Manufacturing

Technology

1
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
MANUFACTURING TECHNOLOGY

MA
NUF
ACT
URI
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
2

NG
 Manufacturing

Technology

MME 2105: MANUFACTURING TECHNOLOGY [4 0 0 4]

Foundry: Moulding, Types of moulding, Moulding materials, Moulding sand,

Composition of moulding sand. Sand Testing - Permeability test, Strength test,
Moisture content test, Clay content test, Grain fineness test. [05]

Casting: Types of casting- Investment casting, Permanent mould casting, Slush

casting, Pressure die casting (Hot chamber & Cold chamber), Centrifugal
casting and Continuous casting, Advantages & limitations of casting process.
[05] 3
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
Welding: Classification of welding processes, Metal arc welding, Consumable
and nonconsumable arc welding process, Submerged arc welding, Atomic-
hydrogen welding, TIG, MIG, Electro-slag, Resistance welding - Spot, Seam,
 Manufacturing

Technology

4
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

5
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

MME 2105: MANUFACTURING TECHNOLOGY [4 0 0 4]

6
Non-conventional
Department machining:
of Mechanical Principles, Working,
& Manufacturing Equipment,
Engineering, Advantages, Limitations,
MIT, Manipal
Applications of Abrasive Jet Machining (AJM), Water Jet achining (WJM), Abrasive Water
Jet Machining (AWJM), Ultrasonic Machining (USM), Electro Chemical Machining (ECM),
Electro Chemical Grinding (ECG), Electrical Discharge Machining (EDM), Chemical
 Manufacturing

Technology

7
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

8
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

9
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

10
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
1. Foundry
Introduction:
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting
them into a liquid, pouring the metal in a mold, and removing the mold material or casting
after the metal has solidified as it cools. The most common metals processed are aluminium
and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are
also used to produce castings in foundries. In this process, parts of desired shapes and sizes
can be formed.

11
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

Moulding:
Sand casting, also known as sand molded casting, is a metal casting process characterized by
using sand as the mold material. It is relatively cheap and sufficiently refractory even for steel
foundry use. A suitable bonding agent (usually clay) is mixed or occurs with the sand. The
mixture is moistened with water to develop strength and plasticity of the clay and to make
the aggregate suitable for molding. The term "sand casting" can also refer to a casting
produced via the sand casting process. Sand castings are produced in specialized factories
called foundries.
12
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

Molding is the operation necessary to prepare a mold for receiving the metal. It consists of
ramming sand around the pattern placed in support, or flask, removing the pattern, setting
cores in place, and creating the gating/feeding system to direct the metal into the mold cavity
created by the pattern, either by cutting it into the mold by hand or by including it on the
pattern, which is most commonly used.

Types of Moulding:

13
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
Molding processes can be classified in a number of ways. Broadly they are classified either on
the basis of the method used or on the basis of the mold material used.
(i) Classification based on the mold material used:
(a) Sand molding:
1. Green sand mold
2. Dry sand mold,
3. Cement bonded sand mold
4. Carbon-dioxide mold.
5. Shell mold.
14
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
(b) Plaster molding,
(c) Metallic molding.
(ii) Classification based on the method used
(a) Bench molding. (b) Floor molding,
(c) Pit molding. (d) Machine molding.

Molding Material and Properties

A suitable and workable material possessing high refractoriness in nature can be used for
mold making. Thus, the mold making material can be metallic or non-metallic. For metallic
15
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
category, the common materials are cast iron, mild steel and alloy steels.In the non-metallic
group molding sands, plaster of paris, graphite, silicon carbide and ceramics are included. But,
out of all, the molding sand is the most common utilized non-metallic molding material
because of its certain inherent properties namely refractoriness, chemical and thermal
stability at higher temperature, high permeability and workability along with good strength.
Moreover, it is also highly cheap and easily available. A large variety of molding materials is
used in foundries for manufacturing molds and cores. They include molding sand, system sand
or backing sand, facing sand, parting sand, and core sand.

16
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
Types of Molding Sand:
Depending upon the purity and other constituents present, sand is classified into
(i) Natural sand. (ii) Synthetic sand, (iii) loam sand.

(i) Natural sand:

Natural sand is directly used for molding and contains 5-20% of clay as binding material. It
needs 5-8% water for mixing before making the mold. Many natural sands possess a wide
working range of moisture and are capable of retaining moisture content for a long time. Its
main drawback is that it is less refractory as compared to synthetic sand. Many natural sands
17
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
have weak molding properties. These sands are reconditioned by mixing small amounts of
binding materials like bentonite to improve their properties and are known as semi-synthetic
sand.

(II) Synthetic Sands:

Synthetic sand consists of silica sand with or without clay, binder or moisture. It is a
formulated sand i.e. sand formed by adding different ingredients. Sand formulations are done
to get certain desired properties not possessed by natural sand. These sands have better
casting properties like permeability and refractoriness and are suitable for casting ferrous and
18
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
non-ferrous materials. These properties can be controlled by mixing different ingredients.
Synthetic sands are used for making heavy castings.

(III) Loam Sand:

Loam sand contains many ingredients, like fine sand particles, finely ground refractories,
clay, graphite and fiber reinforcements. In many cases, the clay content may be of the order
of 50% or more. When mixed with water, the materials mix to a consistency resembling
mortar and become hard after drying. Big molds for casting are made of brick framework lined

19
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
with loam sand and dried. Sweeps etc. are used for making big castings like big bells by using
loam sand.

Constituents of Molding Sand:

The main constituents of molding sand involve silica sand, binder, moisture content and
additives.

Silica sand

20
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
Silica sand in form of granular quarts is the main constituent of molding sand having enough
refractoriness which can impart strength, stability and permeability to molding and core sand.
Along with silica small amounts of iron oxide, alumina, lime stone, magnesia, soda and potash
are present as impurities. The chemical composition of silica sand gives an idea of the
impurities like lime, magnesia, alkalis etc. present. The presence of excessive amounts of iron
oxide, alkali oxides and lime can lower the fusion point to a considerable extent which is
undesirable.

Moisture
21
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
The amount of moisture content in the molding sand varies generally between 2 to 8 percent.
This amount is added to the mixture of clay and silica sand for developing bonds. This is the
amount of water required to fill the pores between the particles of clay without separating
them. This amount of water is held rigidly by the clay and is mainly responsible for developing
the strength in the sand. The effect of clay and water decreases permeability with increasing
clay and moisture content. The green compressive strength first increases with the increase
in clay content, but after a certain value, it starts decreasing.

Additives
22
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
Additives are the materials generally added to the molding and core sand mixture to develop
some special property in the sand. Some common used additives for enhancing the properties
of molding and core sands are.

(i) Coal dust

Coal dust is added mainly for producing a reducing atmosphere during casting. This reducing
atmosphere results in any oxygen in the poles becoming chemically bound so that it cannot
oxidize the metal.

23
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
(ii) Dextrin
Dextrin belongs to starch family of carbohydrates. It increases dry strength of the molds.

(iii) Pitch
It is distilled form of soft coal. It can be added from 0.02 % to 2% in mold and core sand.
It enhances hot strengths, surface finish on mold surfaces.

(iv) Wood flour

24
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
This is a fibrous material mixed with a granular material like sand; its relatively long thin fibers
prevent the sand grains from making contact with one another. It can be added from 0.05 %
to 2% in mold and core sand. It increases collapsibility of both of mold and core.

The choice of molding materials is based on their processing properties. The properties that
are generally required in molding materials are:

Refractoriness

25
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
It is the ability of the molding material to resist the temperature of the liquid metal to be
poured so that it does not get fused with the metal. The refractoriness of the silica sand is
highest.

Permeability
During pouring and subsequent solidification of a casting, a large amount of gases and steam
is generated. These gases are those that have been absorbed by the metal during melting, air
absorbed from the atmosphere and the steam generated by the molding and core sand. If
these gases are not allowed to escape from the mold, they would be entrapped inside the
26
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
casting and cause casting defects. To overcome this problem the molding material must be
porous. Proper venting of the mold also helps in escaping the gases that are generated inside
the mold cavity.

Green Strength
The molding sand that contains moisture is termed as green sand. The green sand particles
must have the ability to cling to each other to impart sufficient strength to the mold. The
green sand must have enough strength so that the constructed mold retains its shape.

27
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
Dry Strength
When the molten metal is poured in the mold, the sand around the mold cavity is quickly
converted into dry sand as the moisture in the sand evaporates due to the heat of the molten
metal. At this stage the molding sand must possess the sufficient strength to retain the exact
shape of the mold cavity and at the same time it must be able to withstand the metallostatic
pressure of the liquid material.

Hot Strength

28
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
As soon as the moisture is eliminated, the sand would reach at a high temperature when the
metal in the mold is still in liquid state. The strength of the sand that is required to hold the
shape of the cavity is called hot strength.

Collapsibility
The molding sand should also have collapsibility so that during the contraction of the solidified
casting it does not provide any resistance, which may result in cracks in the castings. Besides
29
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
these specific properties the molding material should be cheap, reusable and should have
good thermal conductivity.

Test on Moulding Sands:

⮚ Moisture content test
⮚ Grain fineness test
⮚ Permeability test
⮚ Strength test

30
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
Moisture content test:
● 20 – 50 gms of prepared sand us placed in a pan and is by an infrared heater for 2 – 3
minutes.
● Moulding sand is taken out and reweighed.
● % moisture can be calculated from the difference in the weights.

31
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

32
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
Figure 1.1: Moisture determining apparatus

Grain fineness test:

This test determines
a) Grain size
b) Distribution
c) Grain fineness

33
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
The instrument consists of 11 standard sieves and a shaker. The top is the coarsest and the
bottom finest. To obtain the GRAIN FINENESS NUMBER, % of each sieve size is multiplied by
a factor and added. The result is ÷ total % of sand grains retained.

34
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

35
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

Figure 1.2: Grain fineness tester

Permeability test
Permeability is the property of moulding sand which permits the escape of steam & other
gases generated during pouring.
Permeability depends on:
• Grain size.
• Grain shape.
• Grain distribution.
36
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
• Binder & its content.
• Degree of ramming.
• Water content of the sand.
Since permeability is the property of moulded sand, a standard specimen is to prepared first.
This is done by using the Sand Rammer.

37
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

38
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
Figure 1.3: Sand specimen rammer
Permeability tester
Consists of:
• Inverted Bell jar, which floats in a water seal and can permit 2000 cc of air flow.
• Specimen tube, to hold the sand specimen.
• Manometer to read the Air pressure.
• 2000 cc of air held in the inverted bell jar is forced to pass through the sand specimen.
• A situation comes when the air entering the specimen equals the air escaped through
the specimen. (Constant Pr. ‘P’ on manometer).
39
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
• Simultaneously, measure the time ‘T’ for 2000 cc of air to pass through the specimen.
•

40
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

41
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

Figure 1.4: Permeability tester

42
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

Strength test
The following tests are conducted on foundry sands:
a) Compression
b) Tensile.
c) Shear
d) Transverse (Bending).
43
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
Testing is done on a Strength Tester

44
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

45
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology
Figure 1.5: Strength tester machine

46
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

47
Department of Mechanical & Manufacturing Engineering, MIT, Manipal
 Manufacturing

Technology

Figure 1.6: Shapes for strength tester

48
Department of Mechanical & Manufacturing Engineering, MIT, Manipal