DEPARTMENT OF MECHANICAL ENGINEERING

POLITEKNIK KOTA KINABALU

LAB SHEET & REPORT

DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2
FOUNDRY
PROGRAM : DIPLOMA OF MECHANICAL ENGINEERING (DKM)
CLASS & SECTION :
LECTURER’S NAME :
STUDENT’S NAME :
REGISTRATION NO. :

CHAPTER 3 : FOUNDRY
PLO5 : Modern tool usage
Follow the appropriate procedure for welding, foundry and lathe machining. (P3,
CLO1/CLO2/CLO3 PLO5)/Perform welding, foundry and lathe machining according to Standard
:
Operating Procedure (SOP). (P4, PLO5)/Demonstrate the ability to work as
individual and as a team to complete assigned tasks. (A3, PLO9)
P3/P4/A3 : Guided Response/Mechanism/Valuing
DK6 : Practical Engineering Knowledge
DP1 : Depth of knowledge Depth
DP3 : of analysis required
DP5 : Extensive applicable codes

PREPARED BY : VERIFIED BY :

DARMAN BIN PAWALI

KETUA PROGRAM
HATIMI BINTI MUDIN
DIPLOMA KEJURUTERAAN
Pensyarah
MEKANIKAL
25 OGOSPOLITEKNIK
2023
Jabatan Kejuruteraan Mekanikal
Politeknik Kota Kinabalu, Sabah
YOU MAY ENCLOSE ANY ATTACHMENTS RELATED TO THIS LAB REPORT AND PLEASE MAKE SURE IT IS
AT THE PROPER SECTION.
 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

MECHANICAL ENGINEERING DEPARTMENT

POLITEKNIK KOTA KINABALU
RUBRIC (PRACTICAL TASK P)

NAME :
REGISTRATION NUMBER :
PROGRAMME :
PLO5 : Apply appropriate techniques, resources, and modern engineering and IT tools to well defined engineering problems, with an awareness of
limitations
CLO1 : Follow the appropriate procedure for welding, foundry and lathe machining (P3)
CLO2 : Perform welding, foundry and lathe machining according to Standard Operational Procedure (SOP) (P4)
Sub topic : 3.1 Perform pattern making.............................................................................................................................................................1 Practical Task
3.2 Perform casting works................................................................................................................................................................1 Product
CRITERION ASSESSMENT LEVEL MARKING
NO 4 3 2 1 0 MARK
FACTOR
Student failed to
Student
Student followed follow a
Student followed attempted Student failed to
Identify safety rules most safety rules, significant
1 all safety rules. to follow safety follow any safety 1
(P1) may have forgotten number of safety
rules but failed to rules. rules.
one.
meet several.
Use most
Use complete Use incomplete
Use complete PPE complete
Displays the right PPE most of the PPE all the time No PPE used all
all the time during PPE most of the
2 PPE wearing (P2) time during during the time. 1
workshop time during
workshop workshop
practices. workshop
practices. practices. practices.
The workshop The workshop
The workshop The workshop
The workshop team team did not team did not
team followed team followed
Follow instructions followed all written follow many of follow any of the
3 most written and some written and 3
(P3) and verbal the written and written and
verbal verbal
instructions. verbal verbal
instructions. instructions. instructions. instructions.
TOTAL CLO 1 /20
Able to select Able to select
accurate tools accurate tools
Able to select Able to select
Chooses the right without with little
correct tools correct tools with Unable to select
4 tools assistance assistance 1
with moderate major assistance. correct tools.
(P1) according to according to
assistance.
the the
criteria criteria
Excellent use Selecting and Unable to use
Best use of the Use some
of the tool using the
tool usage appropriate tool
Recognize the tools usage appropriate tool appropriate tool
5 according to usage according 2
usage (P2) according to usage usage according
SOP to
SOP according to to
SOP
SOP SOP
Measurements,
skills or Measurements, Measurements, Measurements,
Measures the Measurements,
techniques are skills or skills or skills or
accuracy/Precesion of skills or
both accurate and techniques are techniques are techniques are
6 the final product (P3) techniques are 2
precise and may accurate with somewhat incomplete,
DP1,DP3,DP5 mostly
show some reasonable inaccurate and inaccurate and/or
innovation. accurate.
precision very imprecise. imprecise

Student was able

Student was Student was unable
Student was to complete the
able to to Student needs
Perform given task able to task with
7 complete the complete task assistance all the 5
(P4) complete the moderate
task with little without major times.
task without assistance.
assistance. assistance.
assistance.
TOTAL CLO2 /40

DEPARTMENT OF MECHANICAL ENGINEERING, POLITEKNIK KOTA KINABALU 1

 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

MECHANICAL ENGINEERING DEPARTMENT

POLITEKNIK KOTA KINABALU
RUBRIC (PRACTICAL TASK A)

NAME :
REGISTRATION NUMBER :
PROGRAMME :
PLO9 : Function effectively as an individual, and as a member in diverse technical teams.
CLO3 : Demonstrate the ability to work as individual and as a team to complete assign task (A3)
Sub topic : 3.3 Demonstrate the ability to work in team.................................................................................................................................1 Practical Task
ASSESSMENT LEVEL MARKING
NO CRITERION 4 3 2 1 0 FACTOR
Always does Usually Rarely Always relies on Not doing
the assigned does the does the other to do the anything
Show work without assigned assigned work
1 responsibility having to work - work - 1
(A1) be reminded rarely needs often
reminding needs
reminding
Take part in Take part in Take part in Not interested
Take part in
carrying out carrying out carrying out and not
carrying out
the work. few work. some of the contributing
some work.
Routinely Sometimes work. Rarely anything for
Contribute in Contributes
contributes contributes contributes team
2 task completion useful ideas 1
useful ideas useful useful ideas
(A2) to
to ideas to
advance the
advance the to advance advance the
work of the
work work of work of
team
of team. team. the team.
Excellent Good Less initiative & No initiative & No
initiative initiative and lack of helping only initiative &
and often sometime other members helping other unhelpful
helps other helps to prepare given members to and only
members in other task prepare focuses on
Initiate to work
3 preparing a members given task if the work 3
with other (A3)
given in requested section
task preparing alone.
a given
task

TOTAL CLO3 20

DEPARTMENT OF MECHANICAL ENGINEERING, POLITEKNIK KOTA KINABALU 2

 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

MECHANICAL ENGINEERING DEPARTMENT

POLITEKNIK KOTA KINABALU
RUBRIC (REPORT P)

NAME :
REGISTRATION NUMBER :
PROGRAMME :
PLO5 : Apply appropriate techniques, resources, and modern engineering and IT tools to well defined engineering problems, with an awareness of
limitations
CLO1 : Follow the appropriate procedure for welding, foundry and lathe machining (P3)
CLO2 : Perform welding, foundry and lathe machining according to Standard Operational Procedure (SOP) (P4)
Sub topic : 3.1 Perform pattern making..................................................................................................................................................................................1 Report
3.2 Perform casting works....................................................................................................................................................................................1 Report
ASSESSMENT LEVEL MARKING
NO CRITERION 4 3 2 1 0 FACTOR
Clearly and Clearly describe Clearly describe the Clearly describe most Not describe any tool
completely all tool use and tool use and their of the tool usage but not usage and the
Describe the tools
1 describe all tool their functions functions but not complete function. 1
usage (P1)
use and their complete
functions
Measurements, Measurements,
Measures the skills or techniques skills or Measurements, Measurements, skills or Measurements, skills or
accuracy/Precesion of are both accurate and techniques are skills or techniques techniques are techniques are
2 1.5
the final product (P3) precise and may accurate with are mostly somewhat inaccurate incomplete, inaccurate
show some reasonable accurate. and very imprecise. and/or imprecise
innovation. precision
TOTAL CLO1 /10
Stated the best Stated the appropriate Stated the Stated only some of the Not stated the
Perform task using techniques to techniques to conduct appropriate appropriate techniques appropriate
3 the right techniques conduct the work. the work. techniques to to conduct the work. techniques to 1
(P4) conduct the work but conduct the work.
not clear.
Explaining in details Discussing the results Discussing the results Discussing the results Not discuss the
and discussing the clearly and compare with the theories but but not comparing with result at all
Explain Findings results clearly and with the theories and not in details and not the theories.
4 0.5
(P2) compare with the the objectives clear
theories and the
objectives
Conclusions are Conclusions are Conclusions are Conclusions are not No conclusion at all
completely summarized slightly summarized in relation summarized in
Make Conclusion
summarized in in relation to the to the studies but not relation to the
5 (P4) 1
relation to the studies. clearly. studies.
studies.

TOTAL CLO2 /10

DEPARTMENT OF MECHANICAL ENGINEERING, POLITEKNIK KOTA KINABALU 3

 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

OBJECTIVES :

1.1 Follow safety procedures when operating machines.

1.2 Demonstrates the skills of making pattern by using polystyrene to provide the shape of the mould cavity in
the sand.
1.3 Demonstrates the skills of moulding process.
1.4 Demonstrates the skills of pouring process of molten metal into the sand mould.
1.5 Perform Visual Inspection on casting quality in terms of :
1.5.1 Finishing
1.5.2 Defects

2.0 EQUIPMENTS :

2.1 Moulding tools

2.2 Power cutting saw
2.3 Furnace
2.4 Casting tools
2.5 Crucible
2.6 Safety Equipment
2.7 Polystyrene cutter

3.0 MATERIALS :

3.1 Polystyrene
3.2 Wood
3.3 Aluminum steel

4.0 THEORY
In simplified terms, a foundry is a factory where castings are produced by melting metal, pouring liquid metal into a
mold, then allowing it to solidify. Even if you have never been to a foundry, or even know what one looks like, you are
surrounded by the metal castings they produce. There is a good chance that you are reading this less than 10 feet away
from one.

Foundries don’t just produce metal products for engine, railroad, or pipe components. They also form components
for machines that are required to make many of the essential consumer products we depend on. 90 percent of all
manufactured goods rely on metal castings.

THE CASTING PROCESS

In order to understand a foundry, you need to understand the casting process. The general steps involved in casting are
patternmaking, molding, melting, pouring, ejection, cleaning, fettling, and inspection.

DEPARTMENT OF MECHANICAL ENGINEERING, POLITEKNIK KOTA KINABALU 4

 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

The final casting shape corresponds with the mold it is poured into, so molds are carefully shaped with a pattern
– a wood or metal replica of the object to be cast. The most common mold material is silica sand, but they can be produced
from a number of different materials depending on the casting metal and method being used.

Charging is one of the most dangerous operations in the foundry. Mistakes can be lethal.
A melting furnace is “charged” with metal and heated above the metal’s melting point. Once the molten metal has reached
a specific pouring temperature it is tapped from the furnace through a spout into a refractory lined steel pouring ladle. Any
slag or impurities are skimmed from the top of the molten metal surface. The ladle is then tipped to pour molten
metal into a mold cavity.

The mold cools and the metal solidifies, then the casting is ejected from the mold and cleaned. The cleaned casting is
finished with fettling, a process which removes excess material from the casting to meet specified dimensions for the
finished product. Depending on the casting specifications, fettling can be quick and simple, or extremely detailed work.
Finished castings are then inspected by the foundry before being shipped.

Foundries don’t just produce raw castings. They house a number of operations that often include part design,
tool building, prototyping, machining, assembly and other after-sales services.

(Source : Reliance Foundry Co. Ltd., 2017 retrieve from https://www.reliance-foundry.com/blog/what-is-a-

foundry#gref)

5.0 SAFETY PRECAUTION

Ensuring high levels of safety is vital when undertaking any welding activity. Ignoring your PPE and safe
working practices can have serious repercussions and might even lead to fatalities. Therefore, you should follow the safety
precautions below to protect yourself at work.
5.1 Personnel safety, health and welfare
5.1.1 Fire resistance clothing/apron/overalls to protect bodies and arms
5.1.2 Eye protection, which is usually supplied in the form of a protective shield
5.1.3 Good quality of gloves, preferably leather gauntlets
5.1.4 Safety boots or shoes and good quality cap and overalls.

5.2 Equipment safety and maintenance

5.2.1 Always read and follow the safety information in the operator's manual
5.2.2 Ensure all connections are tight, including the earth ground.
5.2.3 Ensure the electrode holder and welding cable are in good condition
5.2.4 Ensure all the settings are correct for the task.

5.3 Workplace safety, health and welfare

5.3.1 Lighting conditions are adequate for the work undertaken.
5.3.2 Housekeeping is extremely important to avoid slips, trips and falls.
5.3.3 Adequately ventilated and where necessary have local exhaust ventilation.
5.3.4 Provided with adequate fire-fighting equipment.

DEPARTMENT OF MECHANICAL ENGINEERING, POLITEKNIK KOTA KINABALU 5

 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

6.0 PROCEDURES
DESIGN PATTERN
FOUNDRY WORK SHEET i. Sketch selected pattern onto polystyrene/wood.
TITTLE : Design Pattern ii. Cut the polystyrene/wood into the shape of designed pattern by using
PROGRAMME : the polystyrene/wood cutter.
DKM 2
MATERIAL :
Polystyrene/Wood Polystyrene/Wood
cutter
OBJECTIVES :
GENERAL OBJECTIVE:
To produce pattern.

SPECIFIC OBJECTIVES:
i. To make a pattern by using
polystyrene/wood to provide
the shape of the mould
cavity in the sand.
PRODUCE SIMPLE CASTING
FOUNDRY WORK SHEET i. Place the drag upside down on a bottom board. The drag has to
TITTLE : Produce Simple Casting receive the cope once it has been filled with sand.
PROGRAMME : ii. Place the pattern into the drag. Its position in the drag depends on the
DKM 2 shape of the pattern.
MATERIAL : iii. Shake the parting dust on the bottom board and the pattern. Then,
Band saw shake the sand through a fine riddle over the pattern until it is covered
power cutting saw crucible to a depth of ¾ inch.
furnace iv. Use a rammer to compact the sand firmly. Step iii is repeated until the
sand mixer drag is fully covered by sand. Use the strike off bar to flatten the
OBJECTIVES : surface.
GENERAL OBJECTIVE: v. Invert the drag and place the cope in position.
To understand the process of vi. Put the sprue pins on top of the pattern. Avoid placing them too near
sand casting in producing the the edge of the flask.
engineering components. vii. Repeat step iii– iv. Then using the vent rod to make several holes
in the sand to allow unwanted gasses to escape.
SPECIFIC OBJECTIVES: viii. Remove the sprue pins from the sand. Then carefully lift the
i. To perform the moulding cope from the drag and place it upside down.
process. ix. Close the flask and weight the cope in a suitable place to
ii. To perform the pouring prevent flask separating when the metal is poured.
process of molten metal x. Melt the aluminium bar by using the crucible furnace. When the
into the sand mould. molten metal is ready, pour them slowly into the moulding flask.
xi. After a few minutes, remove the pattern from the sand. Use the pick-
up tong to pick the pattern.
xii. Lastly, do the finishing works to complete the final pattern.

DEPARTMENT OF MECHANICAL ENGINEERING, POLITEKNIK KOTA KINABALU 6

 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

Please submit part 7, 8, 9, 10 & 11 individually.

NAME :

REGISTRATION NUMBER :

PROGRAMME :

7.0 TOOLS (DP1)

Describe all tools used and their functions.
TOOLS FUNCTION

7
 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

TOOLS FUNCTION

8
 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

8.0 RESULT (DP3, DP5)

(Attach your final project’s photos here along with it’s measurement .)

9
 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

9.0 DISCUSSION (DP1, DP3)

Recognize and named the various pattern material in sand casting. (P2)

Explain the requirements of good pattern. (P2)

Explain in brief the applications of sand casting. (P2)

10
 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

Identify any two advantages and disadvantages of sand casting. (P1)

Explain why a riser used in sand casting. (P2)

11
 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

10.0 CONCLUSION

12
 DJJ20042 : MECHANICAL WORKSHOP PRACTICE 2 FOUNDRY

11.0 APPENDIX
(Student may attach any related diagram/picture/document in this section)

13