FOUNDRYMAN

NSQF LEVEL - 4

Volume II of II

TRADE PRACTICAL

SECTOR: Capital Goods & Manufacturing

DIRECTORATE GENERAL OF TRAINING

MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
GOVERNMENT OF INDIA

NATIONAL INSTRUCTIONAL
MEDIA INSTITUTE, CHENNAI
Post Box No. 3142, CTI Campus, Guindy, Chennai - 600 032
(i)
Sector : Capital Goods & Manufacturing
Duration : 1 Year
Trade : Foundryman - Volume II of II - Trade Practical - NSQF level 4

Developed & Published by

National Instructional Media Institute

Post Box No.3142
Guindy, Chennai - 32
INDIA
Email: [email protected]
Website: www.nimi.gov.in

Copyright © 2021 National Instructional Media Institute, Chennai

First Edition :August 2021 Copies:250

Rs.135/-

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 FOREWORD

The Government of India has set an ambitious target of imparting skills to 30 crores people, one out of every
four Indians, by 2020 to help them secure jobs as part of the National Skills Development Policy. Industrial
Training Institutes (ITIs) play a vital role in this process especially in terms of providing skilled manpower.
Keeping this in mind, and for providing the current industry relevant skill training to Trainees, ITI syllabus
has been recently updated with the help of Mentor Councils comprising various stakeholder's viz. Industries,
Entrepreneurs, Academicians and representatives from ITIs.

The National Instructional Media Institute (NIMI), Chennai has now come up with instructional material to
suit the revised curriculum for Foundryman - Volume II of II - Trade Practical - NSQF Level - 4 in
Capital Goods & Manufacturing Sector under annual Pattern. The NSQF Level - 4 Trade Practical will
help the trainees to get an international equivalency standard where their skill proficiency and competency
will be duly recognized across the globe and this will also increase the scope of recognition of prior
learning. NSQF Level - 4 trainees will also get the opportunities to promote life long learning and skill
development. I have no doubt that with NSQF Level - 4 the trainers and trainees of ITIs, and all stakeholders
will derive maximum benefits from these IMPs and that NIMI's effort will go a long way in improving the
quality of Vocational training in the country.

The Executive Director & Staff of NIMI and members of Media Development Committee deserve appreciation
for their contribution in bringing out this publication.

Jai Hind

Director General/ Addl. Secretary

Ministry of Skill Development & Entrepreneurship,
Government of India.

New Delhi - 110 001

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 PREFACE
The National Instructional Media Institute (NIMI) was established in 1986 at Chennai by then Directorate
General of Employment and Training (D.G.E & T), Ministry of Labour and Employment, (now under Directorate
General of Training, Ministry of Skill Development and Entrepreneurship) Government of India, with technical
assistance from the Govt. of the Federal Republic of Germany. The prime objective of this institute is to
develop and provide instructional materials for various trades as per the prescribed syllabi under the Craftsman
and Apprenticeship Training Schemes.

The instructional materials are created keeping in mind, the main objective of Vocational Training under
NCVT/NAC in India, which is to help an individual to master skills to do a job. The instructional materials are
generated in the form of Instructional Media Packages (IMPs). An IMP consists of Theory book, Practical
book, Test and Assignment book, Instructor Guide, Audio Visual Aid (Wall charts and Transparencies) and
other support materials.

The trade practical book consists of series of exercises to be completed by the trainees in the workshop.
These exercises are designed to ensure that all the skills in the prescribed syllabus are covered. The trade
theory book provides related theoretical knowledge required to enable the trainee to do a job. The test and
assignments will enable the instructor to give assignments for the evaluation of the performance of a trainee.
The wall charts and transparencies are unique, as they not only help the instructor to effectively present a
topic but also help him to assess the trainee's understanding. The instructor guide enables the instructor to
plan his schedule of instruction, plan the raw material requirements, day to day lessons and demonstrations.

IMPs also deals with the complex skills required to be developed for effective team work. Necessary care
has also been taken to include important skill areas of allied trades as prescribed in the syllabus.

The availability of a complete Instructional Media Package in an institute helps both the trainer and
management to impart effective training.

The IMPs are the outcome of collective efforts of the staff members of NIMI and the members of the Media
Development Committees specially drawn from Public and Private sector industries, various training institutes
under the Directorate General of Training (DGT), Government and Private ITIs.

NIMI would like to take this opportunity to convey sincere thanks to the Directors of Employment & Training
of various State Governments, Training Departments of Industries both in the Public and Private sectors,
Officers of DGT and DGT field institutes, proof readers, individual media developers and coordinators, but for
whose active support NIMI would not have been able to bring out this materials.

R. P. DHINGRA
Chennai - 600 032 EXECUTIVE DIRECTOR

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 ACKNOWLEDGEMENT
National Instructional Media Institute (NIMI) sincerely acknowledges with thanks for the co-operation and
contribution extended by the following Media Developers and their sponsoring organisations to bring out this
Instructional Material (Trade Practical) for the trade of Foundryman under Capital Goods & Manufacturing
Sector for ITIs.

MEDIA DEVELOPMENT COMMITTEE MEMBERS

Shri. S. Thirumalai Kumar _ Asst.Training Officer,

D.S.T.O, Thirunelveli.

Shri. S. Baskaran _ Asst.Training Officer,

Govt.I.T.I. North Chennai.

Shri. J. Senthil Kumar _ Junior Training Officer

Govt.I.T.I. Hosur.

NIMI CO-ORDINATORS

Shri. Nirmalya Nath - Deputy General Manager,

NIMI, Chennai - 32.

Shri. V. Gopalakrishnan _ Assistant Manager,

NIMI, Chennai - 32

NIMI records its appreciation for the Data Entry, CAD, DTP operators for their excellent and devoted services in
the process of development of this Instructional Material.

NIMI also acknowledges with thanks the invaluable efforts rendered by all other NIMI staff who have contributed
towards the development of this Instructional Material.

NIMI is also grateful to everyone who has directly or indirectly helped in developing this Instructional Material.

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 INTRODUCTION

TRADE PRACTICAL

The trade practical manual is intented to be used in practical workshop. It consists of a series of practical
exercises to be completed by the trainees during the course of the Foundryman trade supplemented and
supported by instructions/ informations to assist in performing the exercises. These exercises are designed
to ensure that all the skills in compliance with NSQF LEVEL - 4 syllabus are covered.

Hrs

Module 1 Moulding Process 125 Hrs

Module 2 Fettling (Casting Yield Percentage) 50 Hrs
Module 3 Core making 25 Hrs
Module 4 Mould & Gating System 118 Hrs
Module 5 Thick casting with larger feeder head 32 Hrs
Module 6 Furnace for melting cast metal 50 Hrs
Module 7 Oil sand & no bake core 25 Hrs
Module 8 Mould without pattern (Trammelling method) 25 Hrs
Module 9 Gravity die casting 25 Hrs
Module 10 Investment casting 25 Hrs
Total 500 Hrs

The skill training in the shop floor is planned through a series of practical exercises centred around some
practical project. However, there are few instances where the individual exercise does not form a part of project.

While developing the practical manual a sincere effort was made to prepare each exercise which will be easy
to understand and carry out even by below average trainee. However the development team accept that there
is a scope for further improvement. NIMI looks forward to the suggestions from the experienced training faculty
for improving the manual.

TRADE THEORY

The manual of trade theory consists of theoretical information for the Course of the Foundry Man
Volume II of II Trade Theory NSQF LEVEL - 4 in Construction. The contents are sequenced according to the
practical exercise contained in NSQF LEVEL - 4 syllabus on TradeTheory attempt has been made to relate
the theoretical aspects with the skill covered in each exercise to the extent possible. This correlation is
maintained to help the trainees to develop the perceptional capabilities for performing the skills.
The trade theory has to be taught and learnt along with the corresponding exercise contained in the manual
on trade practical. The indications about the corresponding practical exercises are given in every sheet of this
manual.
It will be preferable to teach/learn the trade theory connected to each exercise at least one class before
performing the related skills in the shop floor. The trade theory is to be treated as an integrated part of each
exercise.
The material is not for the purpose of self learning and should be considered as supplementary to class room
instruction.

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 CONTENTS

Exercise No. Title of the Exercise Learning Page. No.

outcome

Module 1 : Moulding Process

2.1.58 Prepare dry sand mould with odd sided pattern and make casting 1
2.1.59 Fettle the casting 5
2.1.60 List out casting defects 8
2.1.61 Prepare simple loam sand mould for pan shaped casting 9
2.1.62 Prepare loam sand mould for bell shaped casting 13
2.1.63 Prepare pit mould on foundry floor 14
2.1.64 Prepare mould with pattern having cover core (skin dry sand mould) 1 18
2.1.65 Find out all defects 25
2.1.66 Prepare simple CO2 mould 26
2.1.67 Prepare simple CO2 core 28
2.1.68 Assemble CO2 core in a mould 30
2.1.69 Make a casting 32
2.1.70 Fettle the solidified casting (CO2) 33
2.1.71 List out defects 34
2.1.72 Prepare mould for setting “Balanced core” and set balanced core in
mould with the help of chaplets 35
2.1.73 Make an aluminium casting using pit furnace 38
2.1.74 Fettle the casting 39

Module 2 : Fettling (Casting Yield Percentage)

2.2.75 Prepare a mould for setting hanging core and set hanging core in a
mould with the help of chaplets 40
2.2.76 Make a casting - Aluminium 42
2.2.77 Fettle the casting 43
2.2.78 Find out the yield percentage 2 44
2.2.79 Prepare a mould with chills using chills, densers 45
2.2.80 Make a casting 48
2.2.81 Show a video chart of ferrous and non-ferrous metal 49

Module 3 : Core making

2.3.82 Prepare core halves 50

2.3.83 Bake the core halves 3 51
2.3.84 Join the core halves by different method 52

Module 4 : Mould & Gating System

2.4.85 Prepare a mould with pencil gate 53

2.4.86 Prepare mould with finger gate 4 55
2.4.87 Make casting with aluminium 57

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Exercise No. Title of the Exercise Learning Page. No.
outcome

2.4.88 Prepare mould with wedge gate (coping down the flask) 58
2.4.89 Prepare mould with ring gate 60
2.4.90 Make casting with copper base alloy 62
2.4.91 Prepare mould with branch gate mould with match plate pattern 64
2.4.92 Make casting with cast iron 67
2.4.93 Fettle the casting 68
2.4.94 Prepare a mould with release sprue 4 69
2.4.95 Prepare a mould with skim bob gate 71
2.4.96 Prepare a mould with shrink bob gate(CI casting) 73
2.4.97 Find out the defects 75
2.4.98 Prepare mould with horn - gate (Gear wheel type pattern) 76
2.4.99 Prepare a mould with stepped gate 79

Module 5 : Thick casting with larger feeder head

2.5.100 Industrial visit 81

2.5.101 Prepare mould for extra thick casting with large feeder head 5 82
2.5.102 Make casting with cast iron casting 84

2.5.103 Fettle the casting 85

Module 6 : Furnace for melting cast metal

2.6.104 Re-line the pit furnace 86

2.6.105 Show a video for operation of blast furnace 88
2.6.106 Reline the oil fired furnace 89
2.6.107 Charging of oil fired furnace and melt aluminium 91
2.6.108 Reline of laddle 6 92
2.6.109 Preheat of laddle 94
2.6.110 Reline muffle furnace 96
2.6.111 Metal melt by muffle furnace 98

Module 7 : Oil sand & no bake core

2.7.112 Prepare simple oil sand core by using linseed oil 7 99

2.7.113 Prepare oil sand core by IVP oils 101

Module 8 : Mould without pattern (Trammelling method)

2.8.114 Prepare simple regular shape mould without pattern (By cutting
method) trammelling method 102
2.8.115 Prepare mould by sweep pattern 105
2.8.116 Prepare mould with ram up core 8 108

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Exercise No. Title of the Exercise Learning Page. No.
outcome

Module 9 : Gravity die casting

2.9.117 Simple casting by gravity die casting 9 112

2.9.118 Calculation yield percentage 114

Module 10 : Investment casting

2.10.119 Prepare simple casting by investment casting process 10 115

2.10.120 Binder less dry sand process 119

LEARNING / ASSESSABLE OUTCOME

On completion of this book you shall be able to
S.No Learning Outcome Ref. Ex.No

1 Prepare mould by different moulding process, make cast iron castings identify
defects. 2.1.58 to 74

2 Make a casting, fettle the casting & calculation yield percentage. 2.2.75 to 81

3 Prepare complete core by joining half cores. 2.3.82 to 84

4 Make mould by various types of gate to produce different type of metal casting.
Find out defects and visit industry to show different operation for casting making. 2.4.85 to 99

5 Make an extra thick casting & finish it. 2.5.100 to 103

6 Reline & prepare different types of furnaces for melting cast metals. 2.6.104 to 111

7 Make core by using linseed oil & IVP oils. 2.7.112 to 113

8 Prepare mould without pattern & with sweep pattern 2.8.114 to 116

9 Make casting by die casting process & yield percentage of casting. 2.9.117 to 118

10 Make casting by investment casting process & binder less process. 2.10.119 to 120

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 SYLLABUS FOR FOUNDRYMAN

Duration Reference Learning Professional Skills

Professional Knowledge
Outcome (Trade Practical)
(Trade Theory)
with Indicative hours

Professional Prepare mould by different 58.Prepare dry sand mould with Description of dry sand mould.
Skill 125 Hrs; moulding process, make odd sided pattern and make Brief description types,
cast iron castings identify casting.(10 hrs) advantages & disadvantages of
Professional
defects. die casting, centrifugal casting
Knowledge 35 59.Fettle the casting (07 hrs)
and ceramic moulding
Hrs
60.Find out defect. (08 hrs) process. (07 hrs.)

61.Prepare a loam sand mould for Slush casting process,

pan shape casting. (10 hrs) continuous casting process,
permanent mould casting
62.Prepare a loam sand mould for
process; Nishiyama process
bell shape casting. (15 hrs)
(by using ferrosilicon powder)
common casting defects
appearance- causes and
remedies- salvaging of casting.
(07 hrs.)

63.Prepare a pit mould on foundry Slush casting process,

floor. (10 hrs) continuous casting process,
permanent mould casting
64.Prepare a mould with pattern
process; Nishiyama process
having cover core print,
(by using ferrosilicon powder)
assemble cover core in mould
common casting defects
and cast by cast iron. (12 hrs)
appearance- causes and
65.Find out all defects. (03 hrs) remedies- salvaging of casting.
(07 hrs.)

66.Prepare simple CO2 mould.(07 Fettling of casting knock out

hrs) and removal and removal of
casting from mould removal of
67.Prepare simple CO2 core. (08
gates & risers; Fins &
hrs)
unwanted projection - surface
68.Assemble in CO2 mould gleaning
core.(05 hrs)
trimming and finishing.
69.Make a casting by C.I. (02 hrs) Inspection of casting -
70.Fettle the casting. (02 hrs) destructive method - non-
destructor materials used in
71.List out casting defects. (01 foundry and their grades as
hrs) per I.S. (07 hrs.)

72.Prepare mould for setting Binders - Common binders

"Balancing core" and set used in foundry and their
balanced core in mould with application and their grades as
the help of chaplets. (20 hrs) per I.S. Common "Facing
Materials" used in foundry and
73.Make an aluminium casting
their application and their
using pit furnace. (03 hrs)
grades as per I.S. Casting
74.Fettle the casting. (02 hrs) design functional design,
simplification of foundry
practice. Metallurgical design,
economic consideration. (07
hrs.)

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Professional Skill Make a casting, fettle the 75.Prepare a mould for setting Common "Fluxes" used in
50 Hrs; casting & calculation "Hanging core and set hanging foundry and their
yield percentage. core in mould with the help of application. Specification (07
Professional
chaplets". (15 hrs) hrs.)
Knowledge 14 Hrs
76.Make a casting. (05 hrs)
77.Fettle the casting.(03 hrs)
78.Find out yield percentage. (02 hrs)

79.Prepare a mould using chills, Function of chills, densers.

densers. (20 hrs) Different between ferrous
&non-ferrous metals.
80.Make a casting. (04 hrs)
Physical & mechanical
81.Show a video chart of ferrous & properties of metals. (07
non-ferrous metals. (01 hr) hrs.)
Professional Skill Prepare complete core by 82.Prepare core halves. (15 hrs) Classification of iron ores &
25 Hrs; joining half cores. its treatments. (07 hrs.)
83.Bake the core halves. (05 hrs)
Professional
84.Join the core valves by different
Knowledge 07 Hrs
methods. (05 hrs)

Professional Skill Make mould by various 85.Prepare mould with pencil gate. Different gating system
125 Hrs; types of gate to produce (10 hrs)
Common cost iron-alloys.
different type of metal
Professional 86.Prepare mould with finger gate. (10
casting. Find out defects Manufacturing process of
Knowledge 35 Hrs hrs)
and visit industry to show chilled cast iron; S.G. iron
different operation for 87.Make casting with aluminium.(05 and malleable cast iron. (07
casting making. hrs) hrs.)

88.Prepare mould with wedge gate. Effect of alloying elements

(10 hrs) for ferrous metals.
89.Prepare mould with ring gate.(10 Iron-carbon-equilibrium
hrs) diagram of plain carbon
steel.
90.Make casting with copper base
alloy. (05 hrs) Inoculation: Purpose of
inoculation. (07 hrs.)

91.Prepare mould with branch gate Steel manufacturing process

mould with match plate pattern. classification common steel
(15 hrs) alloys and use. (07 hrs.)
92.Make casting with cast iron.(06
hrs)
93.Fettle the casting. (04 hrs)

94.Prepare mould with relief sprue Advantages of sprue gate &

gate. (10 hrs) skim bob gates.
95.Prepare mould with skim bob gate. Wrought iron-manufacturing
(10 hrs) process- uses.
96.Make a casting with cast iron. (04 Copper manufacturing
hrs) process -properties use. (07
hrs.)
97.Find out defects. (01 hr)

98.Prepare mould with horn gate Manufacturing process

[Gear wheel type pattern]. (09 hrs) properties and use of
aluminium, tin, zinc, lead
99.Prepare mould with stepped gate.
etc. Properties of grey iron.
(09 hrs)

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 100 Industrial visit to observe the Microstructure, fracture,
special casting process mechanical test-tensile test,
machine moulding process, hardness test etc. (07 hrs.)
operation of different furnaces
sand reconditioning process,
inspection of casting, fettling
process etc. (07 hrs)
Professional Make an extra thick 101 Prepare mould for extra thick Manufacturing process of copper
Skill 25 Hrs; casting & finish it. casting with large feeder base alloys, aluminium base
heads. (18 hrs) alloys and magnesium base
Professional
102 Make casting with cast alloys.
Knowledge 07
Hrs iron.(04 hrs) Brief information about cupola
103 Fettle the casting. (03 hrs) furnace. (07 hrs.)

Professional Reline & prepare different 104 Reline the pit furnace. (10 hrs) Brief information about blast
Skill 50 Hrs; types of furnaces for 105 Show a video show for furnace, electric furnaces such
melting cast metals. operation of blast furnace. (02 as arc furnace and induction
Professional
hrs) furnace. Brief information about
Knowledge 14
open hearth furnace, air furnace,
Hrs 106 Relining the oil fired furnace. paddling furnace and convertors.
(10 hrs) (07 hrs.)
107 Charging of oil fired furnace &
melt aluminium. (03 hrs)
108 Reline of ladle. (08 hrs) Heat treatment of casting. (07
109 Pre heat of ladle. (03 hrs) hrs.)

110 Reline of muffle furnace.(10

hrs)
111 Metal melt by muffle furnace.
(04 hrs)

Professional Make core by using 112 Prepare simple oil sand core Calculation of ferrostatic
Skill 25 Hrs; linseed oil & IVP oils. by using linseed oil. (15 hrs) pressure. Calculation of weight
113 Rrepare oil sand core by IVP required on a mould. (07 hrs.)
Professional
Knowledge 07 oils. (10 hrs)
Hrs

Professional Prepare mould without 114 Prepare simple, regular shape Calculation of molten metal
Skill 25 Hrs; pattern & with sweep mould without pattern (by required for different size mould
pattern cutting practice). (08 hrs) (Aluminium, brass, copper, C.I.
Professional
115.Prepare mould by sweep etc.) (07 hrs.)
Knowledge 07
Hrs pattern. (08 hrs)
116. Make mould by ram up core.
(09 hrs)

Professional Make casting by die 117.Prepare simple casting by Cost estimate of simple castings
Skill 25 Hrs; casting process & yield gravity die casting. (22hrs) of different metals. Low
percentage of casting. 118.Calculation yield pressure, high pressure, gravity
Professional
percentage.(03hrs) die casting process. (07 hrs.)
Knowledge 07
Hrs
Professional Make casting by 119.Prepare simple casting by Foundry mechanization- layout
Skill 25 Hrs; investment casting investment casting of a small foundry- list of
process.(13hrs)
Professional process & binder less material handling equipments
Knowledge 07 process. 120.Prepare simple casting with and their use. (07 hrs.)
Hrs binder less dry sand process.
(12hrs)

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Capital Goods & Manufacturing Exercise No 2.1.58
Foundryman - Moulding Process

Prepare dry sand mould with odd sided pattern and make casting
Objectives: At the end of this Exerciseercise you shall be able to
• prepare dry sand
• prepare flase box
• prepare the drag
• prepare the cope
• prepare gating system
• prepare mould for pouring.

Requirements

Tools/Instruments Equipment/Machines

• Shovel - 1 No. • Three moulding boxes with guide pin

• Moulding board / trowel - 1 No. with clamp - 3 Nos.
• Cleaners - 1 No. • Pattern - 1 No.
• Rammers - 1 No. • Core boxes - 2 Nos.
• Vent wire - 1 No. • Auto sand riddle - as reqd.
• Leveler - 1 No. • Sand mixer - as reqd.
• Mallet - 1 No. • Sand muller - as reqd.
• Sprue pins - 1 No. Materials
• Gate cutter - 1 No.
• Smoothers - 1 No. • Silica sand - as reqd.
• Cleaning brush - 1 No. • New silica flour - as reqd.
• Dust bag - 1 No. • Bentonite (or) clay/molasses - as reqd.
• Painting brush - 1 No. • Tempered moulding sand - as reqd.
• Blow lamp or LPG heating torch - 1 No. • Water - as reqd.
• ‘C’ clamp - 1 No. • Kerosene - as reqd.
• Water jug or water sprinkler - 1 No. Facing material
• Mould hardness tester - 1 No.
• Plumbago or graphite powder - as reqd.

PROCEDURE

TASK 1: Study the pattern

3 Selection of sand
These must be followed for all practical
Exerciseercise before making job. 4 Location of runner and riser

1 To know the colouring and marking system of wooden

pattern equipment as per 1513 - 1980
i The colour and marking system of wooden pattern
help us to know:-
ii the position of bedding
iii allowance provided on pattern (mainly draft
allowances)
iv metal to be casted
v position of chills and densers loose piece and stop
- off - pieces
vi the cast metal
2 Selection of moulding flask (moulding box).

1
TASK 2: Prepare dry sand

Using sand muller.

Silica sand - 40%
1 Sieve the materials
New silica flour - 15%
2 Weight the materials
Bentonite - 4%
3 as per the following composition for dry sand mixture:-
Molasses - 1%
Water - 4 to 5% by weight

TASK 3: Prepare false box

1 Place the flask over the moulding board (Fig 2) 3 Fill the backing sand ram it by peen wedge rammer
more than 50 mm height flask level
2 Sprinkle parting sand
4 Strike - off Exercisetra sand from the surface by strike-
off-bar
5 Sleek the parting surface.
6 Turn over the false box and keep it on the board / or
sand bed.

Sleek circular motion on the sleeking surface

by trowel and sleeker.
Prepare sand bed more than 2” height to the
size of the flask to give crusher action and
avoid crack during preparation of flask.

TASK 4: Bedding-in odd side pattern

1 Mark the profile 3 Prepare cutting joint as shown in the Fig 3.

2 Bed in the pattern on false box 4 Sleek the surface of the mould
5 Withdraw the pattern
6 Check the mould cavity
7 It any damage repair the cavity
8 Reset the pattern
9 Sprinkle parting sand with help of dusting bag.

Rap the pattern in all side not Exerciseceeding

1.5 mm overall size with the help of draw spike
or raping plate.

TASK 5: Prepare drag

1 Place the drag over the false box 7 Prepare sand bed and sprinkle parting sand on the
sand bed.
2 Fill the facing sand one layer and tuck with hand.
8 Turn over the drag (Fig 5)
3 Again fill the sand over 2-4” above the box level.
9 Sleek the surface.
4 Ram the sand with peen wedge rammer
10 Dust parting sand with dust bag.
5 File the sand and ram it with butt rammer.
11 Keep the cope over the drag
6 Strike-off the Exercisetra sand from the top surface of
the drag. (Fig 4) 12 Set closing pins (Fig 6)
13 Locate sprue pin.

2 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.58

TASK 6: Prepare cope

1 Fill facing sand layer by layer and tuck with hand. 9 Connect the sprue and mould cavity using gate cutter
2 Fill backing sand with hand 10 Apply facing materials
3 Ramming, levelling and vent the cope 11 Bake the cope drag in core over.
4 Cut pouring basin While venting lake care that vent wire should
5 Coping down the flask, (roll over the mould) not strike the finger.
6 Remove the sprue turn over the cope and keep it on the Don’t insert rapping rod too deep, other wise
sand bed. the pattern way break.
7 With draw the pattern using draw spike after rapping Rap the pattern in all side not Exerciseceeding
the pattern 1.5 mm all over side with help of spike.
8 Clean the mould cavity with hand bellows

TASK 7: Make a casting (using oil fired furnace)

Reline the furnace as per Exercise No.2.6.106. 9 After one hour, open the furnace cap with the help of
Reline and prehead the laddle as per Exercise tongs and check the moltenmetal with the help of
No.2.6.108,109. heated rod (if the metal is sticked on the heated rod
required melting temperature is not attained.)
1 Place the crucible stand in the center of the oil fired
furnace. 10 Again charge the scrap with the help of tongs.
2 Place the crucible (No 100) on the crucible stand. 11 Repeat the step No.9 (if the metal is not sticked on the
heated rod the required melting temperature is attained.)
3 Place the fire bricks around the crucible in curved
shape. 12 Check the chemical composition of the metal, if the
required.
4 Put iron scraps in the crucible.
13 Tittle the furnace hand wheel in 80° and remove the slag
Ensure the fuel level in the fuel tank.
using slag remover.
5 Switch on the heating unit.
14 Place the laddle on the laddle stand, tittle the furnace
6 Fired the furnace with the help of oil chocked waste. and pour the molten metal into the laddle.
7 Switch on the blower after 10 minutes. 15 After filled the laddle tittle the furnace on the standard
8 Adjust the oil valve and fuel valve of furnace, to touch the position.
flame on the crucible. 16 Pour the molten metal into the mould.

3
Capital Goods & Manufacturing Exercise No 2.1.59
Foundryman - Moulding Process

Fettle the casting

Objectives: At the end of this Exerciseercise you shall be able to
• surface cleaning of the solidified casting
• remove the fins and flash of the casting
• cut the runner and riser of the casting
• file the gated reportion of the casting
• file the cutted gating portion of the casting
• trim the casting.

Requirements

Tools/Instruments Equipment/Machines

• Tongs - 1 No. • Shack out machine - as reqd.

• Mallet - 1 No. • Grinding machine - as reqd.
• Hammer - 1 No. Materials
• Chisel - 1 No.
• Hacksaw frame with blade - 1 No. • Emery sheet - as reqd.
• Wire brush - 1 No. • Painting brush - as reqd.
• File-rough - 1 No. • Marker - as reqd.
• Smooth file - 1 No. • Hacksaw blade - as reqd.
• Fine finish file - 1 No.

PROCEDURE

TASK 1: Knock out

1 Remove the weight and guide pin from the mould. While knock out use mallet, sledge hammer
2 Lift the cope from the mould by hand or lifting device. (or) crow bar, shack out machine according to
weight of the casting.
3 Hit on the runner and riser head by mallet/crow bar.
Always use leather hand gloves, safety shoes,
4 Collect the solidified object from the mould by tongs. helmet, respirator.

TASK 2: Remove the fins and flashes

1 Keep the solidified casting on the table.

Give the force towards the casting.
2 Cut the unwanted portion of metallic from the casting.
Take care about broken the edge of the castings.
Chipping, sawing, shearing, flame cutting,
flame scarfing, grinding, abrasive belt machine,
rotary tools, trimming and sizing.

TASK 3: Surface cleaning

1 Hold the casting on the bench vice.

Adhering or sintering sand particles from the
2 Rubbing the casting surface with wire brush. casting (Internal/Exerciseternal surface).
Capacity of materials only process are followed
by rubbing, blast cleaning.

4
TASK 4: Cut the runner and riser

1 Cut the runner and riser 2 Select any one following method flogging, sawing,
kintching.

TASK 5: Finishing of casting

1 Finish the gating profile of the casting

Different finishing operations carried on the
2 Smoothen the areas of the casting from cutted gates castings depending upon the casting size,
and riser portions. shapes, casted metals: Grinding, rotary filing,
machining, chemical treatment, polishing,
3 Verify the dimension ref to job sheet.
brushing, buffing, painting.
4 Found defect in casting
Flogging, Sawing, Kintching, Shearing,
5 If necessity to repair / solve casting. Abrasive wheel slitting, Matching, Flame cutting
are followed by depending upon the casting
size, shape, casted metals only.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.59 5

 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.59 6
Buffing
Grinding
Flogging

Brushing
Hand file
Shearing

Hacksaw
Bandsaw

Polishing
Rotary file
Wire brush

Flame cutting
Flame scaring
Flame gouging
Chipping hammer
Water-blast cleaning

Abrasive cut-off wheel

Tumbling barrel cleaning
Mechanical blast cleaning
on the castings
Cleaning method different carried

Air-blast cleaning Sandblast, shot blast)

X
X
X
X

Removal of Refractories
X
X
X

Removal of Gates and Risers

Finish Cleaning
Magnesium

X
X
X
X
X
X
Aluminium and

X
X

X X
X X
X X Preparation for Wedding or Repair
X
X
X
X

Removal of Refractories

X
X
X
X
X
X
X
X
X

Removal of Gates and Risers

and copper

Finish Cleaning

X
X
X
X
X
X
Brass, Bronze

Preparation for Wedding or Repair

X
X
X

X
X
Removal of Refractories
X
X
X
X
X

Removal of Gates and Risers

iron

X
X
X
Finish Cleaning

X
X
X
Gray cast

Preparation for Wedding or Repair

X
Removal of Refractories

X
X
X
X
X
Removal of Gates and Risers
iron

X
X
Method for cleaning casting

Finish Cleaning

X
X
X
Preparation for Wedding or Repair

X
X
Malleable cast

Removal of Refractories

X
X
X
X
X
Removal of Gates and Risers
iron

X
X
Finish Cleaning

X
Ductile cast

Preparation for Wedding or Repair

X
Removal of Refractories

X
X
X
X
X
Removal of Gates and Risers

X
X
X
Finish Cleaning

X
X
X
X
steel

X
X
X
X
X
Preparation for Wedding or Repair
Capital Goods & Manufacturing Exercise No 2.1.60
Foundryman - Moulding Process

List out casting defects

Objectives: At the end of this Exerciseercise you shall be able to
• list out the defects appeared on the cast
• prepare defect analysing chart.

PROCEDURE

1 Ask trainee to list out the defects of casting produced 2 Write the causes & remedies of the listed defects.
in Exercise 2.1.58 in the given table - 1.
3 Verify with instructor.

Table 1

S.No Appearance Defect Causes Remedies

7
Capital Goods & Manufacturing Exercise No 2.1.61
Foundryman - Moulding Process

Prepare a (simple) loam sand mould for pan shaped casting

Objectives: At the end of this Exerciseercise you shall be able to
• study the pattern
• select tools, materials, equipment for sweep mould
• prepare cope and drag
• prepare drag part of sweep
• prepare core part of sweep
• cut runner and riser
• assemble the mould.

8
 Requirements

Tools/Instruments
• Riddle - 1 No. • Sweep pattern - 1 No.
• Shovel - 1 No. . • Strickle board - 1 No.
• Moulding board - 1 No. • Socket flask - 2 Nos.
• Trowel - 1 No. • Auto sand riddle - as reqd.
• Cleaner - 1 No. • Sand mixer - as reqd.
• Rammers - 1 No. Materials
• Vent wire - 1 No.
• Leveler - 1 No. • Parting materials - as reqd.
• Mallet - 1 No. • New red sand - as reqd.
• Spike - 1 No. • Old red sand - as reqd.
• Spure pins - 2 Nos. • Bentonite - as reqd.
• Gate cutter - 1 No. • Horse manure, cow dung - as reqd.
• Smoothers - 1 No. • Tempered loam moulding sand - as reqd.
• Cleaning brush - 1 No. • Loam slurry - as reqd.
• Dust bag - 1 No. • Moisture - as reqd.
• Painting brush - 1 No. • Fusion coke - as reqd.
• Blow lamp or LPG heating torch - as reqd. • Kerosene or LPG - as reqd.
• ‘C’ clamp - 1 No. Facing materials
• Water jug or water sprinklers - 1 No.
• French chalk powder - as reqd.
Equipment/Machines
• Spindle base - 1 No.

PROCEDURE

TASK 1: Study the pattern

1 Refer Exercise No.2.1.58 Task 1. 2 Arrange require tools. Require materials and require
equipments.

TASK 2: Prepare loam sand as per composition

Old red moulding sand - 40% 1 Sieve all the materials with Auto sand riddle
New red moulding sand - 40% 2 Put the materials in sand muller and mix it dry state for
three to five minutes.
Bentonite - 15%
3 Add water and mix it well.
Horse manure - 4%
4 Collect the loam sand and cover it with wet gunny bag.
Cow dung - 1%
Water - 20%

TASK 3: Prepare cope and drag (Fig 1)

1 Level the sand bed 8 Ram, level and vent it

2 Place the spindle base 9 level the surface
3 Set the spindle 10 Prepare internal location
4 Level the floor 11 Sprinkle parting sand
5 Sprinkle parting sand 12 Place the cope
6 Place the drag after clay wash 13 Ram, level, vent and finishing the cope
7 fill the drag with moulding sand 14 Prepare Exerciseternal mark with clay

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.61 9

15 Turn over the cope on sand bed.

TASK 4: Prepare drag part of sweep (Fig 2)

1 Dip the drag part of template (sweep pattern in the 2 Sprinkle water on drag part of mould
water bucket)
3 Set the sweep
4 Slowly tap the sweep with wooden mallet
5 Rotate the sweep
6 Sprinkle water if necessary
7 Sweep the drag continuously till the sweep touch the
box level.
8 Make a loam sand slurry
9 Pour over the mould and sweep finally
10 Finish the mould
11 Remove the sweep pattern
12 Turn over the drag on sand bed.

TASK 5: Prepare cope part of sweep (Fig 3)

1 Re-place the cope on this spindle 2 Set the cope part of sweep
3 Mark the core portion
4 Rough the marked portion with vent-wire
5 Built-up the portion with loam sand
6 Ram with butt rammer
7 Sprinkle water
8 Rotate the spindle with sweep pattern slowly
9 Sweep the mould till you get the core portion of cope.
10 Pour loam sand slurry on the cope part mould and
rotate the sweep pattern finally to get shape.
11 Remove the sweep pattern and spindle.
12 Air dry the cope and drag.

TASK 6: Cut runner and riser

1 Cut runner and riser with hollow pipe 2 Connect the runner and riser by cutting in gate.

10 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.61

TASK 7: Assemble the mould

1 File up the spindle hole cope and drag. 6 Clean the mould
2 Coat the cope and drag 7 Assemble cope on drag
3 Provide pouring basin 8 Place the weight or clamp the box
4 Cut in-gate 9 The mould is ready for pouring
5 Dry the mould with fire wood or by torch 10 Check it with instructor.

TASK 8: Prepare a casting

Refer 2.1.58 task 7

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.61 11

Capital Goods & Manufacturing Exercise No 2.1.62
Foundryman - Moulding Process

Prepare loam sand mould for bell shaped casting

Objectives: At the end of this Exerciseercise you shall be able to
• select the sweep pattern and accessories
• prepare drag part
• prepare cope part
• assemble the cope and drag.

PROCEDURE

Refer the Exerciseercise 2.1.61 Task 1 to 7 with bell shape sweep pattern.

12
Capital Goods & Manufacturing Exercise No 2.1.63
Foundryman - Moulding Process

Prepare pit mould on foundry floor

Objectives: At the end of this Exerciseercise you shall be able to
• prepare green sand baking and dry sand facing as per our composition
• form the cinder bed on foundry floor
• prepare drag on foundry floor
• prepare cope
• provide gating system
• assemble the mould for pouring.

Requirements

Tools/Instruments Equipment/Machines
• Riddle - 1 No. • One of moulding boxes with guide pin - 1 No.
• Shovel - 1 No. • Pattern - 1 No.
• Moulding board - 1 No. • Core boxes - 1 No.
• Trowel - 1 No. • Auto sand riddler - as reqd.
• Cleaner - 1 No. • Sand mixer - as reqd.
• Rammers - 1 No. • Mould hardness tester - as reqd.
• Vent wire - 1 No. • Core hardness tester - 1 No.
• Leveler, Hand bellows - 1 No. Materials
• Wooden mallet - 1 No.
• Drag spike - 1 No. • Parting materials (silica sand) - as reqd.
• Sprue pins - 2 Nos. • Tempered moulding sand - as reqd.
• Gate cutter - 1 No. • Moisture - as reqd.
• Smoothers - 1 No. • Clay - as reqd.
• Dust bag - 1 No. • Facing materials (Plumbago or
• Painting brush - 1 No. graphite powder) - as reqd.
• Blow lamp or LPG heating torch - as reqd. • Kerosene or LPG - as reqd.
• ‘C’ clamp - as reqd. • Gunny bag - as reqd.
• Water jug or water sprinklers - 1 No. • Fusion hard coke - as reqd.
• Vent pipe - as reqd.
• Cotton waste - as reqd.

13
PROCEDURE
1 Study the pattern (follow task 1 Exercise No. 2 Arrange require tools, materials and
2.1.58) equipments.

TASK 1: Prepare green sand backing sand as per composition

Prepare dry sand facing as per composition

Silica sand - 60%
New silica sand - 34% Silica and AFS NO 60-80 - 60%
Sodium bentonite - 4% Bentonite or clay - 7.5%
Coal dust - 2% DExercisetrine - 2%
Water - 3 t o4% by Coal dust or sea coal - 6%
weight
Wood flour - 0.5%
Water - 4 to 5% by weight

TASK 2: Prepare cinder bed (Fig 1)

1 Mark the mould area. 3 Add one layer of fusion hard coke upto 40mm height.

Before marking the dig the floor, loose the 4 Locate the 2 no of vent pipe above the fusion hard
sand. Clean the foundry floor. Dig the drag up coke bed inclinedposition.
to more than 3 times of given pattern height.
Close the top of the vent pipe by cotton waste.
2 Coat the clay wash on inside the mould wall. Add one
5 Cover the gunny bag above the fusion hard coke.
layer or backing sand ram it.
6 Add one layer of dry silica sand.
7 Fill one layer of backing sand, ram it by peen wedge
rammer.
8 Fill one layer of facing sand-ram it by peen wedge
rammer.
9 Fill the sand above the floor level, tuck in with hand
ram it by butt rammer.
10 Strike off Exercisetra sand from the surface.

TASK 3: Prepare drag on foundry floor (Fig 2)

1 Sleek the parting surface.

2 Mark the mould and pattern area.
3 Sprinkle the parting compound at parting surface.
4 Bed in the pattern is the sand bed.

14 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.63

TASK 4: Prepare drag on foundry floor (Fig 2)
1 Sleek the parting surface. 5 Reset the pattern from the mould cavity pack it with
help of facing sand tightly ram it.
2 Mark the mould and pattern area.
6 Maintain pattern level and ground level.
3 Dig the pattern height.
7 Sleek the parting surface on plain mould.
4 Set the pattern in dig at ground level.
8 Sprinkle the parting sand.

TASK 5: Provide cope on foundry floor (Fig 3)

1 Locate the cope box on foundry floor.
2 Fill the facing sand one layer tuck with hand.
3 Again fill the backing sand one more layer ram it with
help of peen wedge rammer carry out above skill on 2
or 3 times up to top level of the moulding box.
4 Fill the sand at height of 50 mm, above the box level.
5 Strike off Exercisecess sand of the top surface of the
cope with help of strike-off-bar.
6 Insert the “L” shaped angle on opposite sides of cope
box for Exerciseternal marking.

TASK 6: Provide gating system in a mould (Fig 4)

1 Mark the pouring basin in the parting surface. 4 Provide venting with help of vent wires.
2 Cut the pouring basin’s and riser basin with help of 5 Remove the spure pins, lift the cope, turn over and
cleaners/lifters. keep the sand bed.
3 Clean and finish area. 6 Mark the gated portion in the parting surface, apply
the water with swap.
7 Cut the runner in gate and riser gate with help of
cleaners or gate cutter.
8 Connect runner’s in gate, sprue base and mould
cavity.
9 Withdrawn the pattern from the cope (or) drag.
10 Remove the loose particles in the cavity and gating
system.
11 Dust the facing material with help of dust bag or coat
the plumbago coating.

TASK 7: Prepare mould for pouring

1 Bake the mould cavity (drag and cope). 5 Close the pouring basin runner basin and vent pipes
with cotton waste.
2 Prepare core dry it and set the core.
6 Check it with instructor
3 Blow the loose particles form the cavity with help of
bellows. 7 The mould is ready for pouring.
4 Close the cope, with help of Exerciseternal marking or Clean and repair the mould cavity if necessary
guide clamp. with help of fire wood, kerosine, LPG and dry
the surface.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.63 15

Capital Goods & Manufacturing Exercise No 2.1.64
Foundryman - Moulding Process

Prepare mould with pattern having cover core print assemble cover core
mould
Objectives: At the end of this Exerciseercise you shall be able to
• prepare mould with pattern having cover core (skin dry sand mould)
• prepare cover core
• assemble cover core
• casting the cover core mould
• fettle cast iron casting.

16
 Requirements

Tools/Instruments Equipments/Machines
• Riddle - 1 No. • Set of moulding boxes with guide pin - 2 Nos.
• Shovel - 1 No. • Pattern - 1 No.
• Moulding board - 1 No. • Core boxes - 1 No.
• Trowel - 1 No. • Auto sand riddle - as reqd.
• Cleaner - 1 No. • Sand mixer - as reqd.
• Rammers - 1 No. • Sand muller - as reqd.
• Vent wire - 1 No. • Mould hardness tester - 1 No.
• Leveler - 1 No. • Core hardness tester - 1 No.
• Wooden mallet - 1 No. • Furnace - 1 No.
• Draw spike - 1 No. • Ladle with shank - 1 No.
• Sprue pins - 1 No. Materials
• Gate cutter - 1 No.
• Smoothers - 1 No. • Parting materials - as reqd.
• Cleaning brush (or) swab - 1 No. • Silica sand - as reqd.
• Dust bag - 1 No. • New silica sand - as reqd.
• Painting brush - 1 No. • Bentonite (sodium) - as reqd.
• Blow lamp or LPG heating torch - as reqd. • Coal dust (Tempered moulding sand) - as reqd.
• ‘C’ clamp - 1 No. • Water - as reqd.
• Water jug / water sprinklers - 1 No. • Clay - as reqd.
• Pyrometer - 1 No. • Aluminium - 1 No.
• Casting hand tool - as reqd. Facing materials
• Fetling hand tool - as reqd.
• Metal cutting tools - as reqd. • Plumbago or graphite powder - as reqd.
• Kerosene / LPG - as reqd.

PROCEDURE

TASK 1 : Study the pattern

1 Study the pattern (follow Exercise No.2.1.58 Task 1). 2 Arrange require tools, materials & equipments.

TASK 2 : Prepare green sand backing sand as per composition

Prepare dry sand facing sand as per composition

Silica sand - 60%
New silica sand - 34% Silica sand AFS NO 60-80 - 85%

Sodium bentonite - 4% Bentonite or clay - 7.5%

Cole dust - 2% DExercisetrine - 2%

Coal dust or sea coal - 6%
Water - 3 to 4% by weight
Wood flour - 0.5%
Water - 4 to 5% by weight

TASK 3 : Prepare drag

1 Place the pattern over the moulding board, sprinkle it 5 Ram it with help of peen wedge rammer carry out above
the parting materials. (Fig 1 & 2) skill followed by 2 to 3 times upto top level of the
moulding box or flask.
2 Place the flask on the moulding board.
6 Fill the baking sand at height of 50 mm. above the box
3 Fill the facing sand tuck in with hand.
level.
4 Fill the backing sand one more layer.
7 Press the sand by hand.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.64 17

 11 Turn over the drag mould. (Fig 3)
12 Sprinkle parting sand.
13 Sleek the parting surface.

8 Ram it by butt/flat rammer.

9 Strike off Exercisecess sand from the surface.
10 Sleek the parting surface.

TASK 4 : Prepare cope

1 Place the cope box over the drag, and set the closing 7 Carry out above skill 2 to 3 times up to top level of the
pins. Fill the facing sand one layer tuck in by hand. moulding box.
(Fig 4)
8 Fill the baking sand at above the 50 mm, above the box
level. Press the sand by hand after ram it by butt/flat
rammer.
9 Strike off Exercisetra loose sand from the top surface
of the cope.
10 Sleek the parting surface.

2 Place the clay coated reinforcement wire for cover core

in the cope.
3 Fill the facing sand one layer tuck in by hand.
4 Locate runner & risers pegs.
5 Fill the facing sand one layer tuck by hand.
6 Fill the backing sand one layer ram it with help of peen
wedge rammer.

TASK 5 : Gating system in a mould

1 Mark the pouring basin in the parting surface.
If any damaged repair the portion
2 Cut the pouring basin’s & riser basin with help of
cleaners / lifter. 6 Mark the gated portion in the parting surface and apply
the water with swap.
3 Provide venting with help of vent wires to connect drag
& cope. 7 Cut the runner in gate & riser gate with help of cleaners
or gate cutter. Clean and finish the gated area.
4 Remove the sprue pins, lift the cope, turn over and keep
the sand bed. 8 Connect runner’s in gate, sprue base and mould cavity.
Remove the loose particles in the cavity and gating
5 Withdrawn the pattern from the cope (or) drag. (Fig 6)
system.
18 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.64
 9 Dust the facing material with help of dust bag (or) coat
the plumbago coating.

TASK 6 : Prepare mould for pouring

1 Clean and bake the mould cavity. (drag & cope)

2 Blow off the loose particles from the mould cavity.
3 Close the drag and cope, with help guide clamp. (Fig 7)
4 Keep the weight.
5 Close the pouring, runner basin & vent pipes with help
of cotton waste.

Refer Exercise No.2.1.65 and 2.1.66 for

preparation of core and assembling the core in
the mould.

TASK 7 : Prepare the dry core sand

1 Study the core box. Heavy section casting (Proportions by weight)
2 Prepare dry core sand as per composition.
Silica sand - 83%
Average casting
Silica flour - 9.5%
Silica sand - 93% Core oil - 5%
Core oil - 5% Sodium bentonite - 2.5%
Sodium bentonite - 2% Water - 3 to 4% by weight

Water - 3 to 4% by weight 3 Arrange require tools, materials & equipments.

TASK 8 : Prepare core sand for cover core

1 Sieve the required materials. 5 Mix the mixer with additives.
2 Weigh the materials as per composition. 6 Mix the mixer with moisture.
3 Mix materials in dry state. 7 Remove the sand from sand muller collect with trolly
4 Mix the mixer with binder.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.64 19

TASK 9 : Prepare reinforcements
1 Select the reinforcements as per design of core box. 2 Clay wash the reinforcements.

TASK 10 : Prepare the dry cover core

1 Collect the materials to prepare the core. (Fig 1) 2 Fill the core sand.
3 Pack the core sand in the core box ram it.
4 Assemble reinforcement with core box.
5 Sleek it top surface and provide vents.
6 Loose the clamp and upper part of the core box.
7 Cover the core plate in the top surface with dry backing
materials.
8 Turn over the core box on core plate.
9 Apply core wash.

TASK 11 : Bake the core

1 Load the core inside the core oven.
2 Close the oven door.
3 Switch on the core oven.
4 Allow the baking time.
5 Open the core oven allow to cool at room temperature.

TASK 12 : Check the core and core print dimensions

1 Measure the overall dimension for core and core print. 3 Verify the dimensions core & core print.
2 Trim it if necessary. 4 Finish the core.

TASK 13 : Prepare clay ball

1 Place the mould over the sand bed. 6 Fix the core in core print of the mould, keep the clay ball
in core body of the cope mould, close the cope.
2 Blow off loose particles by hand bellows.
7 Open the cope, remove the core, check the drag and
3 Bake the drag if need.
cope ball thickness. Verify the dimension.
4 Allow to room temperature.
8 If the clay ball thickness is equal all the side. Set the
5 Fix the clay ball in core body of the drag mould, fix the core. If dimension differ change the core.
core in core print of the mould.

TASK 14 : Set the core on the core print (Fig 2&3)

1 Place the drag mould over the sand bed. 5 Check the wall thickness of the mould wall.
2 Blow off the loose particles by bellows. 6 Close the cope mould over the drag with help of guide
pin.
3 Bake the drag, cope and core if need, allow to cool.
7 Cover the pouring basin with rolled cotton waste.
4 Fix the core in core print of the drag mould with core
hook or thread. 8 Keep the weight over the cope.

20 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.64

9 The mould is ready for pouring
10 Check it with instructor.

If the case touches the bottom of mould it is

cover case.
It does not touches balanced case.

TASK 15 : Pouring the mould

Prepare the ladle for pouring. Before pouring, trap the slag from the ladle.
Prepare daubing, lining, preheat the laddle. Maintain the center of pouring cups.

1 Collect the molten metal in a laddle. Maintain the distance between the pouring cup
and lip of the ladle.
Check the molten metal temperature by
pyrometer. Pouring may continuous if filled cavity, not in
short fall.
2 Skim the slag in the molten metal by skimmer.
While box run out the molten metal, seal the
3 Centre the ladle over the pouring cup. tempered moulding sand by shovel and also
continuous pouring is required in same mould.
4 Pour the molten metal by slowly and steadily.

5 Take care that the pouring cup is filled till end of the 6 Allow to solidify.
pouring.
7 Open the clamp.
Before pouring check the properly close the
mould, clamp and seal the drag and cope.

TASK 16 : Fettle the solidified casting

1 Knock out the solidified casting.

2 Remove the fins and flashes from the solidified casting
by chisel, hammer.
3 Clean the surface of solidified casting by wire brush.
4 Cut and remove runner in a solidified casting by hack-
saw.
5 Cut and remove riser in a solidified casting by hacksaw.
6 Trim the casting by metal finish files.
7 Check the profile as per job sheet.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.64 21

Capital Goods & Manufacturing Exercise No 2.1.65
Foundryman - Moulding Process

Find out all defects

Objectives: At the end of this Exerciseercise you shall be able to
• list out the defects appeared on the cast
• prepare defect analysing chart.

Refer the Exercise No.2.1.60

22
Capital Goods & Manufacturing Exercise No 2.1.66
Foundryman - Moulding Process

Prepare simple CO2 mould

Objectives: At the end of this Exerciseercise you shall be able to
• prepare Co2 sand
• prepare Co2 drag mould
• make Co2 cope mould.

Requirements
Tools/Instruments
• Riddle - 1 No. • Pattern - 1 No.
• Shovel - 1 No. • Core boxes - 1 No.
• Molding board - 1 No. • Auto sand riddle - 1 No.
• Trowel - 1 No. • Sand mixer - as reqd.
• Cleaner - 1 No. • Sand muller - as reqd.
• Rammers - 1 No. • Mould hardness tester - 1 No.
• Vent-wire - 1 No. • Tray big 450mmx450mmx50 height - 1 No.
• Leveller - 1 No. • Trolly - 1 No.
• Wooden mallet - 1 No. Materials
• Draw spike - 1 No.
• Sprue pins - 1 No. • Parting materials - as reqd.
• Gate cutter - 1 No. • Silica sand - as reqd.
• Smoothers - 1 No. • Iron oxide - as reqd.
• Cleaning brush - 1 No. • Sodium silicate oil - as reqd.
• Dust bag - 1 No. • Kerosene - as reqd.
• Painting brush - 1 No. • Cousin materials - as reqd.
• Blow lamp or LPG heating torch - 1 No. Facing materials
• ‘C’ clamp - 1 No.
• Lighting torch lamp - 1 No. • Plumbago or graphite powder - as reqd.
• Water jug or water sprinklers - 1 No. • Kerosene or LPG - as reqd.
• Co2 cylinder with trolly - as reqd.
Equipments/Machines • Co2 closing set - as reqd.
• Set of molding boxes with guide pin - 2 Nos.

23
PROCEDURE

TASK 1 : Prepare CO2 sand as per composition

1 Arrange require tools, materials & equipments.
4 Mix base materials.
2 Weighing the materials as per composition.
5 Add 50% binder in the sand mixture.
3 Sieve and filter the materials to remove the foreign
6 Mix it properly.
materials.
7 Add balance 50% of binder.
Dry fine grain silica sand - 100 kg.
8 Keep the CO2 sand in in the trolly covered with gunny
Sodium silicate - 4 to 6 kg.
bag.
Additives - 1 to 2 kg.
Mulling time - 3 to 5 minutes.
CO2 gas - 1/3rd of sodium
silicate

TASK 2 : Prepare CO2 drag mould

1 Sprinkle parting material over the parting surface of 2 Place the flask over the moulding board.
molding board. 3 Place the pattern centrally inside the flask.
Dry fine grain silica sand: AFS NO : 60 to 80 4 Fill the sand - gentle ram it by hand.

i) Sand must clay content should be less than 0.5% 5 Fill the sand above the flask level.
and carbonates less than 1%. 6 Pack the sand by hand.

Sodium silicate : sodium, silicate ratio is 1.90 to 7 Ram it by flat rammer.

2.80 8 Strike off Exercisecess sand above the surface of flask.

i) The ratio should be constant with in limits to get 9 Make vent holes.
good sound results. 10 Insert through vents 50% CO2 gas to the CO2 mixture
ii) If ratio is too high, the binder looses viscosity. sand binder in the sand mixture.

Additives 11 Check the hardness of mould cavity.

i) It improve the surface finish and collapsibility, (coal 12 Pass reminder of 50% CO2 gas through vents to the CO2
dust, pitch, wood flour). mixture check the hardness of mould.

ii) Break down agents in Exercisetrine, pure sugar

cane.

TASK 3 : Prepare CO2 cope mould

1 Turn over the drag. 12 Pass through vents 50% CO2 gas to the CO2. Mixture
sand binder in the sand mixture.
2 Sprinkle parting material over the parting surface of
drag. 13 Check the hardness of mould.
3 Place the pattern on above the drag mould. 14 Pass reminder of 50% CO2 gas through vents to the CO2
mixture.
4 Fix the cope box over the drag, and set the closing pins.
15 Remove the sprue base and pins
5 Locate the sprue base and pins gate pieces, where its
needs for runner & risers. 16 Lift the cops and keep the sand bed
6 Fill the CO2 sand - gentle ram it by hand. 17 Draw the pattern from the drag and cope
7 Fill the sand above the flask level. 18 Clean the mould cavity.
8 Pack the sand by hand. 19 Dust the facing materials.
9 Ram gently by flat rammer. 20 The mould is ready for pouring
10 Strike off Exercisecess sand above the surface. 21 Check it with instructor
11 Make vent holes.

24 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.66

Capital Goods & Manufacturing Exercise No 2.1.67
Foundryman - Moulding Process

Prepare simple CO2 core

Objectives: At the end of this Exerciseercise you shall be able to
• prepare co2 sand as per composition
• prepare co2 core
• dry Co2 core.

Requirements

Tools/Instruments
• Woodern rammer - 1 No. • Clay ball - as reqd.
• C.clamp - 1 No. • Core sand mixer - as reqd.
• Vent-wire - 1 No. • Core hardness tester - as reqd.
• Squril hair brush - 1 No. Materials
• Wooden mallet - 1 No.
• Leveller - 1 No. • Parting materials - as reqd.
• Dust-bag - 1 No. • Silica sand - as reqd.
• Lighting torch lamp - 1 No. • Tempered molding sand - as reqd.
• Moisture - as reqd.
Equipments/Machines • Clay - as reqd.
• Core boxes - 1 No. • Kerosene or LPG - as reqd.
• Auto sand riddler - as reqd.

PROCEDURE

TASK 1 : Prepare CO2 sand as per composition

1 Arrange require tools, materials & equipments. 4 Add 50% binder in the sand mixture.
2 Weigh the materials as per composition. 5 Mix it properly.
3 Sieve the materials to remove the foreign materials. 6 Add balance 50% of binder. Mix it properly.

Dry fine grain silica sand - 100 kg. 7 Keep the CO2 sand in covered bag.

Sodium silicate - 4 to 6 kg.

Additives - 1 to 2 kg.
Mulling time - 3 to 5 minutes.
CO2 gas - 1/3rd of sodium silicate
25
TASK 2 : Prepare CO2 core
1 Clean the core box.
Additives
2 Place the core box on the moulding board.
i) It improve the surface finish and collapsibility,
3 Fill the CO2 sand - Ram it by wooden rammer. (coal dust, pitch, wood flour).
4 Fill the CO2 sand above the core box level. ii) Break down agents in dExercisetrine, pure sugar
cane.
5 Tuck in with hand.
6 Ram it by but rammer gently. 2 Keep the vent template and provide the vents to the
core.
7 Strike off Exercisetra sand from the surface.
3 Pass through vents 50% CO2 gas to the CO2 mixture
8 Sleek the parting surface.
sand binder in the sand mixture. (1.4 kg per cm2)
Dry fine grain silica sand: AFS NO : 60 to 80 4 Check the hardness of mould cavity.
i) Sand must clay content should be less than 5 Pass reminder of 50% CO2 gas through vents to the CO2
0.5% and carbonates less than 1%. mixture. (30 seconds)
Sodium silicate : sodium silicate is 1.90 to 2.80
i) The ratio should be constant with in limits to get
good sound results.
ii) If ratio is too high, the binder looses viscosity.

TASK 3: Dry Co2 core

1 Check the hardness of core. 8 Switch ON the core oven.
2 Withdrawn the core from the core box. 9 Allow the drying time.
3 Check it whether damaged wall in the core. 10 Open the core oven allow to cool at room temperature.
4 If necessary to clean & finish the damaged wall in the 11 Check the core hardness with help of core hardness
core. tester.
12 Check the surface smoothness other smooth surface
Safety: Pack the core with loose sand to avoid
by core coating.
rolling out from core plate while placing in the
case previous. 13 Measure the dimension.
14 Compare with profile.
5 Dust the facing material with help of dust bag. Coat the
facing material with help of painting brush. 15 The core is ready.
6 Load the core inside the core oven with core plate. 16 Check it with instructor.
7 Close the core oven door.

26 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.67

Capital Goods & Manufacturing Exercise No 2.1.68
Foundryman - Moulding Process

Assemble CO2 core in a mould

Objectives: At the end of this Exerciseercise you shall be able to
• prepare the core for assemble
• set the core
• assemble the core in the mould.

Requirements

Tools/Instruments Equipments/Machines

• File (smooth) - 1 No. • Clay ball - as reqd.

• File (rough) - 1 No. • Clay for looking the box - as reqd.
• Sand paper - 1 No. • Water - as reqd.
• Vent-wire - 1 No • Clay - as reqd.
• Profile - 1 No. Materials
• Inside/Outside - 1 No.
• Caliper - 1 No. • Clay - as reqd.
• Scale - 1 No Facing materials
• Lighting torch lamp - 1 No.
• Water jug or water sprinklers - 1 No. • Plumbago or graphite powder - as reqd.
• Kerosene or LPG - as reqd.

PROCEDURE

Arrange require tools, material & equipments for assemble the core.

TASK 1 : Prepare the core for assembly

1 Measure the overall dimension for core and core print. 5 Blow off the sand loose particles by hand bellows.
2 Trim it if necessary. 6 Bake the drag and cope & core.
3 Verify the dimensions core & core print. 7 Allow to cool.
4 Place the mould over the sand bed.

TASK 2 : Set the core on the core print (Fig 1)

1 Fix the core in core print of the drag mould with help of
core hook or thread.
2 Check the wall thickness of the mould wall.
3 Dust the facing material on pouring & riser cups with
help of dust bag or coat core and mould.

27
TASK 3 : Assembly the mould (Fig 2)
1 Close the cope mould over the drag with help of guide
pin.
2 Cover the pouring basin with rolled cotton waste.
3 Keep the weight over the cope.
4 Now ready for pour the molten metal into the mould.

28 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.68

Capital Goods & Manufacturing Exercise No 2.1.69
Foundryman - Moulding Process

Make a casting by CI
Objectives: At the end of this Exerciseercise you shall be able to
• melt cast iron in a furnace
• pour cast iron in a co2 mould.

Requirements

Tools/Instruments
• Casting hand tools - as reqd. • Laddle - 1 No.

Equipments/Machines Materials

• Melting furnace - 1 No. • Molten cast iron - as reqd.

• Pyrometer - 1 No. • Safety dress & device - as reqd.
• Weighing machine - 1 No.

PROCEDURE

Refer the Exercise No.2.1.58 Task 7

29
Capital Goods & Manufacturing Exercise No 2.1.70
Foundryman - Moulding Process

Fettle the solidified casting (CO2)

Objectives: At the end of this Exerciseercise you shall be able to
• knock out
• remove fins & flash
• remove runner
• remove riser
• surface clean.

Refer the Exercise No.2.1.59

30
Capital Goods & Manufacturing Exercise No 2.1.71
Foundryman - Moulding Process

List out casting defects

Objectives: At the end of this Exerciseercise you shall be able to
• find the defect occur on the casting
• list out the defects on the casting
• classify and find out remedies
• prepare defect analysing chart.

Refer the Exercise No.2.1.60

31
Capital Goods & Manufacturing Exercise No 2.1.72
Foundryman - Moulding Process

Prepare mould for setting “Balanced core” and set balanced core in mould
with the help of chaplets
Objectives: At the end of this Exerciseercise you shall be able to
• prepare balanced core with chaplet
• prepare mould and set balanced core with chaplet.

32
 Requirements
Tools/Instruments Equipments/Machines

• Riddle - 1 No. • Set of moulding boxes with guide pin - 2 Nos.

• Shovel - 1 No. • Pattern - 1 No.
• Moulding board - 1 No. • Core boxes - 2 Nos.
• Trowel - 1 No. • Auto sand riddler - as reqd.
• Cleaner - 1 No. • Sand mixer - as reqd.
• Rammers - 1 No. • Sand muller - as reqd.
• Vent wire - 1 No. • Mould hardness tester - as reqd.
• Leveler - 1 No. • Core hardness tester - as reqd.
• Wooden mallet - 1 No. Materials
• Draw spike - 1 No.
• Sprue pins - 1 No. • Parting materials - as reqd.
• Gate cutter - 1 No. • Silica sand - as reqd.
• Smoothers - 1 No. • New silica sand - as reqd.
• Cleaning brush (or) swab - 1 No. • Bentonite (sodium) - as reqd.
• Dust bag - 1 No. • Coal dust - as reqd.
• Painting brush - 1 No. • Tempered moulding sand - as reqd.
• Blow lamp or LPG heating torch - 1 No. • Water - as reqd.
• ‘C’ clamp - 1 No. • Clay - as reqd.
• Water jug / water sprinklers - 1 No. Facing materials
• Plumbago or graphite powder - as reqd.
• Kerosene / LPG - as reqd.

PROCEDURE

TASK 1 : Prepare moulding & core sand

1 Weight the following material and mixing by hand or

shovel. Silica sand - 90%
New silica flour - 4%
Bentonite - 6%
Water - 4%

TASK 2 : Prepare mould for setting balance core (Fig 1)

1 Place the drag pattern on the moulding board. 4 Fill the drag with tempering moulding sand and ram the
sand uniformly.
2 Apply facing sand carefully all around the pattern.
5 Strike off Exercisecess sand.
3 Tucking the sand uniformly.
6 Sprinkle parting sand turn over the drag, smooth surface.
7 Place cope over the drag.
8 Sprinkle parting materials.
9 Set the runner and riser peg in proper position.
10 Fill the cope with sand and ram, level and vent.
11 Strike off the Exercisecess sand.
12 Remove sprue and riser pins.
13 Cut the pouring basin.
14 Vent the cope with a vent wire.
15 Marking the box.
16 Separate cope & drag box.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.72 33

17 Rapping and remove the pattern. 19 Cut the in-gate.
18 Repair the mould, if necessary. 20 Dressing the mould cavity.

TASK 3 : Prepare balance core (Fig 2)

1 Select core box & clamping.

2 Prepare by core sand.
3 Reinforced the core.
4 Venting the core by vent wire, coat the core.
5 Set the core on core plate.
6 Bake the core.
7 Dressing the core.

TASK 4 : Set balance core by chaplet (Fig 3)

1 Check the clearance of mould wall 3 Prepare chaplet from the same metal
2 Select the chaplet suitable for job. 4 Clean the mould and set the chaplet
5 Set the core
6 Close and clamp the moulding box.

A balanced core is one which is supported and

balanced from its one end only. Balanced core
may be supported on chaplets.
Chaplet should be the same material which is
being cast.
Chaplet should be clean dry free from oil
before pleasing.

34 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exerciseercise 2.1.72

Capital Goods & Manufacturing Exercise No 2.1.73
Foundryman - Moulding Process

Make an aluminium casting using pit furnace

Objectives: At the end of this Exerciseercise you shall be able to
• make a aluminium casting.

Requirements
Tools/Instruments Materials
• Lifting tongs - 1 No. • Crucible - as reqd.
• Resting tongs - 1 No. • Aluminium ingot - as reqd.
• Skimmer rod - 1 No. • Kerosine - as reqd.
• De-gassing pluncher - 1 No. • Fire wood - as reqd.
• Core - as reqd.
Equipments/Machines
• Degassing tablet - as reqd.
• Pit furnace with accessories - as reqd. • Normal salt - as reqd.

PROCEDURE

TASK 1 : Make a aluminium casting

8 Charge the aluminium ingot in the crucible and place
Reline the pit furnace as per Exercise No.2.6.104 the filled crucible in the center of the furnace.
1 Open the furnace fire door and clean the ash. 9 Pack the crucible with small size coke.
2 Place the kerosine chocked cotton waste on the fire 10 Switch on the blower.
grid or fire bar. 11 After 30 minutes, check the molten metal with the help
3 Place the bed coke on the cotton waste in half the of heated rod. (If the metal is not sticked on the heated
height of the furnace. rod the required melting temperature is attained)
4 Put the fire wood, cotton waste under the fire bar and 12 Put the flux, (normal salt) and remove the slag with the
fired it. help of skimmer rod.
5 Switch on the blower, while the bed coke is fired. 13 Degas the metal with the help of degassing plunger.
6 After the fire woods are fired switch off the blower. 14 Lift the crucible with the help of lifting tongs and place
the crucible in the lifting tongs.
7 Close the fire door tightly and cover the fire door with the
help of clay or red sand. 15 Pour the aluminium metal into the mould with the help
of resting tongs.

35
Capital Goods & Manufacturing Exercise No 2.1.74
Foundryman - Moulding Process

Fettle the casting

Refer the Exercise No.2.1.59

36
Capital Goods & Manufacturing Exercise No 2.2.75
Foundryman - Fettling (Casting yield percentage)

Prepare a mould for setting hanging core and set hanging core in a mould
with the help of chaplets
Objectives: At the end of this exercise you shall be able to
• prepare mould & core sand
• prepare mould for setting hanging core
• prepare hanging core
• set the hanging core.

Requirements
Tools/Instruments Equipments/Machines
• Shovel - 1 No. • Flask - 2 Nos.
• Riddle - 1 No. • Core plate - 1 No.
• Cleaner - 1 No. • Core box - 1 No.
• Smoother - 1 No. Materials
• Vent wire - 1 No.
• Gaggers - as reqd. • Silica sand - as reqd.
• ‘C’ clamp - 1 No. • Bentonite - as reqd.
• Coal dust - as reqd.
• Water - as reqd.

PROCEDURE

TASK 1 : Prepare moulding & core sand

1 Weigh the following material sand mixing by hand or Silica sand - 90%
shovel.
New silica flour - 4%
Bentonite - 6%
Water - 4%

TASK 2 : Prepare mould for setting hanging core

1 Place the drag pattern on the moulding board. 11 Strike off the excess sand.
2 Sprinkling facing sand all around the pattern. 12 Remove sprue and riser pins.
3 Tuck the sand uniformly with hand. 13 Cut the pouring basin.
4 Fill the drag with tempering moulding sand and ram the 14 Vent the cope with a vent wire.
sand uniformly.
15 Marking the box.
5 Strike off excess sand.
16 Separate cope & drag box.
6 Roll over the drag and place the cope pattern over drag
17 Rapping and remove the pattern.
pattern.
18 Repair the mould, if necessary.
7 Place cope box (Flask) over the drag.
19 Cut the in-gate.
8 Sprinkle parting materials.
20 Dressing the mould cavity.
9 Set the runner and riser peg in proper position.
10 Fill the cope with sand and ram.

35
TASK 3 : Prepare hanging core
1 Select core box & clamping. 6 Vent the core by vent wire.
2 Prepare core sand. 7 Set the core on core plate.
3 Prepare the required core. 8 Bake the core.
4 It can be made up of either green or dry sand. 9 Dress the core.
5 Re-inforce the core. 10 Coating the core.

TASK 4 : Set the hanging core

1 Set core supported from above and it hangs vertically in
the mould cavity with help of string.
2 A hanging core has supported by chaplets from bottom
(Fig 1).
3 Now the mould is ready for pouring.

A hanging core is one which is not suppported

on any seat rather it hang from the cope with
the help of wires, etc.

36 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.2.75

Capital Goods & Manufacturing Exercise No 2.2.76
Foundryman - Fettling (Casting yield percentage)

Make a casting - Aluminium

Refer the Exercise No.2.1.73 Make a casting

Capital Goods & Manufacturing Exercise No 2.2.77

Foundryman - Fettling (Casting yield percentage)

Fettle the casting

Refer the Exercise No.2.1.59

37
Capital Goods & Manufacturing Exercise No 2.2.78
Foundryman - Fettling (Casting yield percentage)

Find out the yield percentage

Objectives: At the end of this exercise you shall be able to
• calculate the yield percentage of casting.

Requirements

Equipments/Machines Materials
• Weighing balance • Casting tree (Including in casting, Runner, Riser,
Ingate, Fins and Flashes)

PROCEDURE

Find out the yield percentage Pouring weight: Including in casting, Runner, Riser, Ingate,
Fins and Flashes weight.
Casting weight
Yield percentage = x 100
Pouring weight

38
Capital Goods & Manufacturing Exercise No 2.2.79
Foundryman - Fettling (Casting yield percentage)

Prepare a mould using chills and densers

Objectives: At the end of this exercise you shall be able to
• select the chills
• locate the thick section
• prepare mould with chill
• prepare cope & drag.

Requirements

Tools/Instruments Equipments/Machines
• Foundryman tool kits • Sand muller
• Vent wire • Sand erator
• Swab
Materials
• Smoother
• Cleaners • Chill and densersas percasting
• Shovel
• ‘C’ clamp

PROCEDURE

TASK 1 : Select the chills and densers (Fig 1&2)

1 Select the size & shape as per casting. 3 Clean the chill.
2 Select the required chill and denser. 4 Pre-heat the chill. (Fig 2)

39
TASK 2 : Locate the section
1 Locate the thick section in the pattern. (Fig 3)

TASK 3 : Prepare a mould with chills and densers

1 Place drag on bottom board with pattern. 5 Select suitable size and shape of the chills as per
casting to proportional cooling.
2 Set the chill in the thickest portion of the pattern.
3 Set the densers in the mould cavity. Chills and densers should be free from moisture,
dust, rust, etc.
4 Ram, level, vent and turnover the drag.

TASK 4 : Prepare cope with chill

1 Locate runner & riser. (Fig 4) 2 Ram level, firms and vent cope
3 The mould is ready for casting.

Turn over the pattern and chill along with

moulding board.

Use ‘C’ clamp while turn-over the drag.

4 Remove the RN & RN

5 Separate cope and drag cut
6 Pouring basin and provide in gate
7 Check with instructor.

TASK 5 : Make a casting

Refer the Exercise No.2.1.58 Task 7

Skill Sequence

Cut the runner and in-gate

Objectives: This shall help you to
• cut the runner/sprue
• cut the in-gate/ingates
• cut the pencil gate
• cut the step gate, horn gate.

1 Mark the position of the runner and the in-gate. 4 Give slant cuts within the marked area with the leaf of
the runner.
2 Swab the marked area. (Fig 1)
5 Remove the sand with help of the cleaner.
3 Cut the sand, “deep on the marked line with straight
edge and leaf of the cleaner”. 6 Slick the surface of the runner and in-gate with smoothers.
(Fig 2A & 2B)
40 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.2.79
 Mark the gate and give deep cut (1”) on the
moulding.
Always cut gate from the mould towards the
runner.
Study the mould carefully and locate in gate or
in gates.
Study the deep portion of the mould.
Study the sand moudits in the cavity of the
mould.

7 Ready made runner-riser are fixed and removed after

moulding.
8 Follow same procedures for marking & cutting horn
gate, pencil gate and step gate. (Fig 3,4 & 5)

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.2.79 41

Capital Goods & Manufacturing Exercise No 2.2.80
Foundryman - Fettling (Casting yield percentage)

Make a casting

Refer the Exercise No.2.1.58 Task 7 for casting

Refer the Exercise No.2.1.59 for fettling

42
Capital Goods & Manufacturing Exercise No 2.2.81
Foundryman - Fettling (Casting yield percentage)

Show a video chart of ferrous and non-ferrous metal

Objectives: At the end of this exercise you shall be able to
• state the ferrous and non-ferrous metals.

Requirements

Equipments/Machines
• Desktop computer • L.E.D projector

PROCEDURE

The instructor can be arrange a ferrous and non-ferrous 3 What is non-ferrous metal?
video chart. 4 List out name and symbol of any four non-ferrous
1 What is ferrous metal? metals?
2 State the type of ferrous metals? 5 What is the melting temperature of copper?

43
Capital Goods & Manufacturing Exercise No 2.3.82
Foundryman - Core Marking

Prepare core halves

Objectives: At the end of this exercise you shall be able to
• prepare core sand
• prepare core halves.

Requirements

Tools/Instruments
• Rammers (wooden) - as reqd. • Core box - as reqd.
• Shovel - as reqd. • Sand muller - as reqd.
• Cleaner - as reqd. Materials
• Vent wire - as reqd.
• Brush - as reqd. • Silica sand - as reqd.
• Dextrine - as reqd.
Equipments/Machines • Linseed oil - as reqd.
• ‘C’ clamp - as reqd. • Water - as reqd.
• Core plate - as reqd.

PROCEDURE

TASK 1 : Prepare core sand

1 Weigh the following materials and mix by hand or Muller

machine.

Silica sand - 94%

Linseed oil - 5%
Dextrine - 1%
Water - as required

TASK 2 : Prepare core halves (Fig 1)

1 Clean the half core box with cotton waste. 5 Fill the core sand and ram the core sand, strike-off extra
sand by strike-off-bar.
2 Apply a coat of kerosene oil or any other parting
materials. 6 Place the core drying place on the core box and turn
over the core box.
3 Place the halves in horizontal position on the table.
7 Rap the core box and lift the core box.
4 Clamp the core box.

44
Capital Goods & Manufacturing Exercise No 2.3.83
Foundryman - Core Marking

Bake the core halves

Objectives: At the end of this exercise you shall be able to
• bake the core halves.

Requirements

Machines
• Core oven - as reqd.

PROCEDURE

1 Place the core halves in the drying oven for baking. (200 3 Dressing the core.
to 260°C - one hour) (Fig 1). 4 The core halves is ready to use.
2 Take out the core halves from the core oven and allowed 5 Check it with instructor.
to cool.

45
Production and Manufacturing Exercise 2.3.84
Foundryman - Core Making

Join the core halves by different methods

Objectives: At the end of this exercise you shall be able to
• pasting the core halves
• binding the core halves by wire.

Requirements

Materials
• Core paste - as reqd. • 3mm iron waste - as reqd.

PROCEDURE

TASK 1 : Pasting the core halves (Fig 1)

1 Make the joint surface rough of both the halves.

2 Cut a vent hole in the center.

3 Apply core paste on the surface.

4 Joint the core halves correctly or

5 Apply a coat of dressing materials and dry the core

again.

6 Now the core is ready for use.

TASK 2 : Binding the core halves (Fig 2)

1 Make the joint surface rough of both the halves.

2 Cut a vent hole in the center.

3 Joint the core halves by binding wire properly.

4 Apply a coat of dressing materials and dry the core

again.

6 Now the core is ready for use.

46
Capital Goods & Manufacturing Exercise No 2.4.85
Foundryman - Mould and Gating

Prepare a mould with pencil gate

Objectives: At the end of this exercise you shall be able to
• prepare a drag
• set the pencil gate
• prepare cope.

Requirements

Tools/Instruments
• Sand erator - 1 No.
• Foundryman tool kits - 1 No.
• ‘C’ clamp - 1 No. Materials
• Wooden rammer - 1 No. • Pencil gate - 1 No.
Equipments/Machines • Facing sand - as reqd.
• Backing sand - as reqd.
• Sand muller - 1 No. • Parting sand - as reqd.
• Sand mixer - 1 No.

PROCEDURE

TASK 1 : Prepare a drag (Fig 1)

1 Place the drag on the moulding board.

2 Place the pattern on moulding board.
3 Ram, level, finish the drag.
4 Turn over the drag on sand bed.

47
TASK 2 : Set the pencil gate

1 Place number of pencil gate over the pattern the tapper

towards the pattern for easy withdraw of gate.
(Fig 2)

TASK 3 : Prepare cope

1 Set the cope on drag. 7 Swap around the pattern.

2 Ram, level, finish and vent the cope. 8 Rap the pattern.
3 Remove the pencil gate after rapping. 9 Withdraw the pattern.
4 Remove the gate one by one. 10 Clean the mould cavity.
5 Cut the pouring basin to connect all the pencil gate. 11 Set the cope.
(Fig 3)
12 Clamp the mould.
6 Turn over the cope on sand bed.
13 The mould is ready to cast.
14 Check with instructor.

Take care while ramming the pencil gate should

not get shifted.
Don’t hit the pencil gate while ramming.
Use wooden rammer for ramming.

48 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.4.85

Capital Goods & Manufacturing Exercise No 2.4.86
Foundryman - Mould and Gating

Prepare mould with finger gate

Objectives: At the end of this exercise you shall be able to
• prepare a drag
• set the finger gate
• prepare cope.

Requirements

Tools/Instruments
• Foundryman tool kits - 1 No. • Auto riddle - 1 No.
• Shovel - 1 No. Materials
Equipments/Machines • Finger gate piece - as reqd.
• Sand muller - 1 No. • Facing sand - as reqd.
• Sand mixer - 1 No. • Backing sand - as reqd.
• Sand erator - 1 No. • Parting sand - as reqd.

PROCEDURE

TASK 1 : Prepare a drag

1 Place the drag on the moulding board. 3 Rain, level, finish and vent the drag.
2 Place the pattern on moulding board. 4 Turn over the drag on sand bed.

TASK 2 : Set the finger gate

1 Set the finger gate tapper towards the pattern as shown

in the (Fig.1).

49
TASK 3 : Prepare cope
1 Set the cope on drag. 10 Clean the mould cavity.
2 Ram, level, finish and vent the cope. 11 Set the cope.
3 Remove the finger gate after rapping. 12 Clamp the mould.
4 Remove the gate one by one. 13 The mould is ready to casting.
5 Cut the pouring basing to connect all the finger gate. 14 Check with instructor.
6 Turn over the cope on sand bed.
Take care while ramming the finger gate should
7 Swap around the pattern. not get shifted.
8 Rap the pattern.
Don’t hit the finger gate while ramming.
9 Withdraw the pattern.

50 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.4.86

Capital Goods & Manufacturing Exercise No 2.4.87
Foundryman - Mould and Gating

Make casting with aluminium

Objectives: At the end of this exercise you shall be able to
• make the aluminium castings.

PROCEDURE

1 The aluminium metal melted by using pit furnace. (Refer 3 Fettling the casting by Refer Exercise No.2.1.59.
Exercise No.2.1.73)
2 Pour the molten metal in the moulds prepared in
Exercise No.2.4.85 & 2.4.86.

51
Production & Manufacturin Exercise No 2.4.88
Foundryman - Mould and Gating

Prepare mould with wedge gate (coping down the flask)

Objectives: At the end of this exercise you shall be able to
• set the wedge gate on drag
• prepare cope
• coping down the flask.

Requirements

Tools/Instruments
• Sand erator - as reqd.
• Foundryman tool kits - 1 No.
Materials
• Wooden rammer - as reqd.
• Wedge gate piece - as reqd.
Equipments/Machines
• Facing sand - as reqd.
• Sand muller - as reqd. • Backing sand - as reqd.
• Sand mixer - as reqd. • Parting sand - as reqd.

PROCEDURE

TASK 1 : Set the wedge gate on drag

1 Place the drag on the moulding board. (Fig 1)
2 Place the pattern with parting surface down on the
bottom board.
3 Set the wedge gate tapper towards the pattern as
shown in Fig 1.

Safety
Select a flask which can accommodate mould
cavity, risers, and the wedge gate.
(mm 4” around pattern)

52
TASK 2 : Prepare cope

1 Place the cope over rammed drag. 3 Fill the cope with sand and ram.
2 Sprinkle parting sand all around drag. 4 Ram, Level, Vent and finish the cope.

Mould cavity should have sufficient wall

thickness.

TASK 3 : Coping down the flask

1 Roll over the cope on sand bed. 6 Clamp the cope and drag.
2 Clean the mould. 7 Place the weight.
3 Withdraw the pattern wedge gate from drag. 8 The mould is ready for casting.
4 Clean the gate and drag. 9 Check it with instructor.
5 Turn-over the drag on cope.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.4.88 53

Capital Goods & Manufacturing Exercise No 2.4.89
Foundryman - Mould and Gating

Prepare mould with ring gate

Objectives: At the end of this exercise you shall be able to
• prepare drag
• set the ring gate
• prepare cope.

PROCEDURE

TASK 1 : Prepare drag

1 Place the drag on the moulding board.
2 Place the pattern on moulding board.
3 Ram, level, fins the drag.
4 Turn over the drag on sand bed.

TASK 2 : Set the ring gate

1 Place the ring gate (Ram up core) over the pattern.

TASK 3 : Prepare cope

1 Set cope on drag. 5 Swab around the pattern.

2 Ram, level finish and vent the cope. 6 Rap and with draw the pattern
7 Clean the mould cavity.
Ready-made ring core also can be made dried
in oven and placed on the pattern and ram up. 8 Set the cope and clamp the mould.
9 The mould is ready to cast.
3 Cut the pouring basin to connect the ring gate.
4 Turn over the cope on sand bed.

54
Capital Goods & Manufacturing Exercise No 2.4.90
Foundryman - Mould and Gating

Make casting with copper base alloy

Objectives: At the end of this exercise you shall be able to
• make the copper base alloy castings.

Requirements

Tools/Instruments
• Tongs - as reqd. • Pyrometer - as reqd.
• Skimmmer rod - as reqd. Materials
• De-gassing plunger - as reqd.
• Copper base - as reqd.
Equipments/Machines • Allo scarp - as reqd.
• Oil fire furnace - as reqd. • Furnace oil - as reqd.
• Crucible - as reqd. • De-gassing tablet - as reqd.
• Ladle - as reqd. • Fun material - as reqd.

PROCEDURE

TASK 1 : Place crucible stand on the middle of the tilting furnace

1 Place the crucible stand bottom center of the tilting

furnace.
2 Take crucible (No 100) put on the crucible stand.
3 Place the fire bricks four sides around the crucible.
4 Place the oil waste around the crucible.
5 Check the oil valve and air valve.
6 Light the oil waste and open the oil valve and air valve.
7 Switch on the blower continuously air and oil fired
around the crucible.
8 Heat the crucible up to red hot.

TASK 2 : Melt copper in the tilting furnace

1 Charge copper scrap ingate, runner piece and ingot on 3 Flame produced by the compustion of oil or gas with air
the top of crucible. is allowed to sweep around to crucible and uniformly
heat it.
2 Cover it with lid to avoid oxidation.
4 Check the temperature with pyrometer.
5 Tilt the furnace and the molten metal in the preheat hand
laddle.
6 De-gas the metal (de-gasser tablet into the crucible use
the degasser dipped by plunger rod)
7 Remove slag with help skimming.
8 Cover the molten metal with flux.
9 Carry the laddle with flux.
10 Pour the molten metal in the mould slowly, steady
comes up into the riser of the mould.

55
11 Stop pouring till the molten metal comes out from the
Use the flux to reduce the atmospheric pressure
riser.
gone out avoid the pin holes defect.

TASK 3: Fettling of the casting

Refer the Exercise No.2.1.59

56 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.4.90

Capital Goods & Manufacturing Exercise No 2.4.91
Foundryman - Mould and Gating

Prepare mould with branch gate mould with match plate pattern
Objectives: At the end of this exercise you shall be able to
• set the match plate
• mount the pneumatic vibrator on match plate
• assemble the cope and drag with match plate
• prepare drag
• roll over the drag.

Requirements

Tools/Instruments Materials

• Foundryman Tool kit - 1 No. • Unit sand - as reqd.

• Kerosene - as reqd.
Equipments/Machines • Parting sand - as reqd.
• Moulding machine (jolt & squeeze) - 1 Set • Plumbago powder - as reqd.
• Match plate - as reqd.
• Air operated pattern - as reqd.

PROCEDURE

TASK 1 : Set the match plate

1 Clean the match plate
The kerosene will help to remove the match
2 Apply little kerosene and clean the branch gate plate easily from the mould and avoid breakage
of mould.

TASK 2 : Mount the pneumatic vibrator

1 Mount the pneumatic vibrator on one end of match plate

(Fig 1)

57
TASK 3 : Assemble the cope and drag with match plate
1 Assemble the cope and drag with match plate to avoid
shift (Fig 2)

TASK 4 : Prepare drag

1 Place the assembly on machine table with drag up
(Fig 3)
2 Dust parting materials
3 Fill the drag with sand
4 Jolt the machine till you get sufficient density.
5 Bottom board which fits into the box is positioned over
the sand properly located with a couple of more jolts.

TASK 5 : Roll over the drag

1 Roll over entire assemble by hand. (Fig 4)

1 Set the cope

Prepare cope (Fig 5) 2 Dust parting medium

58 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.4.91

3 Fill the sand and level the box.
4 Squeeze board is positioned in the box and mould is
squeezed. (Fig 6)

Take care the jolting of cope is normally not

done since it may undo the jolting of drag done
earlier.

5 Squeeze board is removed.

6 Clean the runner, riser and pouring basin.
7 Loose the match plate by operating vibrator
8 Cope is lifted and placed the board.
9 Vibrate and remove the match plate.
10 Clean the cope and drag.
11 Assemble the cope and drag.
12 Clamp the mould
13 The mould is ready for pouring cast iron pouring
14 Check with Instructor.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.4.91 59

Capital Goods & Manufacturing Exercise No 2.4.92
Foundryman - Mould and Gating

Make casting with cast iron

Objectives: At the end of this exercise you shall be able to
• make the cast iron castings.

Refer the Exercise No.2.1.58 for Task 7 for casting

Capital Goods & Manufacturing Exercise No 2.4.93

Foundryman - Mould and Gating

Fettle the casting

Refer the Exercise No.2.1.59

60
Capital Goods & Manufacturing Exercise No 2.4.94
Foundryman - Mould and Gating

Prepare a mould with release sprue gate

Objectives: At the end of this exercise you shall be able to
• prepare a drag
• locate release sprue
• prepare a cope
• cut from the release sprue.

Requirements

Tools/Instruments Materials
• Foundryman tool kits - 1 No. • Facing sand - as reqd.
• Backing sand - as reqd.
Equipments/Machines
• Parting sand - as reqd.
• Sand muller - as reqd. • Wooden pattern - as reqd.
• Sand erator - as reqd.

PROCEDURE

TASK 1 : Prepare a drag

1 Refer the Exercise No.2.4.85 Task 1

Drag turn over after ramming.

TASK 2 : Locate release sprue (Fig 4)

1 Locate sprue, releasing sprue to form suitable sized

cavity.
2 Erect riser on pattern.

61
TASK 3 : Prepare a cope

1 Follow Ex. No:2.4.85 Task 3

2 Cut pouring basin.

TASK 4 : Cut and form the release sprue

1 Clean the release sprue with cleaner. 6 Set the prepared core.
2 Clean the riser and runner holes. 7 Invert the cope on drag.
3 Mark the runner with vent wire and cut the runner on 8 Clamp the box.
cope.
9 Keep weight on mould.
4 Cut in gate on cope.
10 The mould is ready for pouring.
5 Clean the mould.

62 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.4.94

Capital Goods & Manufacturing Exercise No 2.4.95
Foundryman - Mould and Gating

Prepare a mould with skim bob gate

Objectives: At the end of this exercise you shall be able to
• set the skin bob gate
• prepare cope.

Requirements

Tools/Instruments
• Foundryman tool kits - 1 No. • Sand erator - as reqd.
• Draw spice - as reqd. • Auto sand riddle - as reqd.
• Mallet(wooden) - as reqd. Materials
• Cleaners - as reqd.
• Trowel - as reqd. • Facing sand - as reqd.
• Backing sand - as reqd.
Equipments/Machines • Parting sand - as reqd.
• Sand muller - as reqd.
• Ready made skim bob gate - as reqd.

PROCEDURE

TASK 1 : Prepare drag (Fig 1)

1 Place the pattern on moulding board and place the drag.
2 Place drag portion of gate along with pattern.
3 Ram, level, finish and vent the drag.
4 Turn over the drag on sand bed.

63
TASK 2 : Set the skim bob gate (Fig 2)
1 Set the skim bob gate with pattern part.
2 If ready made gates not available this can be cut on drag
with help hand tools.

Take care while ramming the skim bob gate

should not get shifted.
Don’t hit the gate while ramming.

TASK 3 : Prepare cope

1 Set skim bob gate cope part. 8 Connect all the gates.
2 Place the cope. 9 Clean the mould cavity.
3 Ram, level, rent and finish the cope. 10 Set the cope on drag.
4 Rap & remove the sprue. 11 Clamp the mould.
5 Turn over the cope. 12 The mould is ready for casting.
6 Rap the gates & pattern. 13 Check it with instructor.
7 Withdraw the gates & pattern one by one by using draw
spike.

TASK 4: Make a casting

Refer the Exercise No.2.1.58 for Task 7 for casting

64 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.4.95

Capital Goods & Manufacturing Exercise No 2.4.96
Foundryman - Mould and Gating

Prepare a mould with shrink bob gate(CI casting)

Objectives: At the end of this exercise you shall be able to
• prepare drag
• set shrink bob gate
• prepare cope.

Requirements
Materials
Tools/Instruments
• Facing sand - as reqd.
• Foundry tools kit - 1 No. • Backing sand - as reqd.
Equipments/Machines • Parting sand - as reqd.
• Shrink bob gate - as reqd.
• Sand muller - as reqd.
• Auto sand riddle - as reqd.
• Sand eractor - as reqd.

PROCEDURE

TASK 1 : Prepare drag

Refer the Exercise No. 2.4.95 Task 1 and prepare the Shrink bob gate

TASK 2 : Set the shrink bob gate (Fig 1)

1 Set the shrink bob gate with pattern.

65
TASK 3 : Prepare cope (Fig 2)
1 Refer the procedure Exercise No : 2.4.94 - Task 3.

TASK 4: Make a casting

Refer the Exercise No.2.1.58 for Task 7 for casting

66 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.4.96

Capital Goods & Manufacturing Exercise No 2.4.97
Foundryman - Mould and Gating

Find out the defects

Objectives: At the end of this exercise you shall be able to
• list out the defects appeared on the castings.

Refer the Exercise No. 2.1.60

67
Capital Goods & Manufacturing Exercise No 2.4.98
Foundryman - Mould and Gating

Prepare mould with horn - gate (Gear wheel type pattern)

Objectives: At the end of this exercise you shall be able to
• prepare drag with horn gate
• prepare cheek
• prepare cope.

Requirements

Tools/Instruments
• Sand erator - as reqd.
• Foundryman tool kits - 1 No. • Auto sand riddle - as reqd.
• Cleaners - as reqd.
• Draw spike - as reqd. Materials
• Wooden mallet - as reqd. • Horn gate piece - as reqd.
• Hand bellows - as reqd. • Facing sand - as reqd.
Equipments/Machines • Backing sand - as reqd.
• Parting sand - as reqd.
• Sand muller - as reqd.

PROCEDURE

TASK 1 : Set horn gate (Fig 1)

1 Place the moulding board on floor.

2 Fix the drag on board.
3 Set the horn gate piece, the choke towards pattern.
4 Ram, Level, Vent and roll over the drag.

68
TASK 2 : Prepare check (Fig 2)
1 Locate the common sprue.
2 Place the cheek on drag.
3 Ram, Level, Vent and finish the check.
4 Locate riser on pattern.

TASK 3 : Prepare cope (Fig 3)

1 Set the cope on cheek.
2 Ram, Level, Vent the cope.
3 Cut pouring basin & riser.
4 Remove the common sprue & riser.
5 Roll over cope on sand bed.
6 Withdraw the pattern.
7 Roll over the cheek.
8 Rest the cheek on brick.

TASK 4 : Remove the horn-gate piece

1 Swap around horn-gate. 6 Replace the cheek & cope.

2 Rap the gate with draw spice with wooden pattern. 7 Clamp the mould.
3 Slowly press with draw-spike on choke and remove the 8 Keep weight on mould & loot with clay.
horn-gate from largest thickness side by hand.
9 The mould is ready for casting.
4 Use cleaners to clean the horn gate cavity.
10 Check it with instructor.
5 Blow the loose sand with hand bellows.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.4.98 69

Capital Goods & Manufacturing Exercise No 2.4.99
Foundryman - Mould and Gating

Prepare a mould with stepped gate

Objectives: At the end of this exercise you shall be able to
• prepare drag
• set the stepped gate
• prepare cheeks
• prepare cope.

Requirements

Tools/Instruments Materials
• Swab - 1 No. • Facing sand - as reqd.
• Foundryman Tool kit - 1 No. • Packing sand - as reqd.
• Cleaner - 1 No. • Parting sand - as reqd.
• Smoothers - 1 No. • Plumbago powder - as reqd.
• Step gate (ready made) - as reqd.
Equipments/Machines
as per casty dimension
• Plane - 5 Nos.
• Sand muller - as reqd.

PROCEDURE

TASK 1 : Prepare drag

1 Place the moulding board on floor.

2 Place drag on moulding board.
3 Ram, level, vent and finish drag.

TASK 2 : Set the step gate, prepare cheek

1 Sleek the drag surface. 5 Set the step gate shown in the figure. (Fig 2)
2 Sprinkle parting sand. 6 Ram, Level, Finish and vent the check.
3 Set the cheek on drag. 7 Repeat same procedure for preparing other the cheeks.
(Fig 3 (B,C,D,E)
4 Embed the core prial portion on drag and fix the pattern
on drag. (Fig 1)

70
TASK 3: Prepare cope
1 Set the cope on check. (Fig 3(F))
2 Ram, Level, Vent and finish the cope.
3 Cut the pouring basin.
4 Remove runner and rises.
5 Turn-over the cope on sand bed.
6 Remove the cheek and step gate one by one.
7 Clean the drag.
8 Apply mould coat.
9 Fix the core vertically.
10 Close the mould by inverting cheeks over drag.
11 Set the cope.
12 Clamp the mould, and keep weight.
13 The mould is ready to pouring.
14 Check with instructor.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.4.99 71

Capital Goods & Manufacturing Exercise No 2.5.100
Foundryman - Thick Casting with Larger Feeder Head

Industrial visit to observe the various foundry process

Objectives: At the end of this exercise you shall be able to
• visit the foundry, industry and understand process carried in the industry.

Visit the foundry, industry and study the processes like special casting process. Machine moulding
process, sand recycling methods, core making methods casting testing methods fettling methods etc..

72
Capital Goods & Manufacturing Exercise No 2.5.101
Foundryman - Thick Casting with Larger Feeder Head

Prepare mould for extra thick casting with large feeder head
Objectives: At the end of this exercise you shall be able to
• prepare drag
• locate runner and riser (extra feeder head)
• prepare cope.

PROCEDURE

TASK 1 : Prepare drag

1 Place the pattern on the moulding board. (Fig 1&2)

2 Coat the drag with clay.
3 Set on the box.
4 Sprinkle the parting sand.
5 Fill the layer facing sand.
6 Tuck with hand.
7 Add some more facing sand
8 Ram with peen wedge rammer.
9 Fill the drag with sand 4” above the box.
10 Ram the drag with butt rammer
11 Level the drag
12 Vent the drag
13 Ram butt rammer.
14 Strick - off the excess sand
15 Sprinkle parting sand
16 Perforate the mould with vent wire. (Fig 2)
17 Turn over the drag on board or sand bed.
18 Clean and sleek the surface.

TASK 2 : Locating runner and riser

1 Locate runner 3 Sprinkle parting sand

2 Place extra feeder head 4 Set the cope on drag.

TASK 3 : Prepare cope

1 Fill the cope with a layer of facing sand. 7 Withdraw the pattern from the mould
2 Tuck with hand. 8 Clean the mould
3 Follow Task 1 from 1 to 12 steps. 9 Dust facing materials
4 Remove runner and riser peg. 10 The mould in ready for pouring
5 Prepare pouring basin. 11 Check it with instructor.
6 Cut the in gate as shown in Fig 3.
73
74 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.5.101
Capital Goods & Manufacturing Exercise No 2.5.102
Foundryman - Thick Casting with Larger Feeder Head

Make casting with cast iron casting

Objectives: At the end of this exercise you shall be able to
• make the cast iron castings.

Refer the Execise No.2.1.58 for Task 7.

Capital Goods & Manufacturing Exercise No 2.5.103

Foundryman - Thick Casting with Larger Feeder Head

Fettle the casting

Refer the Execise No.2.1.59

75
Capital Goods & Manufacturing Exercise No 2.6.104
Foundryman - Furnaces for Melting Cast Metal

Re-line the pit furnace

Objectives: At the end of this exercise you shall be able to
• remove the old lining from furnace wall
• prepare daubing mixture for lining
• lay the lining inside the fire bricks wall.

Requirements
Tools/Instruments • Water sprinkler - 1 No.

• Chipping chisel 25mm - 1 No. Materials

• Ball pein hammer 2 kg - 1 No. • Silica sand - 80 kg.
• Trowel smoother - 1 No. • Fire clay or red sand - 40 kg.
Equipments/Machines • Water
• Fire bricks circle shape - as reqd.
• Shovel - 1 No. • Round stick - as reqd.
• Sand muller - 1 No.

PROCEDURE

TASK 1 : Repair the old lining from furnace wall

1 Remove the old lining from the furnace wall using by 2 Take new fire bricks and place then inside of the wall as
chisel and hammer. shown in Fig 1.

If any damage of fire bricks remove from the

furnace wall.

76
TASK 2 : Prepare daubing mixture
1 Take silica sand - 80 kg, Fire clay or red sand - 40 kg, 4 Switch on the sand muller and run for 5 minutes on dry
Water 8%. stage.
Add too much silica sand strength is reduce. 5 Sprinkle water 8% and mull the sand 5 to 8 minutes.
Too low fire clay strength is reduce.
Exercise moisture in the lining may be crack
2 Prepare the mixture in dry stage. when pre-heating. Low moisture may not strick
the fire bricks.
3 Fill the mixture in sand muller using shovel.
6 Switch off the sand muller, taken out daubing mixture.

TASK 3 : Lay the lining inside the fire bricks wall

1 Apply the clay wash inside fire bricks and stick daubing 3 Lay the lining from top to bottom evenly. (Fig 3)
mixture on the fire bricks wall shown in Fig 2.
4 Finish the lining by trowel or smoother.
Lining should be in even all sides. Furnace is ready to melt the metal.
2 Ram the linings by using round stick. 5 Check it with your instructor.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.6.104 77

Capital Goods & Manufacturing Exercise No 2.6.105
Foundryman - Furnaces for Melting Cast Metal

Show a video for operation of blast furnace

Objectives: At the end of this exercise you shall be able to
• state the operation of blast furnace.

Requirements

Equipments/Machines
• Desktop computer - as reqd. • L.E.D projector - as reqd.

PROCEDURE

The instructor can be arrange the operation of blast 3 Which flux is used in the blast furnace?
furnacevideo.
4 What are the parts are in blast furnace?
1 What is the fuel used in blast furnace?
5 What are the zones are in blast furnace?
2 What is the product blast of furnace?

78
Capital Goods & Manufacturing Exercise No 2.6.106
Foundryman - Furnaces for Melting Cast Metal

Re-line the oil fired furnace

Objectives: At the end of this exercise you shall be able to
• remove the old lining from furnace wall
• prepare daubing mixture
• lay the lining inside the fire bricks wall.

79
 Requirements

Tools/Instruments Materials
• Chipping chisel 25mm - 1 No. • Silica sand - 80 kg.
• Ball pein hammer 2 kg - 1 No. • Fire clay or red sand - 40 kg.
• Trowel smoother - 1 No. • Water
• Shovel - 1 No. • Fire bricks circle shape - as reqd.
• Sand muller - 1 No.
• Saw vice - 1 No.
• Water sprinkler - 1 No.

PROCEDURE

TASK 1 : Repair the old lining from furnace wall

1 Remove the old lining from the furnace wall using by

chisel and hammer.

Remove the broken and burned fire brick from

the furnace wall.

2 Take new fire bricks and place then inside of the wall as
shown in Fig 1.

TASK 2 : Prepare daubing mixture

1 Take silica sand - 80 kg, Fire clay or red sand - 40 kg, 4 Switch on the sand muller and run for 5 minutes on dry
Water 8%. stage.
2 Prepare the mixture in dry stage. 5 Sprinkle water 8% and mull the sand 5 to 8 minutes.
3 Fill the mixture in sand muller using shovel. 6 Switch off the sand muller, taken out daubing mixture.

TASK 3 : Lay the lining inside the fire bricks wall

1 Apply the clay wash inside fire bricks and stick daubing 4 Finish the lining by trowel or smoother.
mixture on the fire bricks wall.
Furnace is ready to melt the metal.
2 Ram the linings by using round stick.
5 Check it with your instructor.
3 Lay the lining from top to bottom.

80 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.6.106

Capital Goods & Manufacturing Exercise No 2.6.107
Foundryman - Furnaces for Melting Cast Metal

Charging of oil fired furnace and melt aluminium

Objectives: At the end of this exercise you shall be able to
• charge and melt the aluminium in oil fired furnace.

Requirements

Equipments/Machines Materials
• Oil fired furnace with accessories - as reqd. • Aluminium - as reqd.
• Crucible (No.100) - as reqd.

PROCEDURE

TASK 1: Make a casting (using oil fired furnace)

9 After one hour, open the furnace cap with the help of
Reline the furnace as per Ex.No.2.6.106 reline tongs and check the molten metal with the help of
and preheat the laddle as per Ex.No.2.6.109 heated rod (if the metal is sticked of the heated rod
required melting temperature is not attained.)
1 Place the crucible stand in the center of the oil fired
furnace. 10 Again charge the scrap with the help of tongs.
2 Place the crucible (No 100) on the crucible stand. 11 Repeat the Sq.No.9 (if the metal is not sticked on the
heated rod the required melting temperature is attained)
3 Place the fire bricks around the crucible in curved
shape. 12 Check the chemical composition of the metal, if the
required chemical composition is not attained add the
4 Put aluminium in got in the crucible.
required alloying element.
Ensure the fuel level in the fuel tank. 13 Tittle the furnace hand wheel in 80° and remove the slag
using slag remover.
5 Switch on the heating unit.
14 Insert the degasser bale into the molten metal and
6 Fired the furnace with the help of oil chocked waste. remove the gases. Place the laddle on the laddle
stand, tittle the furnace and pour the molten metal into
7 Switch on the blower after 10 minutes.
the laddle.
8 Adjust the oil valve and fuel valve of furnace to touch the
15 After filled the laddle tittle the furnace on the standard
flame on the crucible.
position.
16 Pour the molten into the mould.

TASK 2: Charging and melting of aluminium in oil fired furnace

Note: Preheat the metal in the top side of

furnace

81
Capital Goods & Manufacturing Exercise No 2.6.108
Foundryman - Furnaces for Melting Cast Metal

Re - line of laddle
Objectives: At the end of this exercise you shall be able to
• remove the old lining
• prepare the refractory mix
• re-line the laddle.

Requirements

Tools/Instruments
• Wood mallet - as reqd. • Trowels - as reqd.
• Wood stick - as reqd. Materials require
• Broom stick - as reqd.
• Hammer - as reqd. • Fire clay - as reqd.
• Cleaner - as reqd. • Silica sand - as reqd.
• Cotton waste - as reqd.

PROCEDURE
TASK 1 : Prepare daubing mixture

1 Take silicas and-80kg,Fire clay or red sand - 40kg, 4 Switch on the sand muller and run for 5 minutes on dry
Water 8%. stage
2 Prepare the mixture in dry stage. 5 Sprinkle water 8% and mullthes and 5 to 8 minutes
3 Fill the mixture in sand muller using shovel. 6 Switch off the sand muller, taken out daubing mixture.

TASK 2 : Remove the old lining

1 Use hammer and break the old lining

TASK 3 : Prepare laddle

1 Apply fire clay coating 6 Smooth the surface.
2 Add lining mixture in the bottom and ram with butt rammer 7 Remove the broom stick
upto 20 mm to 40 mm. 8 Apply graphite coating
3 Apply a layer of daubing mixture around the side of the 9 Dry the laddle in the sunlight or with fire wood.
laddle ram it with a wooden stick. 10 The laddle is ready for use.
4 Select six or eight broom stick and set around the rammer 11 Check it with instructor.
laddle.
5 Add some more mixture ram the mixture with wooden
stick.
82
Capital Goods & Manufacturing Exercise No 2.6.109
Foundryman - Furnaces for Melting Cast Metal

Pre-heat of laddle
Objectives: At the end of this exercise you shall be able to
• state the preheat of laddle.

Requirements
Equipment
• Linned laddle - as reqd. • Furnace oil / gas - as reqd.
• Heating torch (Oil fired / gas fired) - as reqd. • Wood - as reqd.
• Safety equipment - as reqd. • Kerosine - as reqd.
• Cotton waste - as reqd.

PROCEDURE

TASK 1 : Heating of small laddle

1 Place the laddle in the open space to avoid smoke. 3 Squeeze the cotton waste.
2 Take kerosene soaked cotton waste. 4 Place a small plank and cotton waste on the plank.

83
5 Take wooden pieces place in the laddle with lot of space 9 Tilt the ashes on the ground and put off the fire.
between each wooden piece in the vertical position.
The laddle should not be under/over heated
6 Light the cotton.
under heat will produce boil the metal, over
7 Add wood little by little. heat will fuse the sand.
8 Heat the laddle properly. 9 Keep the laddle in the dry place.

TASK 2 : Pre - heating a medium and big laddle

1 Tilt the lined laddle in the horizontal position. 6 Adjust the flame so that the flame should pre heat the
laddle.
2 Take either cotton waste soaked in kerosine oil.
7 Put off the fire it laddle sufficiently dried.
3 Wear safety dress mainly goggle gloves.
8 The laddle is ready for pouring.
4 Light the torch oil fired / gas.
9 Check it with instructor.
5 Keep the torch near the laddle

84 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.6.109

Capital Goods & Manufacturing Exercise No 2.6.110
Foundryman - Furnaces for Melting Cast Metal

Re-line muffle furnace

Objectives: At the end of this exercise you shall be able to
• prepare muffle for furnace
• select the crucible and tongs
• operate muffle furnace.

Requirements

Tools and Equipment

• Crucible - 1 No.
• Trowel - 1 No. • Broken fire bricks - as reqd.
• Wooden ramming strick - 1 No. • Fire clay - as reqd.
• Peen wedge rammer - 1 No. • Fire bricks powder - as reqd.
• Butt rammer - 1 No. • Fire clay power - as reqd.
Materials • Thin tin sheet - as reqd.

• Tongs - 1 No.

PROCEDURE

TASK 1 : Lining the muffle for furnace

1 Make a thin tin sheet to prepare muffle having 18 and 7 Insulate with ceramic beads.
high internal diameter 10 cms.
8 The muffle stands on a brick “soft” fire brick sown to the
2 Make former round and split type. required thickness and packed ground with a clay
aggregate of broken fire bricks.
3 Mould a fire clay on split type.
9 Another fire bricks from a cover to retain the heat while
4 Smooth the fire clay.
the melting is in process.
5 One kilowatt coil element stretched out, the turns round
Let the muffle dry in the air for a day or two.
the out side of the muffle.
Then you can bake it in the oven.
6 The muffle being separate one from the other lead in
wises from an ex-electric cooker connector are nut and
bold to the ends of the elements.

TASK 2 : Select the tongs crucible

Lifting tongs specially made to suit the furnace interior
diameter as well as particular size of crucible. (Fig 1 & 3)

85
TASK 3 : Linning of the muffle furnace
1 Set the fire brick in the bottom upto 10 cms.
2 Take a layer of gray (broken fire bricks) along with fire
clay
3 Put a layer of grag over fire bricks, ram and level the
bottom.
4 Place the muffle clay tube in the centre of the furnace.
5 Pack the grag (fire by broken fire bricks) in between clay
tube and furnace shell.
Leave the linning for air dry for a day.
The furnace is ready for melt.

TASK 4 : Operation of an Gl tired muffle furnace

The same furnace can be also run with oil tired and the
operation and linning are similar to oil tired linning furnace.

86 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.6.110

Capital Goods & Manufacturing Exercise No 2.6.111
Foundryman - Furnaces for Melting Cast Metal

Metal melt by muffle furnace

Objectives: At the end of this exercise you shall be able to
• melt aluminium alloy in muffle furnace.

Requirements

Tools/Equipment Materials

• Tongs - as reqd. • Aluminium - as reqd.

• Muffle furnace - as reqd. • Flux - as reqd.

PROCEDURE

TASK : Melt aluminium alloy in muffle furnace

1 Check the electric connection. 6 After the crucible bottom becomes red charge the
metal.
2 Switch on the furnace.
7 First add heavy metal, then runner and riser return and
3 Pre heat the furnace.
scrap is on the top.
4 Place the crucible.
8 Increase the temperature from 300°C to 800°C.
5 Pre heat the crucible.
9 Check the metal temperature by introducing a hot rod
into the metal.
10 Switch of the furnace.
11 Open the door & take out the crucible with the help of
tong.
12 De gas the metal
13 Pour the metal into the mould.
14 Clean the crucible.
15 Clean the furnace.
16 Check it with instructor.

87
Capital Goods & Manufacturing Exercise No 2.7.112
Foundryman - Oil Sand and No Bake Core

Prepare simple oil sand core by using linseed oil

Objectives: At the end of this exercise you shall be able to
• prepare oil sand
• making oil sand core
• venting the core.

Requirements

Tools/Instruments
• Rammer (wooden) - as reqd. • Core oven - as reqd.
• Shovel - as reqd. Materials
• Riddle - as reqd.
• Vent wire - as reqd. • Linseed oil - as reqd.
• Mallet - as reqd. • Silica sand - as reqd.
• Dextrine - as reqd.
Equipments/Machines • Saw dust - as reqd.
• Core plate - as reqd. • Water - as reqd.
• Core box - as reqd.

PROCEDURE

TASK 1 : Prepare oil sand

1 Weight the following material and tempering by shovel

or Muller machine.
Silica sand - 94 to 95%
Lin seed oil - 2.5 to 3.5%
Dextrine - 2%
Saw dust - 0.5 to 1%

Little water to be sprinkled on linseed oil sand

to get green strength.

88
TASK 2 : Prepare oil sand core
1 Select simple dump core box. 10 Backing the core.
2 Clean the box. 11 Dressing the core.
3 Fill up the box with oil sand. 12 Core is ready for use.
4 Ram the sand. 13 Check it with instructor.
5 Reinforced the core.
Oil bonded cores base themselves on the
6 Venting the core by vent wire. principle of oxidation and polymerization if a
combination of oils containing chemical
7 Rapp the core box with wooden mallet.
additives which activated by an oxygen bearing
8 Strip oil sand core on core plate. material, set in a pre-determined time.
9 Pack the core with dry sand to rolling of core from core
plate.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.7.112 89

Capital Goods & Manufacturing Exercise No 2.7.113
Foundryman - Oil Sand and No Bake Core

Prepare oil sand core by IVP oils

Objectives: At the end of this exercise you shall be able to
• preparation of no bake core sand
• make simple core.

Requirements

Tools/Instruments Equipments/Machines
• Rammer (Wooden) - as reqd. • Core plate - as reqd.
• Cleaner - as reqd. • Core box - as reqd.
• Trowel - as reqd. Materials
• Vent wire - as reqd.
• Rammer - as reqd. • Dry silica sand - as reqd.
• IVP core oil (Part A,B,C) - as reqd.

PROCEDURE

TASK 1 : Prepare no-bake core sand

1 Weigh the following material and place in the sand
muller.
Clay free dry silica sand - 500 kg.
Oil no-bake binder and catalyst - 7 kg.
Oil no-bake cross linking agent - 1.4 kg.

TASK 2 : Making a simple core (Fig 1)

1 Place the cleaned core box on the moulding board. 9 Set the core on the core plate.
2 Apply a coat of kerosene oil 10 Core hard at the natural atmosphere.
3 Fill the box with no bake sand. 11 Core is ready for use.
4 Ram the sand softly. 12 Check it with instructor.
5 Fill the core box completely and ram the box.
The core is removed from the core box and
6 Strike off excess sand. hard the core at natural atmosphere in few
minutes.
7 Turn over the core on core box
8 Venting the core.

90
Capital Goods & Manufacturing Exercise No 2.8.114
Foundryman - Mould Without Pattern (Trammelling Method)

Prepare simple regular shape mould without pattern (By cutting method)
trammelling method
Objectives: At the end of this exercise you shall be able to
• prepare the drag
• mark the object
• cut the object profile in the mould
• provide gating system
• trim the object profile in the mould.

91
 Requirements

Tools/Instruments
• Wooden rammer - 1 No. • Water jug or water sprinklers - 1 No.
• Riddle - 1 No. Equipments/Machines
• Shovel - 1 No.
• Moulding board - 1 No. • Set of moulding boxes with guide pin - as reqd.
• Trowel - 1 No. • Pattern - as reqd.
• Cleaner - 1 No. • Auto sand siever - as reqd.
• Rammers - 1 No. • Sand mixer - as reqd.
• Vent wire - 1 No. • Sand muller - as reqd.
• Leveler - 1 No. • Mould hardness tester - as reqd.
• Mallet - 1 No. Materials
• Spike - 1 No.
• Sprue pins - 1 No. • Parting materials - as reqd.
• Gate cutter - 1 No. • Silica sand - as reqd.
• Smoothers - 1 No. • Tempered moulding sand - as reqd.
• Cleaning brush - 1 No. • Moisture - as reqd.
• Dust bag - 1 No. • Clay - as reqd.
• Painting brush - 1 No. • Facing materials (Plumbago
• Blow lamp or LPG heating torch - 1 No. or graphite powder) - as reqd.
• ‘C’ clamp - 1 No. • Kerosene or LPG - as reqd.

PROCEDURE

TASK 1: Prepare plain mould

1 Place the drag over the moulding board. 6 Strike-off excess sand from the surface.
2 Fill the sand - Ram it by peen wedge rammer. 7 Sleek the surface.
3 Fill the sand 50 mm above the flask level. 8 Turn over the drag.
4 Pack the moulding sand by hand. 9 Sleek the surface.
5 Ram it by butt/flat rammer.

TASK 2 : Mark the profile or object

1 Mark mould cavity in sleeked surface. (use vent-wire) 2 Spread the parting materials.

TASK 3 : Prepare the cope

1 Set the cope on drag. 6 Fill the sand 50mm above the cope level.
2 Locate the sprue pins. Where it needs for runner & 7 Ram by butt/flat rammer.
risers.
8 Strike off excess sand above the top surface of the
3 Fill the facing sand one layer. cope.
4 Ram it with help of peen wedge rammer. 9 Make vent holes by vent wire.
5 Repeat 2 or 3 more times up to flask level. 10 Turn over the cope on sand bed.

TASK 4 : Cut the object profile in the mould

1 Cut the sand in marked area in drag as per required 3 Finish the sand in marked area in drag as per required
cavity. cavity with help of smoothers.
2 Trim the sand in marked area in drag as per required
cavity with help of trowel & cleaner.
92 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.8.114
TASK 5 : Provide gates to the mould
1 Cut the in-gates. 2 Smooth, cut cavity & gates by smoothers.

TASK 6 : Prepare the mould for casting

1 Verify the dimension with job sheet. 5 Clean the loose particles in the cope.
2 Place the mould over the sand bed. 6 Close the drag and cope with guide pins.
3 Clean the loose particles in the drag. 7 Cover the pouring basin with rolled cotton waste keep
the weight over the cope or clamp the box.
4 Bake the drag and cope allow to room temperature.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.8.114 93

Capital Goods & Manufacturing Exercise No 2.8.115
Foundryman - Mould Without Pattern (Trammelling Method)

Prepare mould by sweep pattern

Objectives: At the end of this exercise you shall be able to
• prepare mould by sweep pattern
• prepare core and set the core.

Requirements

Tools/Instruments
• Riddle - 1 No. • Sweep pattern - 1 No.
• Shovel - 1 No. . • Strickle board - 1 No.
• Moulding board - 1 No. • Socket flask - 2 Nos.
• Trowel - 1 No. • Auto sand riddle - as reqd.
• Cleaner - 1 No. • Sand mixer - as reqd.
• Rammers - 1 No. Materials
• Vent wire - 1 No.
• Leveler - 1 No. • Parting materials - as reqd.
• Mallet - 1 No. • New red sand - as reqd.
• Spike - 1 No. • Old red sand - as reqd.
• Spure pins - 2 Nos. • Bentonite - as reqd.
• Gate cutter - 1 No. • Horse manure, cow dung - as reqd.
• Smoothers - 1 No. • Tempered loam moulding sand - as reqd.
• Cleaning brush - 1 No. • Loam slurry - as reqd.
• Dust bag - 1 No. • Moisture - as reqd.
• Painting brush - 1 No. • Fusion coke - as reqd.
• Blow lamp or LPG heating torch - as reqd. • Kerosene or LPG - as reqd.
• ‘C’ clamp - 1 No. Facing materials
• Water jug or water sprinklers - 1 No.
• French chalk powder - as reqd.
Equipment/Machines
• Spindle base - 1 No.

PROCEDURE

TASK 1 : Prepare mould by sweep pattern (Fig 1)

1 Set the sweep pattern on the spindle.
2 Tap the pattern and rotate a round and remove the
excess sand.
3 Sprinkle water
4 Rotate the sweep till sweep touch the box level.
5 Pour loam mixture and rotate finally.
6 Dry the mould.

The mould can be dried in the open sun, by fire

wood (or) core oven can be used.

TASK 2 : Prepare core and set the core

1 Sieve and weight the following materials. 3 Switch on the sand muller and run for 5 to 8 minutes.
2 Shift the materials in the sand muller using shovel. 4 Switch off the sand muller
94
5 Take out the tempered core sand in the tray. Silica sand - 97 kgs
6 Cover it with ganny bag. Starch - 1.5 kgs
6 Test the sand physically. Core oil - 1.5 kgs
Water - 2.5 kgs

TASK 3 : Prepare re-inforcement rod as per cose size

1 Measure the re-inforcement rod as required for core. 3 Cut the wire using chisel and hammer.
2 Mark the dimension on the reinforcement wire. 4 Form the required profile of core (reinforcement to the
core box)

TASK 4 : Make simple core using core box (Fig 2)

1 Place the cleaned core box on the moulding board. 2 Apply strip coat.
3 Fill the partially with core sand using moulder trowel.
4 Ram the core sand using pin/hook rammer gently.
5 Place the clay coated re-inforcement rod (3mm GI wire)
in the core box.
6 Fill the core sand completely.
7 Ram the sand with butt rammer gently.
8 Sprinkle parting over the core.

TASK 5 : Bake the core

1 Place the core in the core-oven for fully. 7 The core is ready for use.
2 Remove the core from the core-oven
Use gloves to keep and remove the core plate
3 Coat the core with plumbago mixture. from the core oven
4 Dry the core again in the core-oven for half an hour. Same tasks can be applied for preparing slab
core/dump core stop-off piece core/chain core/
5 Remove the core from the core-oven.
tail core having core box.
6 Test the core hardness and physical appearance.

TASK 6 : Assemble the core in the mould (Fig 3)

1 Clean the mould cavity

2 Coat the facing material with help of painting brush core
and mould
3 Set the core in the center of mould using chaplet.
4 Close the cope over the drag.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.8.115 95

Capital Goods & Manufacturing Exercise No 2.8.116
Foundryman - Mould Without Pattern (Trammelling Method)

Prepare mould with ram up core

Objectives: At the end of this exercise you shall be able to
• prepare drag
• provide gatting system
• prepare cope
• prepare mould for pouring.

Requirements

Tools/Instruments
• Riddle - as reqd. • Sand mixer - as reqd.
• Shovel - as reqd. • Sand muller - as reqd.
• Moulding board - as reqd. • Core hardness tester - as reqd.
• Cleaning brush - as reqd. Materials
• Smoothers - as reqd.
• Dust bag - as reqd. • Parting materials - as reqd.
• Painting brush - as reqd. • Silica sand - as reqd.
• Blow lamp or LPG heating torch - as reqd. • Core oil - as reqd.
• ‘C’ clamp - as reqd. • Bentonite - as reqd.
• Water jug or water sprinklers - as reqd. • Water - as reqd.
• Facing materials (Plumbago or graphite powder)
Equipments/Machines • Kerosene or LPG - as reqd.
• Moulding box with pin clamp - 2 Nos • Core oil - as reqd.
• Core box - as reqd. • Western bentonite - as reqd.
• Auto sand sever - as reqd.

PROCEDURE

TASK 1: Prepare drag (Fig 1)

1 Study the pattern 2 Arrange all required material, equipment, tools.

96
3 Clean the moulding board with cotton waste.
4 Place the wooden pattern on the board.
5 Set the Ram-up-core
6 Locate drag, apply the layer of dry sand press with hand
and some facing material.
7 Ram, level, clean and vent the drag
8 Turn over the drag.

Take core the vent-wire should not strike the

core or wooden pattern and Ram-up-core.

TASK 2: Provide gating system (Fig 2)

1 Locate runner and riser.

TASK 3: Prepare cope (Fig 3)

1 Place the cope on drag 11 Roll over the cope on sand bed.
2 Add some facing sand
3 Tuck with hand
4 Add some more facing sand, Ram with wooden rammer.
5 Fill the box with backing sand ram with wooden rammer.
6 Fill backing sand 50mm above the box level and Ram
it with butt rammer.
7 Level the box
8 Sprinkle parting sand, vent the mould
9 Remove the runner and riser
10 Cut-pouring basin.

TASK 4 : Prepare the dry core sand

1 Study the core box. Core oil - 5%
2 Prepare dry core sand as per composition. Sodium bentonite - 2%
Average casting
Water - 3 to 4% by weight
Silica sand - 93% 3 Arrange require tools, materials & equipments.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.8.116 97

TASK 5: Prepare core sand for Ram-up-core
1 Sieve the required materials. 6 Mix the moisture.
2 Weigh the materials as per composition. 7 Mix the mixture by hand.
3 Mix base materials. 8 Test the core sand.
4 Mix the binder. 9 The core sand is ready for use.
5 Mix the additives.

TASK 6: Prepare reinforcements

1 Select the reinforcements as per design of core box. 2 Clay wash the reinforcements.

TASK 7: Prepare the dry Ram-up-core (Fig 1a)

1 Collect the materials for prepare the core. 2 Assemble reinforcement with core box.
3 Clamp the core box.
4 Fill the core sand.
5 Pack the core sand in the core box ram it.
6 Sleek it top surface and provide vents.
7 Loose the clamp and upper part of the core box.
8 Strip the core from core box.
9 Place the core in the core plate.
10 Pack the dry sand both the side of core to avoid rolling
of core when shifting.

TASK 8: Bake the core (Fig 1b)

1 Load the core inside the core oven. 4 Allow to bake in the oven.

2 Close the oven door. 5 Open the core oven allow to cool at room temperature.

3 Switch on the core oven.

TASK 9: Check the core and core print dimensions 3 Verify the dimension core and core print.
1 Measure the overall dimension for core and core print 4 Finish the core.
2 Trim it if necessary.

TASK 10: Prepare the mould for casting

1 Cut the gate 4 Assemble the core in the mould
2 With draw the pattern 5 Close the mould
3 Dry cope and drag 6 Check it with instructor.

98 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.8.116

Capital Goods & Manufacturing Exercise No 2.9.117
Foundryman - Gravity Die Casting

Simple casting by gravity die casting

Objectives: At the end of this exercise you shall be able to
• assemble the die in the gravity die casting machine
• coat refractory solution to the die
• pour the molten metal in the die
• fettle the casting.

99
 Requirements

Tools/Instruments Equipments/Machines
• Hand tongs - as reqd. • Die casting assembly with accessories - as reqd.
• Fettling hand tools - as reqd. Materials
• Casting hand tools - as reqd.
• Pre-heating device - as reqd. • Safety device - as reqd.

PROCEDURE

TASK 1 : Assemble the die in the gravity die casting machine

1 Identify the die parts, assemble the dies, check the 4 Switch on the hydraulic cylinder valve.
parting lines.
5 Switch on the machine to open and close the dies.
2 Locate the die parts in the proper location.
6 Check the die parting line at die casting machine.
3 Assemble the both dies.

TASK 2 : Coat the refractory solution

1 Open the die and clean with soft cloth at cavity and 3 Pre-heating the both dies 300 to 700C.
gating system.
4 Coat the refractory solution.
2 Check the vents are open or not.

TASK 3 : Pour the molten metal into the die

1 Leverage or switch on to close the die. 3 Pour the molten metal in the pouring basin of the die.
2 Collect the molten metal with ladle or scoop. 4 Allow core solidification of the casting.

TASK 4 : Fettle the casting

1 Switch on or levered to open the die. 6 Remove the fins and flashes from the casting.

2 Operate the ejector lever. 7 Hold the casting in bench vice.

3 Separate the casting from die casting machine. 8 Cut the runner riser in the casting.

4 Keep the casting on the working table. 9 Trim and finish the casting.

5 Allow to room temperature.

100 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.9.117
Capital Goods & Manufacturing Exercise No 2.9.118
Foundryman - Gravity Die Casting

Calculate yield percentage

Objectives: At the end of this exercise you shall be able to
• calculate the yield percentage of casting.

Refer the Exercise No.2.2.78

101
Capital Goods & Manufacturing Exercise No 2.10.119
Foundryman - Investment Casting

Prepare simple casting by investment casting process

Objectives: At the end of this exercise you shall be able to
• prepare the pattern and pattern assembly
• prepare refractory slurry
• de wax the pattern assembly
• pour the molten metal to the invested cavity
• fettle the casting.

Requirements

Tools/Instruments
• Molding hand tools - 1 No. • Wax pattern - as reqd.
• Casting hand tools - 1 No. • Core oven - 1 No.
• Painting brush - 1 No. Materials
• Blow lamp or LPG heating torch - as reqd.
• ‘C’ clamp - 1 No. • Tempered molding sand, Pop - as reqd.
• Fettling hand tools - 1 No. • Moisture - as reqd.
• Clay - as reqd.
Equipments/Machines • Honey wax - as reqd.
• Set of molding boxes with guide pin - 2 Nos. • Ethyl silicate - as reqd.

PROCEDURE

TASK 1 : Prepare the pattern and pattern assembly

1 Clean the die (pop).

Injecting the pattern material in a die using a
2 Preheat die. wax with injecting machine/die.
3 Melt wax. Injected patterns are jointed together by wax
or suitable additives.
4 Pour the wax in a die(pop). (Fig 1)
Make in-gates, runners, and risers attach the
5 Allow to solidify.
same process.
6 Eject the pattern. (wax profile)
102
TASK 2 : Prepare refractory slurry

1 Mix zirconium, silica flour, alumina, ethyl silicate and Primary investment coat of 300 mesh refractory
water as slurry. grains made into a slurry in a suitable binder.
2 Dip the pattern into the slurry and lift out. (Fig 2) A layer of refractory slurry coating coated by
3 Dip again the pattern into the slurry after 2 minutes. dipping of slurry it covered with pattern
assembly with 3 to 6 mm thickness.
4 Repeat above until get 6 to 10 mm thickness getting
over the pattern surface. (Fig 3) Investment moulds are allowed to curing and
provided least vibration for avoiding the air
bubbles from the pattern surface.

TASK 3 : De waxing the pattern assembly

1 Place the flask on table.
Setup the pattern assembly in the flask with
2 Stand the pattern assembly in the middle of the flask. help of baking sand.
3 Fill the backing sand around the pattern assembly. Inverted the mould 180 degree.
Preheated the investment mould 500 to 1000C
4 Fix the pattern assembly in the flask, runner basin and
depending upon the metal to cast.
riser basin opened on atmospheric.
Heated to the mould for de waxing (melt out the
5 Inverted the mould. wax from the investment mould)
6 Heat up the inverted mould. Carry solvent vapour bath (trichloroethylene).
It helps to completely remove the wax from the
invested mould.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.10.119 103
TASK 4 : Pour the molten metal to the invested cavity

1 Turn over the invested mould.

2 Pour the molten metal. (Fig 5)
3 Allow to solidify.

After preheated, immediately pour the molten

metal into the invested mould.

TASK 5 : Fettle the casting

1 Knock out the casting. (Fig 6)
2 Removal of fins and flashes.
3 Cut the runner and riser.
4 Finish the runner and riser portion of the casting.
5 Trim the casting.

104 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.10.119
Capital Goods & Manufacturing Exercise No 2.10.120
Foundryman - Investment Casting

Binder less dry sand process

Objectives: At the end of this exercise you shall be able to
• prepare the pattern and pattern assembly
• coat refractory in the pattern
• prepare the mould
• pour the molten metal to the binder less dry sand
• fettle the casting.

Requirements

Tools/Instruments
• Riddle - as reqd. • Auto Sand server - as reqd.
• Shovel - as reqd. • Sand mixer - as reqd.
• Molding board - as reqd. • Sand muller - as reqd.
• Trowel - as reqd. • Mould hardness tester - as reqd.
• Cleaner - as reqd. Materials
• Rammers - as reqd.
• Vent wire - as reqd. • Silica sand - as reqd.
• Leveler - as reqd. • New silica flour - as reqd.
• Mallet - as reqd. • Bentonite - as reqd.
• Cleaning brush - as reqd. • Molasses - as reqd.
• Spray gun - as reqd. • Water - as reqd.
• Painting brush - as reqd. • Zirconium - as reqd.
• Blow lamp or LPG heating torch - as reqd. • Silica flour - as reqd.
• ‘C’ clamp - as reqd. • Alumina - as reqd.
• Water jug or water sprinklers - as reqd. • Ethyl silicate - as reqd.
• Tempered molding sand - as reqd.
Equipments/Machines • Refractory coating materials - as reqd.
• Set of molding boxes with guide pin - as reqd. • Silica sand solution - as reqd.
• Polystyrene foam pattern - as reqd. • Kerosene or LPG - as reqd.

105
PROCEDURE
• Study the job sheet. Silica sand - 70%
• Prepare dry sand as per composition. New silica flour - 23%
• Select the composition as required metals: Bentonite - 5%
• Arrange require tools, materials & equipments for Molasses - 2%
binder less dry sand process.
Water - 4 to 5% by
weight

TASK 1 : Prepare the pattern and pattern assembly

1 Study the job sheet.

2 Prepare the pattern, runner, riser, gating system, with
polystyrene foam.
3 Join the pattern, runner, riser, gating system, with
suitable binder or additives.

If we prepare runner, riser, gating system,

internal core, parting line, and draft for the
need of pattern design only polystyrene foam/
thermocoal.

TASK 2 : Coat refractory in the pattern assembly

1 Place the pattern assembly over the molding board. 6 Coat the pattern assembly into the refractory slurry.
2 Prepare the refractory slurry for coating. (Fig 1) 7 Recoat the pattern assembly into the refractory slurry
after 2 minutes. (Natural baking), repeat above until get
3 Insert the spray gun in the slurry container.
6 to 10 mm thickness getting over the pattern surface.
4 Start the blower. Allow to slurry coated pattern assembly get natural
5 Coat the refractory slurry to the pattern assembly. baking.

Mix zirconium, silica flour, alumina, ethyl

silicate water as slurry.

TASK 3 : Prepare the mould

1 Place the slurry coated pattern assembly over the 4 Fill the sand above the flask level.
molding board.
5 Tuck in with hand.
If casting need fine finishing dust the facing 6 Ram it by but rammer.
materials.
7 Strike off extra sand from the surface.
2 Place the flask over the moulding board.
8 Sleek the parting surface.
3 Fill the tempered moulding stand tuck in with hand after
9 Open the pouring basin’s & riser basin with help of
that, Ram it by peen wedge rammer, fill the sand above
cleaners/lifter.
the flask level.(Fig 2)
10 Provide venting with help of vent wires.

106 Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.10.120
TASK 4 : Prepare the mould for pouring

1 Keep the mould in pouring spot.

2 Keep the weight over the cope.
3 Open the pouring basin in the top surface of the mould.
4 Collect the molten metal with shank ladle.
5 Stand the pouring basin at center.
6 Start the pouring by steadily and continuously.

TASK 5 : Fettle the casting

1 Knock out the solidified casting.
2 Removal of fins and flashes from the solidified casting.
3 Cut the runner and riser in the solidified casting.
4 Trim the casting.

Capital Goods & Manufacturing : Foundryman (NSQF Level - 4) - Exercise 2.10.120 107