BATAN

KSHOP

WORKSHEET
DIPLOMA IN MECHANICAL ENGINEERING (AUTOMATION)

FOUNDRY WORKSHOP

CODE & COURSE : DJF 21012 MANUFACTURING WORKSHOP PRACTICE 1

CLASS: DTP3A GROUP: DATE SUBMISSION:
LECTURER 1 :
LECTURER 2 :

STUDENT INFORMATION:
NO. NAME REGISTRATION NO
1 GUNASELAN A/L B.MOGANATHAS 19DTP20F1017

PREPARED BY: RECEIVED / CHECKED BY:

(STUDENT ) ( LECTURER)
Report and Practical Task Evaluation by Lecturer ( refer rubric)

REPORT EVALUATION( CLO1& CLO2)PRACTICAL TASK EVALUATION ( CLO1 & CLO3)

SKILLS / ASPECT SKILLS / ASPECT CLO MARKS
A. Introduction A. Self-Discipline 3 4/3/2/1
B. Tools /equipment / materials B. Communication skills 3 4/3/2/1
C. Safety Precaution C. Professional ethics 3 4/3/2/1
D. Procedures D. Practice Safety, Health & 3 4/3/2/1
Environment
E. Result & Discussion

F. Conclusion

PRACTICAL
PRACTICAL TASK EVALUATION ( CLO1 & CLO2 ) TASK EVALUATION ( CLO1 & CLO2 )
PROJECT OUTPUT MARKS PROJECT OUTPUT MARKS

SKILLS / ASPECT SKILLS / ASPECT CLO MARKS

1. Length 6. Preparing sand for casting 1 3/2/1
2. Width 7. Prepare the mould by using 1 3/2/1
hand tools
3. Diameter
8. Follow the procedures to 1 3/2/1
4. Thickness produce the mould
5. Hexagon/Shape 9. Remove the pattern 1 3/2/1
10. Accuracy in moulding (final 1 3/2/1
product)
 EVALUATION TOTAL MARKS
REPORT CLO 1 / CLO 2 /12 /12
PRAKTIKAL CLO1 /15
PRAKTIKAL CLO3 /16

TOTAL MARKS
Politeknik Muadzam Shah
Mechanical Engineering Department

Assessment : Sand Casting Workshop Report

Student Name : GUNASELAN A/L B.MOGANATHAS Registration Number : 19DTP20F1017

1.0 Title : SAND CASTING Marks (Filled

by lecturer)

2.0 Introduction :

The main objective of this experiment is to

enhance the practical knowledge of in the field
about metal casting technology and to review
CLO1
the basic principals for the design of casting 4/3/2/1
patterns, feeding systems and gating systems,
inaddition to the investigation of the main
factors affecting the function of such casting
elements.

3.0 Tool / Equipment/ materials :

4)OBB Sand
CLO1
4/3/2/1

1)Pattern

6)Spru and core(with other

 moulding tools)

7)Casting Flask(cope and drag)

2)Diesel Furnace 8)Ladle

3)Melted Aluminium
4.0 Safety Precaution :

1)Wear eye protection, gloves, spats (covering top of feet), and thick clothing protecting all exposed
skin on arms and legs. NO polyester or synthetic clothing.

2)Sand Floor in pouring area shall be clear of all objects not involved in pouring.

3)Clamp or weight up molds that require it.

4)Metal added to heat must be free of moisture and impurities.

5)Metal added to heat during melt must be preheated.

6)Skimmers and other melting tools must be preheated before use.

7)Move Slowly while removing crucible from furnace and moving to mold.

8)Do not look into exhaust during operation.

CLO1
4/3/2/1
6.0 Procedures :

1) The mold box is placed on the board flat and clean. Make sure the floor the floor boards where
the mold is placed is flat. Mold box below must be reversed.

2) The pattern of the mold is placed into the box below. Separator powder sprinkled into the mold
and the pattern of board level.

CLO1
4/3/2/1

3) Mixture of fine sand is placed around the pattern until the sand under the cover thickness of 3 cm
all around the pattern. Mixed sand so pressed by the fingertips around the pattern to make it
compact. Make sure the pattern does not move when a mixture of compacted sand.

4) Available mixture of sand into the mold box below to ¾ of the container. After the ram is used to
compress the sand with a slow shock. Add sand mixture until it is full of mold box below and compact
with a stronger impact . This process is repeated until the compacted mixture of sand above the mold
box below.
5) A bar Smoothing is used to smooth the surface above the sand that has been compressed. Leveler
bar is pulled from one end of the mold box as he moved left and right

6) Mold box is flip over below to pattern is at the top, then the mold box is placed in the correct
position on the mold box like below. Both the mold box is locked with care so that its position is
consistent.

7) The pattern on the right is placed in position on the pattern, then spru placed in a suitable
position. After the powder is sprinkled into the bag separator on the surface of the mold box below.

8) Fine sand is placed around the pattern on the pattern of cover up about 3 cm. Fingers are used to
compact the soft sand around the pattern. A mixture of sand added to the box up and pack the mold
in the same manner as the fourth step.

9) Leveler bar used to smooth the surface of the mold box. Spatula is used to smooth the sand
surface around spru.

10) Loose up the spru and lift it. Use the vent wire to make the pores of the mold of ventilation in the
box.

11) Overturning on a separate box and mold to produce the pattern. Before the adoption pattern tap
gently to the surface pattern and sand distant. Use screws to remove the pattern drawing on the
pattern and the pattern of the mold. Permanent mold cavity will be produced after the pattern
produced.

12) Metal flow at the end of the grooves made by using the square shape casting spoons. Groove
metal flow must connect the cavity and the cavity spru. The groove metal function is to flow of
molten metal into the mold cavity from the hole spru

13) Core is placed in position in the cavity of the mold box and then reversed over the mold box
below.

14. Casting spoon with rounded ends used for flushing the basin of the mold box. Mold that has been
provided earlier to be near the furnace of molten metal is poured. Flow of molten metal is poured to
meet spru and cavity.

15. Give aproper time for the molten metal to solidify inside the cavity. The solidified cavity from
themould is removed after the temperature dropped to a proper handling condition (the melted
aluminium will turn into solidified metal with 10 – 15 minutes).

16. Finally, this process is mainly to detach the sand from the solidified metal (carefully remove the
remaining sand).
CLO1
4/3/2/1
7.0 Result & Discussion :

Practical Task Marks CLO2

CLO2
4/3/2/1
Discussion :

1. Explain on how the water content can be effected the quality of the sand castings
• When mould is applied under drycondition, high moisture content could be an advantage and when
the strength is the major factor under consideration. These important properties, such as
permeability, green compression strength, and dry compression strength attain their highest value
with moisture of 2% and 4% water addition. This makes 2% and 4% water addition more suitable for
optimum moulding properties requirement. Water and clay are the major property variables that
influence the strength of the moulding.

2. Explain the problems and difficulties during the practice

a) Lower Dimensional Accuracy:- No-bake molding can deliver better dimensional accuracy and
repeatability than green sand molding, but this process will, on average, provide less precision than CLO2
other common casting processes. 4/3/2/1

b) Pattern Maintenance:- While of lower cost than tooling for other casting processes, there is still an
art to pattern creation. Patterns can be bulky so the storage must be managed; this is especially
significant if the casting is produced infrequently. Patternless molding can relieve some challenges of
pattern storage and maintenance.

c) Surface Finish:- Sand castings tend to deliver a rougher surface finish than other casting processes.
That point may be moot if certain surfaces are machined anyway, or if surfaces in the as-cast
condition are acceptable.
8.0 Conclusion :

Sand casting is one of the most wide-spread processes in manufacturing. Its

economicviability, technological simplicity and overall naturalness make obvious the reasons of its
popularity. However, sand casting is not the silver bullet of manufacturing. The overhead,
thebmediocre quality of the castings, and the potential hazards of metal casting are of thereasons
why it isn’t so. CLO2
4/3/2/1

9.0 References :

1)https://www.studocu.com/my/document/universiti-malaysia-pahang/mechanical-
engineering/sandcasting-sand-casting-for-manufacturing-lab/6298580
2) https://mechanicalenotes.com/casting-process/

3) https://en.wikipedia.org/wiki/Sand_casting