WORKSHOP PRACTICE

COUSRE CODE 2008

FOUNDRY
 INTRODUCTION

Foundry is an ancient process used in the manufacturing field, which is forming metal
castings. Basically it is consists of pouring the molten metal in to a cavity known as mould, and
allowing it to solidify. There is practically to limit to the size and shape of the casting that may made.
It is the cheapest method and gives high strength and rigidity even to complicated parts, which are
difficult to produce by other manufacturing processes. The molten metal passes through the
following four stages till the solidification takes place in to the mould

1. Liquid stage 2.mussy stage 3.plastic stage 4.solid stage

Foundry consists of many processes like pattern making, moulding sand preparation,
moulding and core making, melting and casting etc. except pattern making, all other stages to
produce casting are done in foundry shop. The important of foundry act in the making of irregular
shapes of metal casting8
 -Cope

1) Shovel
Drag-
2) Riddle Lug
Wooden flask

2) Strike cff bor D

4) Trowel (Square nose} 5} Trowe (Round nose)

3 veri wire

CC mme 11 Draw screw

10) Swao
6) Sick

7) itter 12 allow
8) Sorue pins
 MOULDING TOOLS AND EQUIPMENTS
Moulding boxes (flask): sand moulds are prepared in specially constructed boxes called
moulding boxes or flasks. The purpose of the box is imparting the strength and rigidity to the sand in
moulding. They are usually made in two parts, held in alignment with dovel pins. The top part is
called "cope" and lower part is called "drag". If the moulding box is made in three sections, the
centre is called cheek

Shovel: it is a rectangular pan with handle. It is used for

a mixing moulding sand and for moving
sand one place to another

Riddle: it is a screen consists of a wire mesh fitted with rectangular or circular wooden frame. It is
Used for removing foreign material such as nails, shot metals, splinters of wood etc.

Rammer: it is a wooden tool used for packing or ramming the sand in to the mould

Strike-off bar: it is a piece of metal or wood with a straight edge. It is used to remove or strike-off
excess sand from the mould after ramming to get a level surface.

Vent rode: it is mild steel rod used for making vents or openings in the mould.

Sprue pin: it is wooden or metal tapper pin or rammed in the cope of the mould to make an
opening through which the metal poured in.

Lifter: it is a thin metal piece used for patching deep sections of the mould and removing loose
sand from the pockets.

Slicks: it isa small double ended tool with different sizes havingflat on one end and a spoon on
other end. It is used for repairing and finishing mould.

Trowel: it is a metal blade fitted with a wooden handle. It is used for repairing and finishing flat
surface of the mould.

Draw spike: it is a pointed or screwed end steel rod. It is used for removing the pattern from the
mould.

Bellows: it is an air blower and used to blow loose sand from the mould.
MOULOING SAND

COPE

CHEEK
-ALIGNING ROD

DRAG

MOULDING SAND
8.
Swab: it is a small brush having long hemp fibres. It is used for applying water around the edges of
the pattern. This prevents the sand edges from crumbling when the pattern is removed.

Raw hide mallet: it is a mallet used for loosens the pattern from the moulding by striking slightly,
so that it can be removing easily.

Gate cutter: it is a small piece of tin plate to cut the gate (opening) that connects the sprue with
mould cavity.

Rapping plate or lifting plate: it is used for facilitate rapping and lifting of the pattern from the
mould

Moulding board or bottom board: it is a smooth wooden board used for placing moulding box
and pattern while starting moulding. When the mould is turned over, the mould is placed on a
similar board, which acts as a support for the mould.

Spirit level: it is used to check that the sand bed, moulding box, or table of moulding machine is
horizontal.

Gaggers: These are iron rods bent at one end or both ends, these are used to reinforce the
moulding sand in the top portion of the moulding box and for supporting hanging sand.

Pouring weight: it is a heavy plate of cast iron with a opening at its centre, so that the runner in
the mould can be placed conveniently. It is used
the top of mould for giving
on a a weight to prevent
pressure of the liquid metal from forcing the mould part.

PATTERN MAKING
Pattern making deals with the construction of
pattern. Pattern is the principle tool used during
casting process. It may be defined as a model of desired type of casting. Which when moulded in
sand forms an impression called "mould". The mould filled with molten metal forms
"casting'".
Materials used for making pattern are:

1. Wood (teak, pine, wood, mahogany)

2. Metals( aluminum, cast iron, brass, magnesium alloy)
3. Plasters(gypsum, cement)
4. Plastic compound
5. Wax
Loose piece

Loose piece pattem

Solid pattern

Two-piece split pattem

MOULDING SAND
The mould or cavity, into which the molten metal is poured, is made of some heat resisting
material. sand is most often used. Moulding sand is the principle raw material used in the
foundry shop for moulding. This is because it possesses the properties vital for foundry
purposes. It is easily packed to shape and it is porous and resists high temperatures.
1. Natural sand: it is collected from natural resources like river beds or collected from
pits.
2. Synthetic sand: it is artificial sand prepared in the foundry by mixing clay free sand.

PROPERTIES OF MOULDINGSAND
Permeability or porosity: it is the property of sand to evolve a great deal of steam
and other gases. The mould must be permeable or porous to permit the gases to pass
off, otherwise casting contain gas holes and pores.

Adhesiveness: it is the property due to which the sand particles of stick other
material.

Cohesiveness or strength: it is the property of moulding sand due to which the

sand particles stick with each other.

COMPOSITION OF MOULDINGSAND
The principle ingredients of moulding sand are
1. Silica sand: silica in the form of granular quartz is the chief ingredient of
moulding sand. It contains 80-90% of silicon dioxide and is characterized by high
softening temperature stability.
2. Clay: it is another important ingredient in the mixture of moulding sand which
gives bonding action by holding the sand together. The bonding qualities of clay is
depending upon the maximum thickness of water film it can maintain
3. Moisture: clay imparts bonding action and strength to the sand with
presence
moisture. When water is added to the clay and silica sand
mixture, it penetrates
to each sand particle and form a micro film
coating on the surfaces of particles.
bonding
The action is considered best if the water added is exact
quantity.
4. Sand additives: A good moulding sand contains impurities below 2%. Oxides of
iron, magnesia, lime stone, soda and potash are commonly used additives.
Butt

Peen

Hand rammer
 Many minerals (additives) are often added in small amounts for special purpose-like
to minimize sand expansion defects

PREPARATION OF MOULDING SAND

The preparation of moulding sand consists of these operations:

1. Mixing of sand: The sand is mixing with the other sand (sand additives) to retain
all the qualities that moulding sand should possess. Generally, it is mixed with clay,
lime, magnesia, potash soda etc.

sufficient water (moisture) is added

2. Sand tempering: It is the process by which
to the sand.
the binder (clay)
3. Sand conditioning: It accomplishes uniform distribution of
around the sand grains and preparing the moulding sand to suitable for ramming.

TYPES OF MOULDING SAND

Moulding sands are classified according to their use

1. Green sand:It is a mixture of silica sand with 18-30% clay, having water 6-8%

2. Dry sand: Green sand that has been dried or baked after mould is made is called

dry sand.
3. Facingsand: It is the face of the mould. It is used directly next to the surface of
the pattern.
4. Backing sand: It is used back up the facing sand and fills the whole volume of
moulding box.
5. Partingsand: It is used to keep the green sand from sticking to the pattern and
also allow the sand on the parting surface of the cope and drag to separate
without clinging
6. Core sand: Sand used for making cores is called core sand, sometimes it is called
oil sand.
 Shank

Handwhee
for pouting

bnc( (a) Hand Ladlc. (6) Shank Ladle.

Monoral
Relractory sleeves- (c) Tea pot Ladle.

Trotley
Handwhall lor
199
Q
1o Lever for pouring raising
or lowering

I/+Level lor pouring

d
g02 9tMgs:) Graphite pouringhole- Graphte slopper
Crucidle
(d) Bottom pour Ladle.
(e) Monorail or trolly Ladle.
Fle 4.7. Types of pouring ladles.
GREEN SAND MOULD
Green sand moulding is a type of moulding in which the mould is in moist state while
pouring the metal into it. Here the word green means "wet" or moist. Green sand
mould is widely used for casting all ferrous and non ferrous alloys. It is suitable for
small, medium and large casting

Advantages of green sand mould

Cheap and least expensive method.
Large output can be obtained from given floor size.
Green sand moulds soften than Dry sand mould.
Green sand moulds are quite strong for small depths, as the gases escape from
them
Green sand moulds do not require any backing operation or equipment

Disadvantages
The surface finish of the casting obtained from green sand mould is not very
smooth

Green sand mould cannot be stored for

longtime

CORE MAKING
A core is a portion of the mould, which forms hollow interior in the casting or hole
through the casting. The core is a mass of dry sand which is prepared separately, baked in an
oven and then placed in the mould. The core gives hollow
 Sprue Flow off

Cope
Setting pin

Drag

Core in position

***********************************************
 Foundry procedure
CUSHION PAD HOUSING

AIM EXP: 1

To make a mould of cushion pad housing

TOOL REQUIRED

Moulding box, moulding board, pattern, Shovel, hand rammer, went wire, strike of bar, bellows, lifter,
riddle, trowel.

MATERIAL REQUIRED

Moulding sand, water, parting sand

OPERATIONS

Preparation of green sand, facing sand applications, sand filling, ramming, levelling, and wending.

PROCEDURE

Collect the tools and pattern, prepare the moulding sand, and test it with hand. Keep the
drag box upside down place the patter in the box. Applying facing sand, place the gates. Applying green
sand (backing sand) and ram it fully level with strike of bar and turn the dreg box position so ask to keep
the cop over the drag. Place the cop over the drag without shift and lifts apply facing sand in the Pattern
cavity. Place the screw pins and vertically and fill with moulding sand. Ram completely and level it.
Remove the screw pins and make a basin for pouring the molten metal. Make went holes with went
wire. Part the drag and cope and remove the pattern and gates dry the mould in the atmosphere for
pouring.

RESULT

A mould gets ready for pouring the molten metal.

*********************
 DUM BELL

AIM EXP: 2

To make a mould of Dum bell

TOOL REQUIRED

Moulding box, moulding board, pattern, Shovel, hand rammer, went wire, strike of bar, bellows, lifter,
riddle, trowel.

MATERIAL REQUIRED

Moulding sand, water, parting sand

OPERATIONS

Preparation of green sand, facing sand applications, sand filling, ramming, levelling, and wending.

PROCEDRUE

Collect the tools and pattern; prepare the green sand, place the drag upside down, over
the moulding board. Place the first half of the split pattern place the gates and apply the facing sand
then apply green sand. Ram the sand with hand rammer. Level and remove the exes sand with strike of
bar. Bring the drag box in to normal position and place the cop over the drag carefully fix the other half
of the pattern over the pattern and place the sprues over the gates. Apply parting sand then put facing
sand on the pattern fill the green sand (backing sand) and ram it with hand rammer. Keep the sprues
vertically. Level and remove the excess sand. Make the went holes with went wire remove the sprues
and cut a basin for pouring the molten metal. Remove the sprues part the moulding g box and remove
the pattern and gates. Dry the mould in the atmosphere for pouring the molten metal.

RESULT

A mould got ready for pouring the molten metal

 FLANGED PIPE

AIM EXP: 3

To make a mould with core of Flanged pipe

TOOL REQUIRED

Moulding box, moulding board, pattern, Shovel, hand rammer, went wire, strike of bar, bellows, lifter,
riddle, trowel.

MATERIAL REQUIRED

Moulding sand, water, parting sand

OPERATIONS

Preparation of green sand, facing sand applications, sand filling, ramming, levelling, and core making

PROCEDURE

Collect the tools and pattern prepare the green sand prepare the core and drag it. Place the
moulding box (Drag) on the board as upside down places the half of the split pattern and gate pieces in
the drag box. Apply facing sand. Apply green sand (backing sand) and ram it with hand rammer. Remove
the excess sand and level with strike of bar then turn the box up and place the cop over the drag
without shifts and lifts place the other half the pattern over the first apply parting sand and facing sand.
Place the sprue pins vertically over the gates fill the box with green sand ( backing sand) and ram it
completely level the sand and make went hole with went wire remove the sprues and make basin for
pouring the molten metal. Part the box and remove the split pattern pieces and gates. Dry the mould in
the atmosphere for pouring the molten metal. Fix the core in the core prints of the mould property.

RESULT

The mould got ready for pouring the molten metal.