By
Mr.B.Ramesh, M.E., (Ph.D.),
Research Scholar, CEG, Anna University, Chennai.
Associate Professor,
Department of Mechanical Engineering,,
St. Joseph’s College of Engineering,
Jeppiaar Trust, Chennai-119
What is a Foundry?
A foundry is:
a factory that pours molten metal into molds,
producing cast metal objects.
• Casting is one of the oldest industrial processes
• There are different casting processes.
The focus here is: “GREEN SAND” CASTING
2
SAND-CASTING
Basic materials & equipment for green sand-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
First of all,
mix the sand.
THEN 1
MOLDING: 2 MOLDING:
Sand placed Pattern placed into mold
into bottom
mold form &
compacted
4
SAND-CASTING
MOLDING: Add
3 the top mold A tube or pipe
form provides a path to
pour the metal in
9
CLEANING. Sand is
cleaned off the part, the
“tab” where metal flowed
in must be removed.
8 SHAKE OUT: Break apart the two 10 Mold forms are reused
halves of the mold & take out the
part—usually requires vibrating or Sand is broken up,
striking the mold to break apart 11 screened to remove
the sand debris and clumps, and
sent for remixing
8
SAND-CASTING
Sand-casting is
simple in concept, but
demanding in
execution. It is a
process essential to
making basic and
advanced products. . .
it is also hazardous
and energy-intensive!
9
Sand Casting: Parts of a Sand Mold (expendable mold)
Key terms:
Flask, Cope, Drag, Sprue, Runner, Gate, Riser, Mold Cavity, Core, Parting Line,
Draft (not shown).
Casting Terminology
Parting line
Sand Casting Configuration
Patterns
What is pattern?
• Approximate duplicate of product
Machining Allowance
Allowance required to remove the rough cast surface. 2 to 25 mm (0.1
to 1’)
Draft Allowance
To facilitate ease of removal, usually ½ to 2 deg.
Shrinkage allowance
1
Mould
2
3
Dolly
4
5 Sprue
Pins
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