Foundry

FOUNDRY
Introduction:
Foundry is a process of shaping the metal components in their molten stage. It is the also
called as metal casting the shape and size of the metal casting is obtained depends on the
shape and size of the cavity produced in sand mould by using wooden/ metal pattern .
Classification of foundries;
 Steel foundry
 C.Ifoundry
 Light alloy foundry
 Brass foundry
 Shell moulding foundry
 Die casting foundry (using permanent metal or dies for high volume of low and
pressure die)
Pattern:
A pattern is normally a wooden/ metal model or thermosetting plastic which is facsimile
of the cast product to be made, there are many types of pattern and are either one piece,
two piece or three piece, split pattern, loose piece pattern, Gated and match plate pattern
etc.
Types of foundry sand
1. Natural sand: Sand containing the silica grains and clay bond as found. It varies in
grain size and clay content. Collected from natural recourses.
2. Synthetic sand: It is an artificial sand obtained by mixing relatively clay free sand,
binder
(Water and bentonite). It is better moulding sand as its properties can be easily controlled.
3. Facing sand: It is the fine grade sand used against the face of the pattern and finally
governs the surface finish of the casting.
4. Parting sand: It is fine dry sand + brick dust used to preserve the joint face between
the cope and the drag.
Natural Greensand= sand+ clay+ moisture
(10to15%) (7 to9%)
Synthetic Greensand= sand+ clay+ moisture
(5to7%) (4 to8%)
Moulding methods:
 Bench moulding:
In this method the moulding is carried out on convenient bench and mould are
relatively small.
 Floor moulding:
In this method the moulding is carried out in medium and large moulds are carried
out on the floor.
 Plate moulding:
For large quantity production and for very heavy casting two plates may be used with
pattern.
 Pit moulding:
In this method the moulding is carried out in the pits and generally very large moulds
are made.
 Machine moulding:
A machine is used to prepare moulds of small and medium. This method is faster and
gives uniform moulding.
MOULDING TOOLS & EQUIPMENTS
Trowels:
These are used for working up into a square corner.
Taper trowel:
It is more useful for working along the curved edges of a pattern. Trowels are measured
by the length and width of the blade.
Slicks:
Used for repairing and slicking small surfaces. They are named according to the shape of
the blade and measured at the widest part of the blade.
Lifters and Cleaners:
They are used to clean & finish the bottom and sides of deep narrow openings.
Gate Knife:
Is for cutting the channel from the mould to the bottom of the runner or riser.
Spoon tool:
Is convenient for cutting the pouring basin.
Corner Slicks:
Are, as the shape implies, for finishing off fillets and corners of moulds.
Draw Spike:
Is a spike for knocking into the wooden pattern in order to withdraw it.
Draw Screw:
Is for the same purpose as the draw spike; the end is threaded to screw into the rapping
plate.
Swap:
Is a soft pointed brush for moistening the edges of the mould before lifting the pattern.
The angle at which it is held will decide the area to be covered. Care must be taken not to
get the sand too damp.
Bellows:
Are used for blowing out loose sand from the completed mould; they must be used
gently; too vigorous use will damage the mould.
Types of furnaces:
CORE AND CORE MAKING
CORES:
Cores are sand blocks they are used to make hollow portion in a casting. It is placed in a
mould so that when molten metal is poured into the mould. This apart of mould will
remain vacant
I.e. the molten metal will not fill this part of the mould. So, when the mould is broken and
the castings removed a hollow portion will result in the casting.
Core sand= Moulding sand+ binders (ABC core oil) or sodium silicate
Core making:
Cores are made separately in a core box made of wood or metal.
Fig. 8.1 Core making
Core binders
1. Water soluble binders (2 to 4% by weight)
2. Oil binders (1-3% by weight)

3. Pitch and resin binders (1-35 by weight)
The sand is treated with binder to achieve cohesion
Core Baking
The core is baked (hardened) by heating at 150C depends on core size in oven.
This hardening of the core helps to handle and to place the core in the mould.
The core is supported in the mould by projection known as core prints.
Advantages
• Molten material can flow into very small sections so that intricate shapes can be made
by this process. As a result, many other operations, such as machining, forging, and
welding, can be minimized.
• Possible to cast practically any material: ferrous or non-
ferrous.
• The necessary tools required for casting moulds are very
simple and inexpensive. As a result, for production of a
small lot, it is the ideal process.
• There are certain parts (like turbine blades) made from
metals and alloys that can only be processed this way.
Turbine blades: Fully casting + last machining.
• Size and weight of the product is not a limitation for the casting process.
Limitations
• Dimensional accuracy and surface finish of the castings made by sand casting processes
are a limitation to this technique.
• Many new casting processes have been developed which can take into consideration the
aspects of dimensional accuracy and surface finish. Some of these processes are die
casting process, investment casting process, vacuum-sealed moulding process, and shell
moulding process.

Foundry

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FOUNDRY

Fig. 8.1 Core making

2. Oil binders (1-3% by weight)

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