLDING:
Add the top mold form

A tube or pipe provides a path to pour the metal in

Pattern is still inside!

MOLDING: Fill top form with compacted sand.

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MOLDING: Take the top mold off and remove pattern & pipe

In the middle of the sand is a cavity shaped like the pattern! Pouring hole

MOLDING: Replace the top mold and fasten securely!

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8 7
CASTING: Pour the metal (container is filled from furnace immediately before you are ready to pour)

Wait for the metal to cool (minutes to days, depending on the size of the casting)

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A copy of the pattern has now been made in metal

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CLEANING. Sand is cleaned off the part (SAND BLAST)

SHAKE OUT: Break apart the two halves of the mold & take out the part usually requires vibrating or striking the mold to break apart the sand

10 Mold forms are reused

Sand is broken up, 11 screened to remove debris and clumps, and sent for remixing

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Pattern
A Pattern is a element used for making cavities in the mould, into which molten metal poured to produce casting.

It is not essentially the replica of a casting , because

it is slightly larger than casting because of various allowances like shrinkage and machining allowances
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What should be the Pattern Materials ( Metal ,Wood and Polymers/plastics)

1. Able to make the desire shape of the casting

2. Cheap and readily available

3. Simple in design for ease manufacturing 4. Light weight 5. High strength and durability 6. Definite service life ( Dimension should not change with use) 7. Good wear resistance and surface finish 8. Able to withstand rough handling

Wood is widely used as pattern. Why?

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What is Pattern Allowances ?

The difference in dimension between casting and pattern is
call pattern allowances. It is divided into two types 1. Shrinkage allowance 2. Machining allowance Shrinkage Allowance It is assumed that the casting shrinks linearly during solidification process . The following are the typical shrinkage allowances for

different metal castings. C.I, Malleable Iron = 10mm/m Brass , Cu, Al = 15 mm/m Steel = 20mm/m Zinc, Lead = 25mm/m
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Machining Allowance
Material Cast
Al Alloys Brass, Bronze C.I. Steel Overall length of the external Surfaces, cm 0 to 30 1.6 1.6 2.4 30 to 60 3.2 3.2 3.2 60 to 105 3 3 4.8 105t0 150 3.8 4.8 6.4

3.2

4.8

9.6

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Why Pattern Should have Draft or Tapper?

Generally the draft angle for patterns is 1-3 o depending upon the method of moulding and size of the pattern
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More no of features can be mounted in a plate, which is the reference for other side

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A typical match plate pattern used in sand casting

Cope side

plate

Drag side

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Sprue

In gates

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Moulding and Type of Moulds

1. Green Sand Mould ( Silica Sand, SiO2, Clay(Binder), Water)- because of its wetness)

2. Dry Sand Mould

( Green sand + Additives (1-2% cereal floor and 1-2%pitch)+ baked in an oven at 110 to 260 oC for 5-6 hrs) It has better

strength than green sand mold and used for larger casting)
3. Skin-Dry Sand Mould Casting (Surface of the mould is dry sand mold and rest of the mold is green sand)
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4. Loam Sand Mould Casting

( Fine Sand + Finely ground clay ( 50 %)+ Graphite + reinforcement)- Gives
very good strength and used for very heavy and large parts like Engine bodies, machine tool beds)

5. Cemented bonded Moulds

Sand + cement( 10-15%)as binder- It is also called pit molding and used for large steel casting.

6. CO2 Moulding
( Sodium silicate ( Na2O.xSiO2) as binder instead of clay. CO2 has passed through the mould to achive the strength of the mold) Na2O.xSiO2 + n H2O + CO2 = Na2 CO3 + x SiO2. n (H2O) This reaction is very rapid even within 2 minutes the sand mold gets proper strength

7. Resin- Bonded Sand Mold

( Green Sand Mold + Thermosetting Resin(Polymers) or oils( Soybean) 47 KIIT University
Ramesh K Nayak, Mechanical Engineering,

Molding Sand Constituents

Sand + Binders ( Clay) + Moisture ( Water)+ Additives

SAND
Molding sand contains 80-90 % silica Size of silica particles are in granular form and grain size vary in size from few micrometers to millimeters. It has very good refractoriness , chemical resistivity and

permeability

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Sand + Binders ( Clay) + Moisture ( Water) + Additives

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Sand Mold Binders

1. Fire clay It is a refractory clay usually found in the coal measures

2. Kaolinite - Al2O3 . 2 SiO2 . 2H2O- decaying of granites

Melting point is 1750-1785 oC 3. Illite - K2O . Al2O3. SiO2 . H2O decaying of mica rocks 4. Bentonite - MgO . Al2O3. SiO2 . H2O melting Point 1250-1300 oC 5. Portland Cement and Sodium Silicate

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Molding Sand Constituents

Sand + Binders ( Clay) + Moisture ( Water) + Additives

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Sand + Binders ( Clay) + Moisture ( Water)+ Additives

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Types of Molding Sand

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Characterization of sand Mold

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Permeability or Porosity Plasticity and flow ability Adhesiveness Cohesiveness Green strength Dry Strength Hot strength Refractoriness Collapsibility Co-efficient of thermal expansion Fineness Bench life Chemical Reactivity
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Scratch Hardness Test

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V = Volume of Air = 2000cc

h= Height of the sand specimen = 5.08 cm

P = Air Pressure = 10 gm/cm2 a = Cross- sectional area of the specimen t = Time taken to pass the 2000cc air in minutes Permeability Number = 50.128/t

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Fluidity :
Spiral mold test for fluidity, in which fluidity is measured as the length of the spiral channel that is filled by the molten metal prior to solidification

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Typical Molding Sand Composition ( By Weight)

For Steel Casting

Green Sand Molding Facing Sand

Silica Sand = 95 % Bentonite = 4 %

Cereal type binder = 1 %

Water = 3 4 %

Backing Sand
Floor Sand = 95 % Bentonite = 5 % Water = 2.5 4 %
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For Steel Casting Dry Sand Molding Facing Sand ( Heavy section Casting)
Silica Sand = 70 %

Silica Floor = 23 %
Bentonite = 5.5 % Molaases = 1 .5% Water = 6 7 %

Light Section Casting

Silica Sand = 70 % ,Silica Floor = 20 %,Bentonite = 4 % Molaases = 1 % Water = 6 7 %

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CORE & CORE MAKING

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SAND MIXER/MULLER

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Melting Furnaces

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Cupola

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Construction of Cupola

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Zones in Cupola

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Working of Cupola

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Electric Arc Furnace

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Induction Furnace

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CASTING PROCESSES EXPENDABLE MOLD CASTING In expendable mold casting, the mold is destroyed to remove the casting and a new mold is required for each new casting. Sand Casting The next figure illustrates the basic production steps in sand casting:
Core Making (if Needed) Pattern Making

Sand

Preparation of sand

Mold making

Raw Material

Melting

Pouring

Solidification and cooling

Removal of Sand Mold

Cleaning and Inspection

Finished Casting
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Ramesh K Nayak, Mechanical Engineering, KIIT University