DEPARTMENT OF TECHNICAL EDUCATION ANDHRA PRADESH

Name Designation Branch Institute Year/semester Subject Subject Code Topic Duration Sub. Topic Teaching Aids : : : : : : : : : : : P. Ramulu Work Shop Supdt., Mechanical Engineering Govt.Polytechnic for women, Medak. I year Work shop Technology M-105 Foundry 100 Minutes Appreciate Foundry advantages. List of moulding tools Animation Clips & Images
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Objectives:
On the completion of this period, you would be able to know:
Importance of castings Advantages of castings Disadvantages of castings List of various hand molding tools
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What is manufacturing ?
Manufacturing is the process of transferring the raw material into finished products.

List out the different manufacturing processes

Metal Cutting (Machining)

Metal forming Casting Powder metallurgy

What is Machining
Machining is the process of removing excess

materials from the work piece to make it into finished products:

eg:- shafts, bolts , nuts etc.

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What is foundry?
The process of making products from molten metal is called foundry and products obtained are called castings.. eg:- Fly wheel , gears ,engine cylinder block

Fig. 1 Cylinder block

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Fig.2. Valve
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Advantages of foundry

It is cheapest manufacturing process

It is very fast.

Intricate shapes can be produced.

No wastage of material . Suitable for mass production

Limitations of Foundry
Only suitable for materials with castability such as C I , aluminum, Al alloys, gold etc Needs Furnace to produce molten metal Usually casting are brittle and not to tough.

Steps of Operations
The sequence of steps involved in casting are :
Pattern making Mould and core making

Melting and pouring

Fettling, and

Inspection

Molten Metal
Cast Iron, Aluminum etc. are melted in Various furnaces.

Fig 4. Melting in furnace

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Mould
It is a hollow cavity of casting. Made of moulding sand . Moulding sand is natural sand or synthetic sand . Pattern is kept in the moulding sand to prepare mould.

Fig 5. Mould
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Pattern
A model of required casting . Made of light materials like wood , plastic. Used to make Mould.

Fig 6. Pattern
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List of Hand Moulding Tools

Moulding Flask:
Used for small castings. Made of wooden or metal frame. Made into two parts (cope and drag). It is rigid frame.

Fig 7. Moulding flask

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Fig 8 Moulding tools

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List of Hand Moulding Tools(contd..)

Moulding Boxes:
Used for large castings . Made of wooden frame.

Fig 9. Moulding Boxes

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List of Hand Moulding Tools (contd..)

Moulding Board:
It is a smooth wooden board. Pattern is placed on board. Moulding box also is placed on it. Moulding sand is poured and rammed to make compact.

Fig 10. Moulding Board

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Summary
In this class , we have stated that,
Manufacturing is the process of making products from raw materials. Casting is the process dealing with molten metals Advantages of casting as fast and cheapest manufacturing method Disadvantage as it is suitable to some metals Pattern ,moulding box, board etc are casting tools
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Quiz
1. The Top part of Moulding Box is __________________ . Ans(Cope) 2. Bottom part of Moulding Box is ___________. Ans(Drag)

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Quiz
3.The mould material is _________________.
(Moulding sand) 4. Mould is made by using _____________ which is model of casting . (Pattern)

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Frequently Asked Questions

1. 2. What is meant by mould? What is meant by casting?

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