FOUNDRY AND FORGING LAB

Syllabus

 Part A ( Sand Testing)  Compression. Tensile and shear

tests on universal sand testing
Testing of moulding and core sand
machine
 Permeability test
 Hardness tests
 Sieve analysis
 Clay content test
 Moisture content test
 Part B (Foundry Practice)
Use of foundry tools and other equipments
Preparation of moulds using two moulding
boxes

 Part C( Forging operations)

Preparing minimum three forged models
involving
upsetting, drawing and bending
operations. Estimation
of length of the raw material
 MANUFACTURING

“The Process of Converting Raw Materials

Into Products”
Manufacturing ?

 Manufacturing in its broadest sense is

the process of converting raw materials
in to useful products
 It includes
i) Design of the product
ii) Selection of raw materials and
iii)The sequence of processes
through which the product will be
manufactured
 Manufacturing Processes

Manufacturing Processes

Casting Machining Forming Joining

(Net shape ( Subtractive (Net shape ( Additive
primary process)
secondary process) secondary proces
secondary process)
 Casting
 Casting is the process of pouring molten metal
in to a mould cavity of required shape & size and
allowing for cooling

 It involves a series of operations

i) Pattern making
ii) Core making
iii) Mould making
iv) Melting
v) Pouring
vi) Cleaning
 Types of casting

Casting

onventional Methods Unconventional Methods

Green sand mould CO2 Moulding (Strong mould)
Dry sand mould Permanent (Metal mould)

Shell Moulding (Thinn mould)

Investment casting (Precision

Centrifugal ( without core)

Continuous Casting (Open)

Advantages & Disadvantages
Advantages Disadvantages

 Design flexibility  Lot of molten metal is

wasted in riser & gating
 Reduced costs  Casting may require
machining to remove
rough surfaces
 Dimensional accuracy

 Versatility in production
Machining

 Machining of metal involves forcing of cutting

tool through the excess material of the
workpiece.
 The excess material is progressively
separated from the workpiece in the form
of chips to get required shape
 Types of machining

Machining

Conventional Unconventional
Turning by lathe m/c’s EDM, ECM, EBM, LBM
Grinding by grinding m /c’s
Forming

 Shaping of a component by the application of

external forces
 Metal is deformed plastically under the
action of externally applied forces
 Types of forming

Forming

Based on working temp

Based on stress applied
Based on energy used

Cold Compression Conventional

Forging, rolling, drawing et
Hot Tension
Unconventional
Combined Explosive
forming,
Shear Electro
hydraulic
 Joining

 In engineering practice none of the product can

be made in a single process the products are
assembly of many individual parts
 Joining is a general term covering many process
like welding, brazing, soldering, riveting and
other mechanical fastening methods
 Types of joining
Joining

emporary fastening Permanent fastenin

Bolts & nuts Riveted

Screws Welding
Fusion
Solid state
Soldering
Brazing
Casting
 Casting is one of the oldest manufacturing
process and even today is the first step in
manufacturing most of the products
 It is based on the property of a liquid to take up
the shape of vessel containing it.
 Products ranging from a few mm to several m and
a few grams to several tons

Foundry is the place where metal is melted

and casting are produced

Similar to that of making ice cubes in a refrigerator

Casting Terms
 Pattern- replica of the part to be cast
 Molding material- material that is packed around
the pattern to provide the mold cavity
 Flask- rigid frame that holds the molding
aggregate
 Cope- top half of the pattern
 Drag- bottom half of the pattern
 Core- sand or metal shape that is inserted into
the mold to create internal features
 Casting Terms
 Mold cavity- combination of the mold material
and cores
 Riser-additional void in the mold that provides
additional metal to compensate for shrinkage
 Gating system- network of channels that delivers
the molten metal to the mold
 Pouring cup- portion of the gating system that
controls the delivery of the metal
 Sprue- vertical portion of the gating
system
 Runners- horizontal
 Parting line- separates the cope and
drag
Six Basic Steps of Casting
 Pattern making

 Core making

 Moulding

 Melting

 Pouring

 Cleaning & inspection

 The Pattern

A full‑sized model of the part, slightly enlarged to

account for shrinkage and machining allowances in
the casting

 Pattern materials:
 Wood - common material because it is easy to

work, but it warps

 Metal - more expensive to make, but lasts much

longer
 Plastic - compromise between wood and metal

 Plaster of paris

 Wax –precision casting

Types of Patterns
(a) solid pattern ( single piece)
(b) split pattern ( Two piece)
(c) match‑plate pattern
(d) cope and drag pattern
(e) Sweep pattern
(f) Skeleton pattern
Core in Mold
 A core consists of two portions: the body of the
core and one or more extensions (called prints)
 Cores are used to create internal cavities.
 Core is a separate entity placed in a mould to
produce a corresponding cavity – hole or
undercut – in the casting
 Cores for sand casting are manufactured by
packing specially prepared sand in core boxes
 Chaplets
Moulding
The cavity in the sand mold is formed by packing sand
around a pattern, then separating the mold into two
halves and removing the pattern
Major part of Moulding material in sand casting are
– 85-90% silica sand (SiO2)
– 3-7% bonding material e.g., clay cereal etc.
– 3-6% water
Requirements of molding sand are:
(e) Refractoriness

(f) Cohesiveness
(g) Permeability

(h) Collapsibility
Melting

• Furnaces most commonly used in foundries:

 − Cupolas

 − Direct fuel-fired furnaces

 − Crucible furnaces

 − Electric-arc furnaces

 − Induction furnaces
Pouring the Molten Metal

 For this step to be successful, metal

must flow into all regions of the mold,
most importantly the main cavity,
before solidifying
 Factors that determine success:
 Pouring temperature
 Pouring rate
 Turbulence
Sections of foundry
Sand
Sand additives
Metal

Sand mixing & preparation

Melting

Handling Moulding
molten metal

Pouring
Melting Section Moulding Section
Shaking out

Finishing
Heat treatment

Inspection & Testing

General layout of foundry
Foundry store

Melting
Furnaces
Grinding
Sand

Moulds ready for pouring

Muller

Inspection Bench Core

making
Preparation of sand mould

SAND CASTING
Before any casting can take place a wooden pattern is
made precisely. This is called pattern making and in
industry this is a very skilful job. Any inaccuracy at this
stage will result in the final cast being wrong or even
failing.

Drag is placed inverted on

the mould floor and pattern
is placed at the center of the
box
Preparation of sand mould

Special casting sand will soon

be packed around the pattern
for easy removal of pattern
from
parting powder is sprinkled
over and around it. It stops
the casting sand sticking to
the pattern and pulling away
with it when the pattern is
finally removed from the
Castingsand.
sand is then shaken through a
sieve (called riddled sand) so that only
fine particles fall around the pattern.
This is called facing sand and it must be
fine so that detail on the pattern shows
up on the final casting.
Preparation of sand mould

The drag is then packed with more

casting sand and then ram it down
firmly using a ramming tool. The tool
has two ends, one is cylindrical and is
used for general packing down of the
sand. The other end is quite pointed
and this can be used for packing sand
close up to the pattern.

When the drag is packed fully it is

levelled off (called ‘strickled off’)
using a straight steel bar.
Preparation of sand mould

The entire drag and its contents are then turned over
so that the base of the pattern can be seen

A top box called a ‘cope’ is then placed on top of the

drag and locating pins are put in position so that the
casting boxes cannot move sideways.
Preparation of sand mould

Sprue pins are positioned. One

usually on the back of the pattern
and the other to the side. These will
eventually provide an entrance and
exit for the molten aluminium when
it is poured into the sand.

The sand is packed/rammed into the cope in the same

way as the drag.
Preparation of sand mould

The top box (the cope) is then removed and if all is

well the cope with the sand inside should lift off the drag
(bottom box) without the sand falling out. A small ‘gate’
is cut below the position of one of the sprue pins. This
will help the molten metal to flow into the cavity left
by the mould. Small tools are available or can easily be
made to dig a variety of shapes in the casting sand. They
are similar to small trowels
Preparation of sand mould

The pattern is removed using a

‘spike’. Before removing the
pattern it is a good idea to gently
tap the spike so that it loosens the
pattern from the sand. It can then
be lifted away from the casting box
The cope (top casting
(drag). box) is placed back on top
of the drag and the locating pins put in position. Before
this is done vents can be created using a thin piece of
welding rod, pushing it through the sand . This allows
gases to escape once the molten metal is poured.
Preparation of sand mould
The molten metal is poured with great care. The molten
metal is poured down the hole left by the first sprue pin
(now called the ‘runner’). As it runs down the runner it
flows through the ‘gate’ cut by the trowel, into the cavity
left by the pattern and up the riser (the hole left by the
second sprue pin).

The casting should be left for at leastWhen

an hour before
removed
removal from the sand from the sand, the
runner and riser are
cut away and the
casting is ready for
machining
Sand Testing
Sand testing

 Each foundry should draw out a minimum test

programme which should be strictly followed for
control of the sand system
 Controlling quality of sand in a foundry is very
important as the quality of the casting depends on
the quality of the mould sand
 The quality of the mould and core depends on the
sand, binder, additives used & also on the
percentage of each of the constituents
 Sand testing provides clues for improving casting
quality
 Since molding sands and core sands are important in
foundry operations, their control and testing is
Testing of mould & core sand

 1)Preparation of standard test specimen

 2)Mould hardness test
 3)Core hardness test
 4)Moisture content test on foundry sand
 5)Sieve analysis
 6)Clay content test
 7)Permeability test
 8)Compression, shear test
 1)Preparation of standard test
specimen
 The standard specimen is prepared using
a standard sand rammer and specimen
tube accessories.The specimen is rammed
with three blows.
 The weight of the ram may be 63-72 N by
weight. The ram is dropped from a height of
50mm . The specimen is rammed with
three blows- This is the standard procedure.
 This operation that is ramming sand three
times compacts the sand to a standard
hardness
 2)Mould hardness test

 Mold surface hardness is the resistance

offered by the surface of a green sand mold
 An instrument for determining the mold
surface hardness shall measure the depth
of penetration in to the mold surface of a
plunger having a load applied at a 90º angle
3)Core hardness
to the mold surface test
Core hardness is the resistance offered by the
surface of a dry sand core
4)Moisture content test on
foundry sand
 In clay bonded sand some moisture is essential
to develop working strength.
 The influence of moisture may be harmful if
the proportion is not controlled within the
definite limits.
 The strength of a sand is also influenced by its
moisture content.
 It is therefore important to make certain that
the sand contains the correct percentage of
water
 Two methods i) simply by measuring the
weight difference between the green sand and
the dry sand, then calculating percentage of
moisture = (W1-W2)/W1X100
 ii) chemical method: by speedy moisture teller
 5)Sieve analysis

 The grain size is expressed by number

known as grain fineness number.
 For determination of grain fineness number
of a given sand sample, a standard sieve set
is used.
 The apparatus consists of eleven sieves
mounted one above the other.
 The shaker vibrates the sieve by motor
arrangement. So the sand placed at the top
sieve gets screened and get collected on
different sieves of different sizes depending
up on the size of the grain.
 The sieve system is vibrated for some
 6)Clay content test

 The necessary bonding strength for mouliding

sand is clay, so that after ramming the mould
doesn’t loose its shape.
 However as the quantity of the clay is increased,
the permeability of the sand decreases.
 Clay is responsible for bonding the sand
particles together.
 It influences strength permeability and other
moulding sand properties.
 Known quantity moulding sand is taken and
washed with water and NaOH. Then dried and
reweighed
 The weight of clay is given by the difference
7)Permeability test
 Gases and water vapour are released in the
mould cavity by the molten metal and sand.
 If they do not find opportunity to escape
completely through the mould, they will get
entrapped and form gas holes or pores in the
casting
 The sand must therefore be sufficiently porous to
allow the gases and water vapour to escape out.
 This property of sand is referred to as
permeability.
 The apparatus has an arrangement which allows
controlled amount of air to pass through a sand
sample and the time taken for all the air to pass
through the same is measured
Permeability no = VH/PAT V= volume of air,
H=height, P=pre
 8)Compression, shear test
 Strength tests have been devised to test the
holding power of various bonding materials in
green and dry sand
 The strength is governed by the amount of
bonding materials
 The universal sand strength testing machine is
used to test the strength of sand
 Compressive strength, shear strength, tensile
stregth of the moulding sand is done on this
universal
G sandGstrength machine by replacing
the different grippers
 Test machine gives direct reading
 Hand tools used in moulding

 In hand moulding processes, all the moulding

operations, such as ramming the sand, placing and
drawing the pattern, turning over the moulding
boxes, etc, are performed by hand
 A number of hand tools which are used by the

molder to perform above mentioned operations are

shown below
1)Bellow : A bellow is used to blow loose sand
particles from the pattern and the mold cavity
Hand tools used in moulding

2) Lifter or cleaner: It lifts dirt or loose sand from

the mold. It is used for repairing and finishing the
sand mold cavity

3)Heart & square: It is employed for finishing the

mould cavity

4)Hand rammer:It is used for ramming the sand in

molds
Hand tools used in moulding

5)Floor rammer: It is larger in size as compared to

hand rammer. It is used for floor molding
6)Hand riddle:It consists of wire mesh fitted into a
circular wooden frame. It is used for cleaning,
removing foreign matter from sand

7)Sprue pin: It is tapered wooden rod which is

placed in the
cope to make sprue cavity.
Hand tools used in moulding

8) Trowels: used to finish flat surfaces of the mould,

cut ingates, make joints or repair moulds

9)Smoothers and corner slics:They are employed to

repair and finish corners, edges, round and flat
surfaces
Hand tools used in moulding

9)Gate cutter: it is a shaped piece of sheet metal . It

is used to cut the gate

10)Shovel : used to transfer moulding sand from

store to place of use. Also used to mix and
temper the moulding sand
Thank u