11

CHAPTER

FOUNDRY TOOLS AND EQUIPMENTS

11.1 INTRODUCTION
There are large number of tools and equipments used in foundry shop for carrying out
different operations such as sand preparation, molding, melting, pouring and casting. They
can be broadly classified as hand tools, sand conditioning tool, flasks, power operated equipments,
metal melting equipments and fettling and finishing equipments. Different kinds of hand tools
are used by molder in mold making operations. Sand conditioning tools are basically used for
preparing the various types of molding sands and core sand. Flasks are commonly used for
preparing sand moulds and keeping molten metal and also for handling the same from place
to place. Power operated equipments are used for mechanizing processes in foundries. They
include various types of molding machines, power riddles, sand mixers and conveyors, grinders
etc. Metal melting equipment includes various types of melting furnaces such as cupola, pit
furnace, crucible furnaces etc. Fettling and finishing equipments are also used in foundry
work for cleaning and finishing the casting. General tools and equipment used in foundry are
discussed as under.

11.2 HAND TOOLS USED IN FOUNDRY SHOP

The common hand tools used in foundry shop are fairly numerous. A brief description of the
following foundry tools (Fig. 11.1) used frequently by molder is given as under.

Hand riddle
Hand riddle is shown in Fig. 11.1(a). It consists of a screen
of standard circular wire mesh equipped with circular wooden
frame. It is generally used for cleaning the sand for removing
foreign material such as nails, shot metal, splinters of wood
etc. from it. Even power operated riddles are available for
riddling large volume of sand.
Fig. 11.1 (a)
Shovel
Shovel is shown in Fig. 11.1(b). It consists of an steel pan fitted with a long wooden handle.
It is used in mixing, tempering and conditioning the foundry sand by hand. It is also used for
moving and transforming the molding sand to the container and molding box or flask. It
should always be kept clean.
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Rammers
Rammers are shown in Fig. 11.1(c). These are required for striking the molding sand mass
in the molding box to pack or compact it uniformly all around the pattern. The common forms
of rammers used in ramming are hand rammer, peen rammer, floor rammer and pneumatic
rammer which are briefly described as

Fig. 11.1 (b) Fig. 11.1 (c)

(i) Hand rammer

It is generally made of wood or metal. It is small and one end of which carries a wedge
type construction, called peen and the other end possesses a solid cylindrical shape known as
butt. It is used for ramming the sand in bench molding work.
(ii) Peen rammer
It has a wedge-shaped construction formed at the bottom of a metallic rod. It is generally
used in packing the molding sand in pockets and comers.
(iii) Floor rammer
It consists of a long steel bar carrying a peen at one end and a flat portion on the other.
It is a heavier and larger in comparison to hand rammer. Its specific use is in floor molding
for ramming the sand for larger molds. Due to its large length, the molder can operate it in
standing position.
(iv) Pneumatic rammers
They save considerable time and labor and are used for making large molds.
Sprue pin
Sprue pin is shown in Fig. 11.1(d). It is a tapered rod of wood or
iron which is placed or pushed in cope to join mold cavity while the
molding sand in the cope is being rammed. Later its withdrawal from
cope produce a vertical hole in molding sand, called sprue through
which the molten metal is poured into the mould using gating system.
It helps to make a passage for pouring molten metal in mold through
gating system

Fig. 11.1 (d)

 Foundry Tools and Equipments 199

Strike off bar

Strike off bar (Fig. 11.1(e)) is a flat bar having straight edge and is made of wood or iron.
It is used to strike off or remove the excess sand from the top of a molding box after
completion of ramming thereby making its surface plane and smooth. Its one edge is made
beveled and the other end is kept perfectly smooth and plane.

Fig. 11.1 (e)

Mallet
Mallet is similar to a wooden hammer and is generally as used in carpentry or sheet
metal shops. In molding shop, it is used for driving the draw spike into the pattern and then
rapping it for separation from the mould surfaces so that pattern can be easily withdrawn
leaving the mold cavity without damaging the mold surfaces.
Draw spike
Draw spike is shown Fig. 11.1(f). It is a tapered steel rod having a loop or ring at its one
end and a sharp point at the other. It may have screw threads on the end to engage metal
pattern for it withdrawal from the mold. It is used for driven into pattern which is embedded
in the molding sand and raps the pattern to get separated from the pattern and finally draws
out it from the mold cavity.

Fig. 11.1 (f) Fig. 11.1 (g)

Vent rod
Vent rod is shown in Fig. 11.1(g). It is a thin spiked steel rod or wire carrying a pointed
edge at one end and a wooden handle or a bent loop at the other. After ramming and striking
off the excess sand it is utilized to pierce series of small holes in the molding sand in the cope
portion. The series of pierced small holes are called vents holes which allow the exit or escape
of steam and gases during pouring mold and solidifying of the molten metal for getting a
sound casting.
Lifters
Lifters are shown in Fig. 11.1(h, i, j and k). They are also known as cleaners or finishing
tool which are made of thin sections of steel of various length and width with one end bent
200 Introduction to Basic Manufacturing Processes and Workshop Technology

at right angle. They are used for cleaning, repairing and finishing the bottom and sides of
deep and narrow openings in mold cavity after withdrawal of pattern. They are also used for
removing loose sand from mold cavity.

Fig. 11.1 (h) Fig. 11.1 (i)

Fig. 11.1 (j) Fig. 11.1 (k)

Trowels
Trowels are shown in Fig. 11.1(l, m and n). They are utilized for finishing flat surfaces and
joints and partings lines of the mold. They consist of metal blade made of iron and are equipped
with a wooden handle. The common metal blade shapes of trowels may be pointed or contoured
or rectangular oriented. The trowels are basically employed for smoothing or slicking the
surfaces of molds. They may also be used to cut in-gates and repair the mold surfaces.

Fig. 11.1 (l) Fig. 11.1 (m)

Fig. 11.1 (n)

Slicks
Slicks are shown in Fig. 11.1(o, p, q, and r). They are also recognized as small double
ended mold finishing tool which are generally used for repairing and finishing the mold
surfaces and their edges after withdrawal of the pattern. The commonly used slicks are of the
types of heart and leaf, square and heart, spoon and bead and heart and spoon. The
nomenclatures of the slicks are largely due to their shapes.
 Foundry Tools and Equipments 201

Fig. 11.1 (o) Fig. 11.1 (p)

Fig. 11.1 (q) Fig. 11.1 (r)

Smoothers
Smothers are shown in Fig. 11.1(s and t). According to their use and shape they are
given different names. They are also known as finishing tools which are commonly used for
repairing and finishing flat and round surfaces, round or square corners and edges of molds.

Fig. 11.1 (s) Fig. 11.1 (t)

Swab
Swab is shown in Fig. 11.1(u). It is a small hemp fiber brush used for
moistening the edges of sand mould, which are in contact with the pattern
surface before withdrawing the pattern. It is used for sweeping away the
molding sand from the mold surface and pattern. It is also used for coating
the liquid blacking on the mold faces in dry sand molds.
Spirit level Fig. 11.1 (u)
Spirit level is used by molder to check whether the sand bed or molding box is horizontal
or not.
Gate cutter
Gate cutter (Fig. 11.1(v)) is a small shaped piece of sheet metal commonly used to cut
runners and feeding gates for connecting sprue hole with the mold cavity.

Fig. 11.1 (v)

Gaggers
Gaggers are pieces of wires or rods bent at one or both ends which are used for reinforcing
the downward projecting sand mass in the cope are known as gaggers. They support hanging
202 Introduction to Basic Manufacturing Processes and Workshop Technology

bodies of sand. They possess a length varying from 2 to 50 cm. A gagger is always used in
cope area and it may reach up to 6 mm away from the pattern. It should be coated with clay
wash so that the sand adheres to it. Its surface should be rough in order to have a good grip
with the molding sand. It is made up of steel reinforcing bar.
Spray-gun
Spray gun is mainly used to spray coating of facing materials etc. on a mold or core
surface.
Nails and wire pieces
They are basically used to reinforce thin projections of sand in the mold or cores.
Wire pieces, spring and nails
They are commonly used to reinforce thin projections of sand in molds or cores. They
are also used to fasten cores in molds and reinforce sand in front of an in-gate.
Bellows
Bellows gun is shown in Fig. 11.1(w). It is hand operated leather made device equipped
with compressed air jet to blow or pump air when operated. It is used to blow away the loose
or unwanted sand from the surfaces of mold cavities.

Fig. 11.1 (w)

Fig. 11.1 (a–w) Common hand tools used in foundry

Clamps, cotters and wedges

They are made of steel and are used for clamping the molding boxes firmly together
during pouring.

11.3 FLASKS
The common flasks are also called as containers which are used in foundry shop as mold
boxes, crucibles and ladles.

1. Moulding Boxes
Mold boxes are also known as molding flasks. Boxes used in sand molding are of two types:
(a) Open molding boxes. Open molding boxes are shown in Fig. 11.2. They are made with
the hinge at one corner and a lock on the opposite corner. They are also known as snap
molding boxes which are generally used for making sand molds. A snap molding is made of
wood and is hinged at one corner. It has special applications in bench molding in green sand
work for small nonferrous castings. The mold is first made in the snap flask and then it is
 Foundry Tools and Equipments 203

removed and replaced by a steel jacket. Thus, a number of molds can be prepared using the
same set of boxes. As an alternative to the wooden snap boxes the cast-aluminum tapered
closed boxes are finding favor in modern foundries. They carry a tapered inside surface which
is accurately ground and finished. A solid structure of this box gives more rigidity and
strength than the open type. These boxes are also removed after assembling the mould.
Large molding boxes are equipped with reinforcing cross bars and ribs to hold the heavy mass
of sand and support gaggers. The size, material and construction of the molding box depend
upon the size of the casting.

Hinge

Fig. 11.2 Open molding box

(b) Closed molding boxes. Closed molding boxes
are shown in Fig. 11.3 which may be made of wood,
cast-iron or steel and consist of two or more parts. Cope
The lower part is called the drag, the upper part the
cope and all the intermediate parts, if used, cheeks.
All the parts are individually equipped with suitable
means for clamping arrangements during pouring.
Wooden Boxes are generally used in green-sand
molding. Dry sand moulds always require metallic
boxes because they are heated for drying. Large and
Drag
heavy boxes are made from cast iron or steel and
Lugs
carry handles and grips as they are manipulated by
cranes or hoists, etc. Closed metallic molding boxes
Fig. 11.3 Closed rectangular
may be called as a closed rectangular molding box
molding box
(Fig. 11.3) or a closed round molding box (Fig. 11.4).

2. Crucible
Crucibles are made from graphite or steel shell lined with suitable refractory material like
fire clay. They are commonly named as metal melting pots. The raw material or charge is
broken into small pieces and placed in them. They are then placed in pit furnaces which are
coke-fired. In oil- fired tilting furnaces, they form an integral part of the furnace itself and
the charge is put into them while they are in position. After melting of metals in crucibles,
they are taken out and received in crucible handle. Pouring of molten is generally done
directly by them instead of transferring the molten metal to ladles. But in the case of an oil-
fired furnace, the molten metal is first received in a ladle and then poured into the molds.
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Fig. 11.4 Closed round molding box

3. Ladle
It is similar in shape to the crucible which is also made from graphite or steel shell lined with
suitable refractory material like fire clay. It is commonly used to receive molten metal from
the melting furnace and pour the same into the mold cavity. Its size is designated by its
capacity. Small hand shank ladles are used by a single foundry personal and are provided with
only one handle. It may be available in different capacities up to 20 kg. Medium and large
size ladles are provided with handles on both sides to be handled by two foundry personals.
They are available in various sizes with their capacity varying from 30 kg to 150 kg. Extremely
large sizes, with capacities ranging from 250 kg to 1000 kg, are found in crane ladles. Geared
crane ladles can hold even more than 1000 kg of molten metal. The handling of ladles can
be mechanized for good pouring control and ensuring better safety for foundry personals
workers. All the ladles consist of an outer casing made of steel or plate bent in proper shape
and then welded. Inside this casing, a refractory lining is provided. At its top, the casing is
shaped to have a controlled and well directed flow of molten metal. They are commonly used
to transport molten metal from furnace to mold

11.4 POWER OPERATED EQUIPMENTS

Power operated foundry equipments generally used in foundries are different types of molding
machines and sand slingers, core making, core baking equipment, power riddles, mechanical
conveyors, sand mixers, material handling equipment and sand aerators etc. Few commonly
used types of such equipments are discussed as under.

11.4.1 Moulding Machines

Molding machine acts as a device by means of a large number of co-related parts and
mechanisms, transmits and directs various forces and motions in required directions so as to
help the preparation of a sand mould. The major functions of molding machines involves
ramming of molding sand, rolling over or inverting the mould, rapping the pattern and
withdrawing the pattern from the mould. Most of the molding machines perform a combination
of two or more of functions. However, ramming of sand is the basic function of most of these
machines. Use of molding machine is advisable when large number of repetitive castings is
to be produced as hand molding may be tedious, time consuming, laborious and expensive
comparatively.
 Foundry Tools and Equipments 205

11.4.2 Classification of Moulding Machines

The large variety of molding machines that are available in different designs which can be
classified as squeezer machine, jolt machine, jolt-squeezer machine, slinging machines, pattern
draw machines and roll over machines. These varieties of machines are discussed as under.
11.4.2.1 Squeezer machine
These machines may be hand operated or power operated. The pattern is placed over the
machine table, followed by the molding box. In hand-operated machines, the platen is lifted
by hand operated mechanism. In power machines, it is lifted by the air pressure on a piston
in the cylinder in the same way as in jolt machine. The table is raised gradually. The sand
in the molding box is squeezed between plate and the upward rising table thus enabling a
uniform pressing of sand in the molding box. The main advantage of power operated machines
in comparison hand operated machines is that more pressure can be applied in power operated.
11.4.2.2 Jolt machine
This machine is also known as jar machine which comprises of air operated piston and
cylinder. The air is allowed to enter from the bottom side of the cylinder and acts on the
bottom face of the piston to raise it up. The platen or table of the machine is attached at the
top of the piston which carries the pattern and molding box with sand filled in it. The upward
movement of piston raises the table to a certain height and the air below the piston is
suddenly released, resulting in uniform packing of sand around the pattern in the molding
box. This process is repeated several times rapidly. This operation is known as jolting technique.
11.4.2.3 Jolt-squeezer machine
It uses the principle of both jolt and squeezer machines in which complete mould is
prepared. The cope, match plate and drag are assembled on the machine table in a reverse
position, that is, the drag on the top and the cope below. Initially the drag is filled with sand
followed by ramming by the jolting action of the table. After leveling off the sand on the upper
surface, the assembly is turned upside down and placed over a bottom board placed on the
table. Next, the cope is filled up with sand and is rammed by squeezing between the overhead
plate and the machine table. The overhead plate is then swung aside and sand on the top
leveled off, cope is next removed and the drag is vibrated by air vibrator. This is followed by
removal of match plate and closing of two halves of the mold for pouring the molten metal.
This machine is used to overcome the drawbacks of both squeeze and jolt principles of
ramming molding sand.
11.4.2.4 Slinging machines
These machines are also known as sand slingers and are used for filling and uniform
ramming of molding sand in molds. In the slinging operations, the consolidation and ramming
are obtained by impact of sand which falls at a very high velocity on pattern. These machines
are generally preferred for quick preparation of large sand moulds. These machines can also
be used in combination with other devices such as, roll over machines and pattern draw
machines for reducing manual operations to minimum. These machines can be stationary and
portable types. Stationary machines are used for mass production in bigger foundries whereas
portable type machines are mounted on wheels and travel in the foundry shop on a well
planned fixed path. A typical sand slinger consists of a heavy base, a bin or hopper to carry
sand, a bucket elevator to which are attached a number of buckets and a swinging arm which