MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

PROPERTIES OF ENGINEERING ii) Compressive Strength

MATERIALS  It is the capacity of a material to

withstand destruction when it is
 Property of a material is a factor which
subjected to axial push (compressive
defines the behaviour of a material
load) acting normally across the cross
under various conditions.
section.
MECHANICAL PROPERTIES
iii) Shear Strength
 The properties of materials which are
 It is the capacity of material to
associated with the behaviour of
withstand destruction when it is
materials under the action of external
subjected to tangential load (shear
forces and loads
load) tending to cut or slide the part
1. STRENGTH across the resistive section.

 It is the capacity to withstand

destruction under the action of
external loads. Unit- kg/cm2 OR N/m2

i) Tensile Strength

 It is the capacity of a material to with

stand destruction when it is subjected
to axial pull (tensile load) acting
normally across the cross section.

iv) Torsional Strength

 It is the capacity of a material to

withstand destruction when it is
subjected to torsional load (load
tending to twist the part).

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

v) Bending Strength 4. RESILIENCE

 It is the capacity of a material to  It is the capacity of a material to absorb

withstand destruction, when it is energy elastically.
subjected to bending across the
5. BRITTLENESS
resisting section.
 Brittleness of a material is the property
2. HARDNESS
of breaking without much permanent
 Hardness is the ability of a material to distortion & appreciable deformation.
resist wear, scratching, abrasion,  Eg: cast iron, glass, etc.
indentation or penetration by harder
6. FATIGUE
bodies.
 The failure of a material caused under
repeated or fluctuating loads (stress) is
known as fatigue or fatigue failure.

7. STIFFNESS

 The resistance of a material to elastic

deformation or deflection is called
stiffness or rigidity. Modulus of
elasticity is the measure of stiffness.

8. DUCTILITY
3. TOUGHNESS
 It is the ability of a material to be
 It is the amount of energy a material drawn from a large section to small
can absorb before fracture or failure section without rupture. OR
takes place, OR  It is the property of a material which
 It is the ability of a material to enables it to draw out in to thin wire.
withstand repeated bending or twisting e.g. gold, platinum, silver, iron etc. are
without fracture. the most ductile metals.

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

9. MALLEABILITY • The sand moulds are prepared in

specially constructed boxes called
 Ability of a material to be flattened in
flasks, which are open at the top and
to thin sheets without cracking under
bottom.
compressive stress.
 Ex:-Gold, Aluminium, Copper etc. • They are made in two parts, held in
alignment by dowel pins.
FOUNDRY
• The top part is called the cope and the
 A shop where moulding, casting and lower part as drag.
their related processes are conducted
• If the flask is made in three parts. The
is called a foundry shop.
intermediate part is called a cheek.
 Casting is a process of pouring molten
to a mould and allowing it to solidify. • These flasks can be made of either

 The whole process of producing wood or metal.

castings may be divided in to five Procedure for Green sand moulding or

stages. Steps involved in sand moulding

(1) Pattern making (2) moulding and core 1) First half of the Pattern is placed in drag
making (3) melting and casting box.

(4) fettling (cleaning) and (5) Testing and 2) Facing sand is added.
inspection.
3) Then drag is filled fully with green sand
FOUNDRY TOOLS AND EQUIPMENTS and rammed.

MOULDING BOXES (FLASKS) 4) Vent holes are made.

5) Now drag is tilted upside down.

6) The parting sand is sprinkled over the

pattern and sand.

7) Cope is placed and connected properly.

8) Second half pattern is placed correctly.

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

9) Riser pin and sprue pin is placed in

correct position.

10) The operations like sand filling,

ramming etc are made.

11) Sprue pin and riser are removed.

2. Riddle
12) Cope and drag separated.
• A riddle has a standard wire mesh fixed
13) Pattern is removed by using draw into a circular or square wooden frame.
spikes.
• It is used for cleaning the moulding
14) Now gate is cut and cleaned the cavity. sand.

15) Now ready for pouring molten metal. 3. Rammer

• A hand rammer is made of wood or

metal.

• It is used for packing and ramming the

sand.

 HAND TOOLS

1. Shovel

• A shovel consists of a square pan fitted

with a wooden handle. 4. Slick

• It is used for mixing and for moving the • A slick is a double ended tool having a
sand from one place to another in the flat on one end and a spoon on the
foundry. other.

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

• It is used for repairing and finishing the • It consists of a metal blade with a
mould surfaces after the pattern is wooden handle.
withdrawn.
• The small trowels of various shapes are
5. Lifter used for finishing and repairing mould
cavities as well as for smoothing over
• A lifter is made of thin sections of steel
the parting surface of the mould.
of various width and lengths with one
end bent at right angles

• It is used for smoothing and cleaning

out depressions in the mould.

9. Gate cutter

• It is a U-shaped piece of thin sheet.

• It is used for cutting a shallow trough in

6. Swab the mould to act as a passage for the
hot metal.
• A simple swab has a small brush having
long hemp fibers.

• It is used for moistening the sand

around the edge before the pattern is
removed.

7. Bellow 10. Gaggers

• A hand operated bellow is used to blow • These are iron rods bent at one end or
loose particles of sand from the cavities both ends
and surface of the mould.
• These are used for reinforcement of
8. Trowel sand in the top of the moulding box
and to support hanging bodies of sand.

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

11. Strike off bar 1. Solid or single piece pattern

• Used to remove excess sand from the  These types are made of single solid
moulding box while preparing the piece without joints.
mould.  It is used for making simple castings.

PATTERN 2. Split pattern

 A pattern is a model or the replica of  It is made in two parts.

the object to be cast.  One part for lower half and other half

 It is used for forming an impression for upper part.

called mould cavity in damp sand or  These two parts are connected by

other suitable material. dowel pins.

TYPES OF PATTERNS

(1) Solid or single piece pattern

(2) Split pattern

(3) Match plate pattern

3. Sweep pattern
(4) Loose piece pattern
 A sweep is a board made of wood or
(5) Gated pattern
metal to the required cross section that
(6) Sweep pattern
is rotated about one edge to shape

(7) Segmental pattern mould having symmetrical shape.

 A half board is fitted to the Centre
spindle.

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

6. Segmental pattern

 This pattern is used for forming

circular moulds.

4. Loose piece pattern

 It is impossible to withdraw a pattern

from its mould, if the pattern is a single
7. Gated pattern
piece having projections.
 A group of patterns attached with a
 In this case, the pattern is made into
common gating system are called gated
solid pattern and loose piece pattern.
patterns.
 After making the mould, first solid
 A gated pattern can produce many
pattern is removed and then loose
castings at a time
piece is removed.
 Gated pattern and is used in mass
production systems.

5. Match plate pattern

 The pattern is made into two halves Pattern materials

mounted on both sides of a plate is
 Wood, metal, plaster, plastic, wax.
called match plate pattern.
1. Wood

 Teak wood, mahogany, rose wood

etc are used.

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

Advantages Disadvantages

 Light in weight.  It is used only for small pattern

 Easy to work.  It is affected by moisture.
 It can be easily repaired.
4. Plastics
Disadvantages
 Poly ethylene, poly vinyl chloride can
 It absorbs water from sand and be used.
changes its shape.
Advantages
2. Metal
 It is light in weight but very strong.
Cast iron, brass, aluminium are used.  It is not affected y moisture and more
wear resistant.
Advantages
 It has very smoothy surface.
 It has long life.
Disadvantages
 It is accurate in size.
 It has smooth surface.  It can only be used for small castings.
 It resists wear, tear, and corrosion.
5. Wax
Disadvantages
 It is used in investment casting. Paraffin
 It is costly. wax, shellac wax are used.
 It is heavier than wood.
Advantages
3. Plaster
 It has god surface finish.
 Plaster of paris, gypsum cement is  It has high dimensional accuracy.
used.  It will not absorb moisture.
 It is easy to work.
Advantages
Disadvantages
 Difficult shape can be easily made.
 Very easy to work.  It can only be used for small castings.
 It has high compressive strength.

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

PATTERN ALLOWANCES

 Pattern allowance is provided to avoid

the metal distortion, for easy
withdrawal of pattern, from mould etc.
d) Distortion or camber allowance
 Types of allowances are,
• This allowance is provided on patterns
a) Shrinkage allowance used for castings of such design in

b) Machining or finishing allowance which the contraction is not uniform

throughout.
c) Draft or taper allowance

d) Distortion or camber allowance

e) Rapping or shake allowance

a) Shrinkage allowance
d) Rapping or shake allowance
• It is provided to compensate shrinkage
• This allowance is provided in the
during the solidification of metal.
pattern to compensate the rapping of
b) Machining or finishing allowance mould because the pattern is to be
rapped before removing it from the
• This allowance is provided on the
mould.
pattern if the casting is to be machined
• It is a negative allowance
c) Draft or taper allowance
CORE, CORE PRINTS & CHAPLETS
• It is a taper which is given to all the
vertical walls of the pattern for easy  Cores are used for forming the holes,
and clean withdrawal of the pattern recesses, projections, undercut, and
from the sand without damaging the internal cavities. Usually made of sand.
mould cavity.  The projections provided on the
pattern for the seating of core are
• It may be expressed in millimeters per
known as core print.
meter on a side or in degrees

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

 Chaplets are used to support sand core 3. Adhesiveness

in mould cavity.
• It is that property of sand due to which
it adheres or cling to the sides of the
moulding box.

4. Cohesiveness or strength

• It is that property of sand due to which

the sand grains stick together during
ramming.

• It is defined as the strength of the

PROPERTIES OF MOULDING SAND moulding and.

1. Porosity or permeability. 5. Refractoriness

2. Plasticity or flow ability. • It is that property of sand which

enables it to resist high temperature.
3. Adhesiveness.
6. Collapsibility
4. Cohesiveness or strength.
• The property of moulding sand to
5. Refractoriness.
collapse easily after the casting
6. Collapsibility. solidifies.

1. Porosity or permeability MOULDING SAND CONSTITUENTS

• It is that property of sand which The main ingredients of any molding sand
permits the steam and other gases to are:
pass through the sand mould.
1. Base sand
2. Plasticity or flow ability 2. Binder

 It is that property of sand due to which 3. Additives

it flows to all portions of the moulding 4. moisture

box or flask.

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

Base Sand MOULDING PROCESSES

 Silica sand is most commonly used base The various moulding processes may be
sand. classified as follows
 It gives refractoriness to the sand
(i) According to the method used
Binder
(a) Bench moulding (b) Floor moulding
 It is used to bring the cohesiveness
(c) Pit moulding (d) Machine moulding
property.
(ii) According to the mould materials
Binders are of many types such as:
used.
1. Clay binders
(A) Sand moulding
2. Organic binders and (1) Green sand moulding (2) Dry- sand moulding

3. Inorganic binders (3) Skin-dried moulding (4) Core sand moulding

(5) Loam moulding (6) Cement bonded moulding

 Clay binders are most commonly used
(7) Co2 moulding (8) Shell moulding
binding agents mixed with the molding
(B) Ceramic moulding
sands to provide the strength.
(C) Plaster moulding
Additives
(D) Metallic moulding
 It is used to improve the strength.
 Commonly used additives are coal, saw Classification of moulding processes

dust etc. based on the methods used

Moisture Bench moulding

 Clay acquires its bonding action only in  In this method the moulds are

the presence of the required amount of prepared by the moulder on a bench,

moisture (water). in standing position.

 It is used for small castings which are
light in weight.
 It is slow and laborious method.

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

Floor moulding 2. Dry sand

 The moulding done on the foundry • The green sand moulds when baked or
floor called floor moulding and is dried before pouring the molten metal
employed for medium and large size are called dry sand moulds
articles.
• The sand in this condition is called dry
 It is also slow and laborious
sand. The dry sand moulds have
Pit moulding greater strength, rigidity and thermal
stability.
 In this method, the pit acts as a drag
part of the mould and a separate cope • These moulds are used for steel
is rammed and used above it. castings.

 This is the only method of moulding

• Used for large castings.
used for extremely large castings.
3. Loam sand
Types of moulding sand
• A mixture of 50 % and 50 % clay is
1. Green sand called loam sand.

• The sand in its natural or moist state is • It is used for loam moulding of large
called green sand.
grey-iron castings.

• It is a mixture of silica sand with 20 to

• Suitable only for single casting.
30 % clay, having total amount of water
4. Facing sand
from 6 to 10 %.
• Sand used for facing of the mould to
• The moulds prepared with this sand
give a better surface finish to the
are called green sand moulds.
castings.
• The green sand moulds are used for
• Since it comes in contact with molten
small size castings of ferrous and non-
metal when poured, therefore it must
ferrous metals.
possess high strength and
refractiveness.

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

5. Backing or floor sand (2) External chills

• Sand used to back up the facing sand  External chills are rammed up in the
and not used next to the pattern, is mould walls.
called backing sand.  They control the cooling rates in critical
regions of castings.
• It is sometimes called black sand
 External chills are again divided in to
because of its black colour.
two types
6. Parting sand
(a) Direct external chills and
• Sand employed on the faces of the
(b) Indirect external chills.
patterns and the parting surfaces of
the mould to separate cope and drag  A Direct external chill is placed in the
easily. mould such that they flush with the
mould walls and form a part of it.
7. Core sand
 An indirect external chill does not come
• Sand used for the preparation of cores
in contact with the liquid metal.
is called core sand.
 They are rammed and embedded
• It is sometimes called oil sand. behind the mould wall.

USE OF CHILLS

 Chills are metal shapes inserted in,

moulds; which help in achieving proper
directional solidification.

(1) Internal chills

 They are placed within the mould

cavity, and ultimately form a part of POURING AND FEEDING CASTINGS

the casting. Therefore they should be Pouring

made of the same metal as the casting.
 Pouring of molten metal is an
important step in foundry, because the

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

behaviour of the liquid metal and its  The excess metal absorbed-in gates
subsequent freezing determines the and risers should be minimum
soundness of casting.
ELEMENTS OF A GÁTING SYSTEM
 Pouring temperature is very important
both low and excessive pouring 1. Pouring basin

temperature create defects in castings.  The molten metal from the ladle is
 Pouring temperature also influence poured into the pouring basin from
grain size and crystal structure. where it moves into the sprue and

GATING SYSTEM through the runner to other areas.

 It is provided to minimize the splash
 All channels or passage ways through
and turbulence and to prevent the
which the molten metal is delivered to
entry of dirt or slag in to sprue.
the mould cavity is called gating or
gating system. Sprue

Requirements, purposes or functions of a  t is a vertical passage which connects

gating system the pouring basin with the runner or

gate.
 It should fill the mould cavity
 The sprues are generally circular
completely before freezing.
downwards to or rectangular in shape
 lt should be able to avoid mould
and are tapered avoid aspiration of air
erosion by reducing the metal velocity
during the metal flow.
with in the mould cavity
 lt should prevent slag, and other 3. Sprue base or well

foreign particles from entering the • At the bottom of the sprue is a

mould reservoir for molten metal called sprue
 It should promote directional well.
solidification of the casting
• It serves to dissipate the kinetic energy
 It should be economical and
of the falling stream of molten metal.
practicable in their formation.

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MANUFACTURING TECHNOLOGY M1 PRAVEEN KP Lr: in ME

4. Runner (2) It permits the escape of air and mould

gases
• It is generally located in the horizontal
plane (parting plane) which connects (3) Risers promote directional
the sprue to its ingates, thus letting the solidification
metal enter the mould cavity.
(4) A riser with full of molten metal applies
5. Skim bob sufficient feeding pressure and also
indicates that the mould is completely
• It is an enlargement along the runner
filled.
whose function is to trap heavier and
lighter impurities such as dross or 8. Choke
eroded sand.
• It has the smallest cross sectional area.
• This prevents impurities from going in
Functions
to mould cavity.
1. To control the rate of metal flow
6. Gates
2. To minimize the sand erosion in the
• Gates, also called the ingates, are the
runner
openings through which the molten
metal enters the mould cavity. 3. To hold the slag and foreign material

7. Riser

 A riser is a passage made in the cope

through which the molten metal rises
after the mould is filled up.

It serves the following functions

(1) Its primary function is to feed the

molten metal to the casting, to
compensate the shrinkage during
solidification

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