BY
V.KAMALA
Assistant Professor,
DOIE, Anna University,
Chennai.
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A foundry is:
A factory that pours molten metal into molds,
producing cast metal objects.
Some
typical cast
metal
objects:
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Engine blocks,
axles
Turbine blades
in jet engines
Aluminum
pots
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CASTING
PATTERN
A copy of the shape you want to
produce, made of wood, plastic or
metal
SAND,
Mixed With Clay Binder &
Water (So It Will Hold Its
Shape) Plus Coal Dust To
Improve Surface Finish
MOLDING:
MOLDING:
Sand placed into
bottom mold
form &
compacted
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MOLDING: Add
the top mold
form
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MOLDING: Take
the top mold off
and remove
pattern & pipe
or post
Pouring
hole
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CASTING:
Pour the metal (container is filled
from furnace immediately before
you are ready to pour)
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CLEANING. Sand is
cleaned off the part, the
tab where metal flowed
in must be removed.
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CASTING TERMINOLOGY
FLASK
The frame and support
COPE
The upper half of sand
mold
DRAG
The lower half of the sand
mold
PATTERN
Shape used to mold the
shape of the casting
POURING BASIN
Orifice where molten metal
is poured into the mold
SPRUE
Vertical channel through
which molten metal flows
downward into mold
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CASTING TERMINOLOGY
RUNNERS
Channels that carry molten
metal from sprue to mold
RISER
Reservoirs to supply the
molten metal needed to make
up shrinkage losses during
solidification.
GATE
Portion Of Runner Through
Which The Molten Metal
Enters The Mold Cavity, Used
To Trap Contaminants.
VENTS
Openings used to carry off
gases given off by the metal
and exhaust air.
CORES
Insets
used
to
produce
interior cavities.
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Patternmaking
Core making
Molding
Melting and pouring
Cleaning
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Shrinkage allowance
Machining or finish allowance
Draft or taper allowance
Distortion or camber allowance
Rapping or shake allowance
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1. SHRINKAGE ALLOWANCE
All most all cast metals shrink or contract
volumetrically on cooling. The metal shrinkage is of
two types:
Liquid Shrinkage: it refers to the reduction in
volume when the metal changes from liquid state
to solid state at the solidus temperature. To
account for this shrinkage; riser, which feed the
liquid metal to the casting, are provided in the
mold.
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Material
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Dimension
Shrinkage allowance
(inch/ft)
Up to 2 feet
2 feet to 4 feet
over 4 feet
0.125
0.105
0.083
Cast Steel
Up to 2 feet
2 feet to 6 feet
over 6 feet
0.251
0.191
0.155
Aluminum
Up to 4 feet
4 feet to 6 feet
over 6 feet
0.155
0.143
0.125
Magnesium
Up to 4 feet
Over 4 feet
0.173
0.155
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Pattern material
Height of the
given surface
(inch)
Draft angle
(External
surface)
Draft angle
(Internal
surface)
1
1 to 2
2 to 4
4 to 8
8 to 32
3.00
1.50
1.00
0.75
0.50
3.00
2.50
1.50
1.00
1.00
1
1 to 2
Metal and plastic 2 to 4
4 to 8
8 to 32
1.50
1.00
0.75
0.50
0.50
3.00
2.00
1.00
1.00
0.75
Wood
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Metal
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Dimension (inch)
Allowance (inch)
Cast iron
Up to 12
12 to 20
20 to 40
0.12
0.20
0.25
Cast steel
Up to 6
6 to 20
20 to 40
0.12
0.25
0.30
Non ferrous
Up to 8
8 to 12
12 to 40
0.09
0.12
0.16
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Design of casting
Number of castings to be produced
Degree of accuracy and surface finish
required
Shape, complexity and size of the
castings
Castings or moulding methods adopted
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Advantages:
Inexpensive
Easily available in large quantities
Easy to fabricate
Light in weight
They can be repaired easily
Easy to obtain good surface finish
Limitations:
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Advantages:
Do not absorb moisture
More stronger
Possess much longer life
Do not wrap, retain their shape
Greater resistance to abrasion
Accurate and smooth surface finish
Good machinability
Limitations:
Expensive
Not easily repaired
Ferrous patterns get rusted
Heavy weight
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Advantages:
Durable
Provides a smooth surface
Moisture resistant
Does not involve any appreciable change in size or
shape
Light weight
Good strength
Wear and corrosion resistance
Easy to make
Abrasion resistance
Good resistance to chemical attack
Limitations:
Plastic patterns are Fragile
Advantages:
It can be easily worked by using wood
working tools.
Intricate shapes can be cast without any
difficulty.
It has high compressive strength.
Advantages:
Provide very good surface finish.
Impart high accuracy to castings.
After being molded, the wax pattern is not
taken out of the mould like other patterns;
rather the mould is inverted and heated; the
molten wax comes out and/or is evaporated.
Thus there is no chance of the mould cavity
getting damaged while removing the pattern.
Refractory sand
Binder
Additives
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GREEN SAND
DRY SAND
LEAN SAND
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CO2 sand
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Sea Coal
Silica flour
sawdust
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REFRACTORINESS
POROSITY or PERMEABILITY
STRENGTH or COHESIVINESS
PLASTICITY or FLOWABILITY
FINENESS
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((W1-W2)/(W1) )%
Where, W1-Weight of the sand before
drying,
W2-Weight of the sand after drying
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1. The air (2000cc volume) held in the bell jar is forced to pass through
the sand specimen.
2. At this time air entering the specimen equal to the air escaped
through the specimen
3. Take the pressure reading in the manometer.
4. Note the time required for 2000cc of air to pass the sand
5. Calculate the permeability number
6. Permeability number (N) = ((V x H) / (A x P x T))
Where,
V-Volume of air (cc)
H-Height of the specimen (mm)
A-Area of the specimen (mm2)
P-Air pressure (gm / cm2)
T-Time taken by the air to pass through the sand (seconds)
MOULDING TOOLS
SHOVEL
RIDDLE
RAMMER
TROWEL
SLICK
STRIKE OFF BAR
LIFTER
VENT WIRE
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SPRUCE PIN
RISER PIN
GATE CUTTER
DRAW SPIKE
SWAP
MALLET
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JOLTING MACHINE
SQUEEZING MACHINE
SAND SLINGER
JOLTING MACHINE
Pattern is placed in
the flask on the
table
The table with flask
is raised about
80mm and
suddenly dropped
It is mainly used
for horizontal
surface
Operations is noisy
because of jolting
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SQUEEZING MACHINE
Moulding sand in the flask
is squeezed between the
machine table and
squeezer head
The mould board is
clamped on the table
The flask is placed on the
mould board
The pattern is placed
inside the disk
The table is raised by table
left mechanism against the
squeezer head
After the squeezing is over,
the table comes down to
the starting position
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SAND SLINGER
Pattern is placed on a
board
Flask is placed on it
The slinger has an
impeller rotates at
different speeds
It throws a stream of
sand at great velocity
into the flask
Slinger can be moved to
pack the sand uniformly
around the pattern.
Ramming will be uniform
with good strength
Used for large and
medium size moulds
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CORE BOXES
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CORE BOXES
SPLIT CORE BOX
Two similar half boxes
Box is assembled in correct
position by dowel pins before
filling the sand
Boxes are separated after
ramming the sand
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and
HORIZONTAL CORE
Placed horizontally in the mould
It may have any shape depending
on the design
It is supported in the core seats at
the ends
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VERTICAL CORE
It is positioned vertically in
the mould
Ends of the cores rest on
core seats in core and drag
HANGING CORE
These are supported above
and hang into the mould
No support from the
bottom
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BALANCING CORE
Core is supported and
balanced from its end
It requires a long core seat
so that core does not sag or
fall into the mould
It is used when the blind
holes along a horizontal
axis are to be produced
DROP CORE
This core is used when a
hole is not in line with the
parting surface is to be
produced at a lower surface
Hole may be above or
below the parting line of
the mould
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ADVANTAGES OF CUPOLA
Simple design and easier construction
Low initial cost as compared to other furnaces of same
capacity
Simple to operate and maintain in good condition
Less floor space requirements as compared to those of
other furnaces of capacity
Cupola can be continuously operated for many hours.
Electric Power is not required.
Offer very high melting rate ( 1 to 35 tons per hour)
Shell casting
Investment casting
Ceramic mould
Lost Wax process
Pressure die casting
Centrifugal casting
CO2process