MAPÚA UNIVERSITY

Muralla St. Intramuros Manila

Department of Mechanical and Manufacturing Engineering

ANSWERS TO QUESTIONS:
Operations and Maintenance of
Foundry Shop

ME123L-2

Grade

Instructor
Molding or moulding
Is the process of manufacturing by shaping liquid or pliable raw material using a rigid
frame called a mold or matrix.[1] This itself may have been made using a pattern or model of the
final object.
Core Making
The core is a chemically bonded sand shape that creates the interior surfaces of an iron
casting.
A core box is the tooling used to create the core.
High-quality cores are essential to the iron casting process.

Mould Assmebly
Mold assembly is one of the most critical steps of mold making procedure, all the parts
machined or purchased need to be put together and required to be work functionality. Mold
assembly job requires comprehensive understanding of mold structure as well as injection
molding. Quality of mold assembly determines the mold precision and injection productivity.

Raw Materials
Raw material is important element in any foundry. The raw material used, contributes a
lot for the energy consumed in any foundry. The melting energy takes its important role in
consumption and so effective management in this direction is much essential. Apart from this,
the other energies which take lead roles are energy intensive systems such as compressed air and
transport systems for molten metal and so on.
the raw materials used in the process typically include molten metal, but epoxies, concrete, and
clay are also used. Common metals used in the casting process include: Aluminum. Iron.

Melting
Is a physical process that results in the phase transition of a substance from a solid to a
liquid. This occurs when the internal energy of the solid increases, typically by the application of
heat or pressure, which increases the substance's temperature to the melting point.
Iron, out of the ground, melts at around 1510 degrees C (2750°F). Steel often melts at around
1370 degrees C (2500°F).

After treatment
After the controlled run of the casting process and complete solidification of the material
the final step on the road to the perfect spheroidal iron or metal casting can get underway - after-
treatment of the casting. This is necessary if casting is to leave in a "ready-to-use" condition.

Heat Treatment
Heat Treatment is a method of controlled heating and cooling of metals to alter their
mechanical and physical properties without changing the product shape. The technique involves
the use of heating or chilling, usually to extreme temperatures, to attain a desired result, such as -
hardening or softening of a metal.
Painting
Allowing you to achieve a very high collectors' standard.

Inspection
Every step in the process of metal casting, from pattern-making to heat treating, is done
carefully to avoid problems with the soundness, surface finish, mechanical properties, and final
dimensions of the finished casting. Inspection allows foundry and clients to feel confident they
have a quality casting.

Laboratory
A Fully equipped foundry laboratory with casting and melt treatment of metals such as
aluminium, iron, steel, titanium, magnesium and copper based alloys. It design and produce
models for shaped castings.

Sand Preparation
The process of sand treatment is decisive for the quality of the mold. In every
technological step - whether during conditioning, the bunkering of used sand or sand preparation
- it is important to achieve the optimum process parameters as well as to keep them stable and
reproducible.

Pattern Warehouse
When the patterns and core boxes of the products are not in production, they are stored in
a pattern warehouse.

Pattern Shop
A pattern or tooling is a full-size model of the part you are trying to cast, patterns can be
made from various materials such as mahogany, metal, plastic or styrofoam. It is very important
to have suitable patterns, for the quality of the casting is influenced by the quality of the pattern.
 LAYOUT

Selection of metal

New sand

Facing sand miller Pattern making metals Power /fuel

Water, Binders, Additives
ferrous iron electric Diesel/oil
Sand
reclamatio Returns sand miller Molding Melting furnace
n plant Water, Binders, Additives

electric compolar induction

Core mixer Gatling risering
system design laddle
cores Closing/Popuring

Return sand
knockout

Grinding casting rejection

cutting
Runner and risers
 1. What are the things to consider in designing and conditioning of a foundry

shop?

Often someone who does not have the experience in how the foundry works will

trhen inherit problems caused by poor design. Someone who has no knowledge of the

foundry and its requirements should talk with a local foundry expert before starting

working. The concept of foundry design and engineering in spite of hard aspects of the

foundry design and construction is a continuous mix of creative activities. With their

knowledge, combined with their innovative minds and strict adherence to procedures to

implement the client's foundry design, the layout of a well designed foundry is carried

out by Foundry Engineers. This helps further the causes of efficiency and quality into

the client's casting production facility. In other words, from the forces of chaos a foundry

is created, by way of the untiring energies and cumulative contributions of the many

players involved.
QUALITY CONTROL

Quality can be perceived in accordance with requirements, costumer needs. It, in

returns, implicates necessity of verification of this accordance, i.e. quality inspection.

And that means how, on the ground of this inspection, to improve quality of articles and

services. To speak about possible usage of repairing methods in firm, it is necessary to

mention exact qualifications of criterions usage of quality improvement tools.

Separations of quality criterions takes place to investigate all spheres of formation and

usage of products: preproduction, production and after production phase. Casting

defects can negatively impact the bottom line of a foundry.

CLIENT INTERACTIONS

The client is consulted for the project’s requirement in terms of vital and

elementary aspects of the project; before the analysis and assessment of the project is

done by the foundry engineer. These aspects include the nature and specification of

final products as required and the projected output level required of the new plant. The

manufacturing company guarantee that the correct questions are created for the client,

so that the most precise and complete data is collected as a preparatory point for any

further analysis. The database of information collected from the client has a major role

to play on the final outcome of the project. However, other sources (like local authorities

for health and safety, fire marshal, public utilities and municipal corporations) also

contribute to the final design to attain the permits of the buildings.

WORK ENVIRONMENT

A safe, healthy work environment positively influences employee morale, health,

and productivity. Comply with all applicable environmental, health and safety (EHS)

regulations and laws.Provide and maintain a safe, healthy working environment for all

associates, including temporary workers and contractors, consistent with regulatory

requirements and best management practices. As practicable, minimize toxic and

hazardous materials used or generated by our operations. our core values drive us to

do the right thing environmentally for our community—to reclaim, recycle, keep our air

and water clean, and provide the cleanest and safest environment for people to live and

work.

THE CONCEPT STAGE

A competent process engineer is crucial at the concept stage of the process. The

technical focus of the foundry industry requires in-depth technical knowledge of the

engineer. Apart from the input received from the client, the foundry process engineer's

proficiency establishes the framework foundry’s working structure to achieve the client’s

requirement.

This begins with a pre – production report which consists of a pre- production study and

financial viability analysis of the project. The pre – productions study identifies finest

design of the required facility which includes application of the project, selection of the

equipments and materials. It also determines the process timings for the implementation
phase and the total cost involved for an absolute operational unit. Financial viability

analysis forms the basis for the estimation of the financial competency of the

predetermined facility.

ENVIRONMENTAL STUDY

Apart from pre – production report, environmental study is also required in most of

the projects before execution of the design. In cases like, plant location near residential

area can restrict the production unit in many ways. Information on water-table and local

construction codes addressing production in an earthquake area are other building

details required to be addressed at the initial stage of the project and must be resolved

quickly.

2. What are the processes involved inside a foundry?

A foundry is a factory where castings are produced by melting metal, pouring the

metal into a mold and allowing it to solidify. Even if you have never been to a foundry,

you are surrounded by the metal castings that they produce. They don’t just produce

metal products for engines, railroads or pipe components. They also produce

components for machines that are required to make many of the consumer products

that we depend on. A majority of manufactured goods depend on metal castings.

Founders don’t just produce raw castings; they also host a number of operations which

can include part design, tool building, prototyping, machining, assembling and a variety

of other services.

PROCESS

Involve making the mould and the core, melting and pouring the metal into the

mould, and removing the mould and core and finishing the product. Different processes

differ in the number of steps required to make the final product.

Metal casting process starts with creation of mold. Metal that can be molted will

be poured into this mould and cooled. The form of metal being used and shape of final

product required would decide trhe material, which will be used to make the cast. A

commonly used molding material is sand. Investment materials, metals, etc. can also be

used.

Different types of metals are used for melting different metals. Various furnaces

types are cupolas, electric arc, induction, hearth, reverberatory and crucible. Due to the

different nature of metals, varying inputs are required and different toxic wastes are

released from each type.

 After the metals has been melted, is is poured into the cast already made

previously and made so cool and set. Silica sand, moisture, oils and green sand are

mixed together to form a mould cavity. Metal is then poured in the cavity. When the

metal is cooled, it is easily separated from the mould. This type of sand should be

capable of handling high temperatures and pressure, allow gasses to escape, have a

constantly small grain size and be non-reactive with metals.

The wastes produced by foundries depend on the type of metal, foundry types.

Gaseous wastes are usually the largest pollutants. They contain metal, semi-volatile

and volatile organic compounds. Emission control systems can be installed to capture

these gasses.

Liquid wastes I foundry results from water used to chill metal. Water is used for

cleaning the floor &other maintenance can also formulate liquid waste. A water

treatment plant can be installed for water waste.

Solid wastes cone from slag, sand, spend refractories, and emissions control dust. For

this various process like sand reclamation, attrition sand reclamation, dry sand,

reclamation, wet sand reclamation, etc. is used. Sand may be also being recycled for

outside processes.

Slag and emission are also a waste produced by a foundry this can be fed back to

furnace o recover any metal, which can possibly be recovered.Other special foundry

processes are thermal galvanization and electro less nickel plating.

 3. Your report is based on Industry layout, how about for school institution

requirement, are they the same?

The other foundry is for industry and the other focuses in educational purposes, so

ythey have different uses and purposes . Below are the factors that should be

considered in a school type foundry.

Ventilation

 open all windows.

 switch on all exhaust fans.

 switch off all air-conditioners, if applicable.

As shown above are the factors to be considered in a school institution-type of foundry

shop, as we observe those given factors, we had a conclusion that those two examples

of foundry shop don’t have that much differences regarding with the requirements it

needed in constructing one. The list above about the things to be considered which

includes safety and such are almost the same as what we discussed in an industry

foundry, it is just that in an industry foundry, we have this so called a person which is

assigned in supervising and guiding workers on how anything should work including

proper doing such work and quality assurance, but in a school institution-type we only

have the teachers/professors/ instructors which are responsible for almost everything in

the shop.
Also, we had a conclusion about how school institution-type foundry should not be much

different to a regular industry foundry shop. First, we all know that a foundry shop built

in a school facility mostly will be used for educational purposes, thus we should not

degrade or tone down any requirement needed especially for safety just because it

wouldn’t be used as a normal industry foundry shop. Also, although school foundry shop

is only to be used by students, that doesn’t mean that it can be less secured as it is only

would be a replica. Foundry shops does the same thing even in different locations, thus

we should apply the same requirement as what are used in industry foundry shops.

Storage

Storage is required for bulk supplies, sundries, and partly constructed work. Good

cupboard space can often be provided within the workshop for many of the sundries,

but it is essential to have adequate space outside the workshop for other items. Proper

racking facilities are required. Storage of metal bars in a vertical position can be

dangerous, unless a safety chain or bar is used.

Only limited supplies of acid or other chemicals should be kept in stock and these

should be kept in a locked cupboard or container. The use of suitable (plastic) bottles

which do not break when dropped is recommended. Acid in use should be kept, and

used, close to a water supply. Its use should be closely supervised, with instructions

posted as to its danger, the proper method of diluting and the action to be taken in an

emergency.

Layout
 The workshop must be big enough to allow the safe layout of equipment and to

provide adequate working spaces at benches and machines so that pupils do not

impede each other’s movements or disturb each other.

 Overcrowding contributes to accidents. The plan of the room and the layout of

equipment should permit full supervision by the teacher.

 There should be enough space between benches to allow pupils to move without

interrupting other pupils at work. Gangways and working spaces should at all

times be kept free from obstructions; they should never be used for storing

materials or work in progress.

 Machines should be sited so as to reduce the amount of unnecessary movement

of the operator. An adequate free area around the machines is required giving

the operator freedom from interference, and the machines should be arranged so

as to eliminate risks to others from any flying particles, tools, or work which could

be ejected accidentally. Screens can sometimes be helpful, but it is essential that

nothing should interfere with the teacher’s full supervision of the room.

 It is desirable that all school workshop floors should be at one level. The floor

surface needs to be provided and maintained in a non-slip condition and free

from risks of tripping. In woodwork rooms it should be noted that sawdust may

have a burnishing effect on wood floors. Spilt oil or water should be removed at

once.
  Because of the varying heights of pupils using the same workshop it is difficult to

ensure that benches always provide the right working height, important as this

might always be. Some variety in the height of the benches provided can be

helpful for the shortest pupils. Duckboards should not be used unless absolutely

necessary, but if used should be painted around their perimeters with contrasting

paint.

 The approved layout plan of the workshop should be on display in the workshop.

Prior approval should be sought from the Education Bureau if changes or

alterations are to be made to the layout of the workshop.

Electrical Safety

 All electrical wiring installation should comply with the Electricity (wiring)

Regulation.

 Whenever electricity is used, the dangers of electrical shock and fire are ever

present. The main causes of electrical accidents are carelessness, ignorance

and inexperience, and teachers should make every effort to eliminate these

causes by carefully planned courses and teaching methods.

 To prevent electrical shocks, all wiring to sockets and other outlets should be

enclosed in earthed conduit or trunking whenever possible.

 To eliminate the risk of electrical fire, circuits should never be overloaded or over-

fused. Wiring with faulty insulation should be renewed as soon as possible after

detection and unreliable connectors should be replaced immediately.

 Maintenance and repair work should be carried out by a registered electrical

worker.

 A sensitive residual current device (an earth leakage current breaker unit),

should be used as back up protection in the workshop.

 It is essential to educate pupils to handle electrical equipment safely and to be

aware of the danger of improper use.

 The use of two- or three-way adaptors should be avoided.

 Connecting leads must not be allowed to trail where they are liable to damage by

impact or abrasion or where pupils may trip over them.

 Electrical apparatus should never be handled with damp or wet hands or when

the user is standing on a wet surface.

  Portable equipment should be disconnected from the mains socket when not in

use.

 Labels and notices should be displayed for every main switch/distribution board.

Lighting

A good standard of both natural and artificial light is essential. Supplementary lighting to

individual machines is sometimes necessary. This should be of a low voltage. It should

not be regarded as a substitute for a satisfactory standard of general lighting. If

possible, illumination should be obtained by natural light, artificial light being used to

supplement the natural light as necessary and to replace it during hours of darkness. It

is important that the forge and brazing hearth areas have only subdued lighting.

If installing fluorescent lighting in any workshop having moving machinery, steps must

be taken to ensure that no stroboscopic effect is possible as a result of the supply

frequency, i.e. moving parts must not appear to be stationary.

First Aid

A suitably equipped first aid box, fixed to a wall, should be easily accessible in every

workshop. The contents of the box should be checked frequently. It is not sufficient that

there should be first aid equipment in another part of the school. Workshop staff should

have sufficient knowledge of first aid to be able to cope with injuries arising from

ordinary workshop accidents, including electrical shock, with confidence and speed.

(see Appendix A)

Regulation 55(2) of Education Regulation states that “at least two teachers in every

school shall be trained in administering first aid”. In addition, school principals should
encourage their staff to undergo some form of training in first aid. In the event of any

serious injury, or whenever in doubt, medical aid should be sought without delay.

Blood-borne disease (see Appendix B for information on the nature of blood- borne

diseases and their prevention.)

Fire Precautions

Fire service installations and equipment should be inspected by a registered Fire

Service Installation Contractor of the appropriate class at least once in every twelve

months in accordance with Fire Service (Installations and Equipment) Regulations.

Portable fire extinguishers installed in school workshops located in government

premises are to be inspected periodically by Fire Services Department.

Fire extinguishers should be clearly marked to indicate the type of fire on which they

may or may not be used, and staff should be familiar with the correct method of usage.

Adequate means of escape in case of fire are essential and should be kept clear and

free from obstructions at all times.

Advice will be readily given by the Fire Services Department, who will inspect and

advise on fire safety precautions on request. This advice must be sought at all times

when it is proposed to use “dangerous goods” in any quantity. As a general guide, any

dangerous goods in excess of the exempted quantity as specified in the Tables of

Dangerous Goods (General) Regulations, Cap 295, Laws of Hong Kong, should be

stored in an approved dangerous goods store.

REFERENCES

https://depot.ceon.pl/bitstream/handle/123456789/3379/10.pdf?sequence=1

https://en.wikipedia.org/wiki/Foundry