VIIT

MOULD PREPARAT10H
THEORY
INTRODUCTION:
practice deals with the process of making castings in
moulds, formed in
ndry
Cner sand or some other material the process involves the operations of pattern makine
preparation, molding, melting of metals, pouring in moulds, cooling shank-ou
rettling, heat treatment, finishing and inspection.

MOLDINGis SAND
the
Sand material used in a foundry. The principal ingredients
or
principal
molding sands are: 1) Silica sand, 2) clay sand, 3) moisture. Clay impacts the necessary

bonding strength to the molding sand. Moisture when added in correct proportion
and binders are also added to
provides the bonding action to the clay. Special additivesSilica sand can withstand very
develop certain desired properties to the molding sands.
high temperatures and doesn't react with the molten metal
Natural molding sand is either aviailable in river beds or dug from pits. They
of clay and are used as received, with the addition of
water, The appreciable
possess an amount
percentage of clay in this sand is around 20%. It needs 5 to 8%% of water for

making moulds.
other materials to silica
Synthetic sands prepared by adding clay, water and
are
which are not
sand, so that the desired strength and bonding properties
are achieved,
like permeability
possessed by natural sands. These sands have better casting properties
and refractoriness and are suitable for making heavy castings.
binders in
Clay is naturally binder, There are three types of synthetic
available
use. These are: i) Clay type binders, Ex: Bentonite; ii) Organic
binders, Ex: Resins and
molding done with green sand,
iii) Inorganic binders, Ex: Sodium silicate. Most of thecontent
is
10% clay to give it sufficient bond.
i.e., sand containing 6 to 8 % moisture and
Green sand molds are used for pouring the less time to prepare.

silica sand, is used to keep the

green
Parting sand, which is clay free, fine-grained
sand from sticking to the pattern and also to prevent
the cope and drag from clinging.
This is silica sand mixed with core oil and other
Core sand is used for making cores.

additives.

TYPES OF PATTERNS:
a suitable=
replica of the desired casting, which when packed in
A pattern is the
meta
mould. This cavity when filled with molten
material, produces a cavity called the
Wood or metal patterns are used i
produces the desired casting after solidification.
Loose piece, Multi-piece and Corec
foundry practice. There are Single piece, Split,
patterns.ae some ofthecommon types of patterns.

PT LAB
 =

MOULDING BoAR2 MoULDTNG FLASE

SHoVEL
RTDOL-E
Butt

Peen
RAMMER
SLICK

wTSHING TRoEL SaUARe HEART TROEL

TROL EL
TYPES OF TROLSELS
VJIT

TOOLS AND EQUIPMENTS

A
MOLDING BOXD: and ttern,
S a wdoden board with smooth surface. It supports the flasks
while-the mold is being made.
MOLDING FLASK:
I S a box, made of wood or metal, open at both ends. The sand is ramn
after placing the pattern in the molding flask. Usually, it is made oftwo paresm half of
o p nalt of the mold, having guides for the aligning pins. Drag is the bottom
comes in between
of the flask, which
8 agning pins. Check is that part
the cope and drag. Cheek is used when the pattern is a multi-piece pa
SHOVEL transferring the sand
for mixing and tempering molding sand and for
into the s used
tflask. It is made of broad steel blade with a wooden handle.
RIDDLE: fitted with a sereen
of
of a square or circular wooden frame
riddle consists
Hand riddling of sand to remove coa
standard wire mesh at its bottom. It is used for hand It also produces requirea
sand and other foreign material from the foundry sand.
particles
aeration to the sand.
RAMMER the pattern. One ends, of its
Is used for
packing ramming the sand around
or
and
t used for packing sand
is spaces, pockets
called the peen end, is wedge shaped and it has a flat
butt end,
corners in the early stages of ramming.
The other end, called the
Surface and is used for compacting the sand
towards the end of molding.

STRIKE-OFF BAR wood with straight edge. It

is used to remove the excess

It is a piece of metal or
to provide a level surface.
send from the mold after ramming,
SPRUE RUNNER) PIN used to make a hole in the cope through which the
It is a tapered wooden pin,
molten metal is poured into the mould.
RISER PIN over the mold cavity
make a hole in the cope,
It is straight
a
wooden pin used to
the shrinkage that ma
metal to rise in and feed lhe casting to compensate
for the molten
solidification.
take place during
It is used to smoothen the
TROWBL
It consists of a metal
blade fitted into a wooden
handle.
of the mold.
It also be used for repairing the damaged portion
surface of the mould. may
each one suitable for a particular
in different styles and sizes,
Trowels are made many

job.

PT LAB
 LFTER STRIKe-oFP BAR

VENT RODS GATE CUTTER

SWAB

SPRUE PIN
BELLot

PTN DRAD SCRE

 VJIT
DRAW PIN OR DRAw
Apointed steel rod with a loop at the other end. It is used to remov
Trom
purpose.
the mould. A draw screw, with a threaded end, may also De u

SLICK
a small double ended tool having a flat on one end and a spoon on the other.
tis used for
mending and finishing small surfaces of the mold.
LIFTERS
LITters are made of thin sections of steel of various widths and lengths, with one
na bent at
right angles. These are used for cleaning and finishing the bottom and
of the
deep and narrow d
pockets of the mold:
GATE CUTTER
t 1S a semi-circular piece of tin sheet, used to cut gates in the mould. Gates are
meant for easy flow of molten
metal into the mould.
NOte: A gate is a channel made on the surfäce of the drag, to connect the sprue hole to the
mold cavity. The size of the gate depends upon the size of the mold cavity.

BELLOWYS
It is a hand tool, used to blow air, to remove the loose sand particles from the
mold cavity.

VENT ItROD
is a thin rod used for making vents or holes in the sand mold to allow the escape
of mould gases generated during the pouring of molten metal

SAFETY PRECAUTIONS:
1. Do not let the sand too wet.
2. Never sand next look over the mould during the pouring of immediately after
powering because the metal might spit out of the table.
3. While working with molten metali wear protective of thing such as face shields,
the wrist.
safety goggles, leather gloves, which are tight atand funnl.
smoke
4. Provide adequacy ventilation of remove
which may result in second and third
5. Do not shake out a casting too hastily
degree.

PTLAB
 VIDYA JYOTHI
INSTITUTE OF TECHNOLOGY, HD
PRODUCTION TECHNOLOGY LABORATORY
MOULD PREPERATION-II (SPLIT PIECE
AlM: -

To
PATTERN
prepare a sand mould for a
given pattern (Two Piece pattern)
APPARATUS:
pe Box, Drag Box, Bottom Board, Wooden Pattern, Molding Sand, Facing Sand, Backup
Sand, Parting Sand.
TOOLS REQUIRED
novel, Riddle, Hammer, Strike Off Bar, Vent Rods, Trowels,
Lifter, Half Round Edge, Cleaner, Slick, Swab and Draw Sprue Pin, Riser Pin, Gate,Cuter
Spike.
PROCEDURE: A bottom board is placed either
even
on molding pattern or on the floor and mark the surtace
2. Keep the pattern on the bottom board
3. Keep the drag box in the reverse position and pattern is centralized in it
4.
Dry facingsañd is sprinkled
over the board
and pattern to provide
non-sticky layer
. Freshy prepared molding sand of required quantity is now poured ínto the drag and on
the patierm and rammed
6. Fi!! thc rost of thë diag bux with backing sand and uniformly rammed to compact the
sand
1. After ramming is completed, the excess sand in the flask is completely scrapped using a
strike-off bar upto the level of Flask edge
8. Lift the drag
*
flask to a reversed position and keep it on the bottom board exposing the
pattern
9. Dry parting sand is sprinkled all over the drag surface and on the patterm
10.Using slick the uneven surface ofsand around the pattern is repaired
11. Roll over the drag so that pins are pointed upwards and patterm surface is exposed
12. Attach remaining half of the patterm in position to check whether dowel pins and holes
are clean and aligned properly
13. Sprinkle the parting sand over the pattern and on parting surface on the mould
14. Place the cope on the drag. Fill the cop with molding sand keeping the sprue pin and
riser pin in position. Ram the sand around the pattern.
15. Make the vent holes in the mould with the help of vent rods
16. Remove the sprue and Riser Pins, lift the cope from the drag and place it horizontally
 17. Apply water on the edges of the mould in the cope and drag with swad

18. Rap and withdraw each half of the pattern from cope and drag
19. Cut the gates in the drag with gate cutter
20. Assemble the mould and cut a pouring basin. The mould is ready to be poured

PRECAUTIONS:
There should be endugh clearance between pattern and walls of flask
2. Ramming should be done properly
3. Do not wet the sand too much

RESULT
Thus the given sand mould for a single piece pattern is prepared.

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