NATIONAL INSTITUTE OF TECHNOLOGY KURUKSHETRA WORKSHOP MANUAL FOUNDRY SHOP 1* YearCENTRAL WORKSHOP NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA | FOUNDRY SHOP : | WORKSHOP MANUAL 1, Objective: - To study foundry sand, its characteristics, and foundry tools-and equipments and | preparation of mould in foundry shop. In ion: - Foundry practice deals with the process of making casting in moulds formed in either | sand or some other material. This is found to be the cheapest method of metal shaping. MOULDING SAND: - Foundry sand is the principal material used in foundry. Itis collected from rivers, lakes, sea and deserts. The principal ingredients of moulding sands are silica sand, clay and water. Silica is the main constitute of all the sands. Clay imparts the necessary bonding strength to the moulding sand. Moisture when added in correct proporation provides the bonding action to the clay. Special additives and binders are also added to develop certain desired properties to the molding sand. All foundry sand can be mainly grouped as: Natural Moulding Sand: - It is either available in river beds or dug from pits. It possesses an appreciable amount of clay and is used as received, with addition of water. No more binder is required to add to them. Sunthetic Moulding Sand: - They are prepared by adding clay, water and other material (binders’ additives) to Silica sand so that the desired strength and bonding properties are achieved. Allthe foundry sands owe their color to the impurities present in them. The common colures of sands 'sed in foundry work are white, yellow, brown, gray and red. (YPES OF MOULI Most of the moulding is done with green sand. The sand containing 6 to 8% moisture and 10% clay “ontent to give it sufficient bond. Green sand moulds are used for pouring the molten metal aed , mediately after preparing the moulds. No baking is performed in this case. Green sand moulds are | shea er and take less time to prepare. These are used for small and medium size casting. They are | felativel - Y weaker and softer than other types sand moulds. This property is help in producing intricate "ing of such metals, which hav e high solid shrinkage.CENTRAL WORKSHOP. NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA FOUNDRY SHOP WORKSHOP MANUAL Dry sand moulds are obtained after drying or baking green sand moulds by means of a gas torch, hot air, or an infrared lamp. For these mould a suitable binder like resin, linseed oil, molasses, or corn flour are always added to the sand so that on drying it will provide a very hard surface to the mould. After drying the mould, the molten metal is poured immediately into it. Dry sand moulds are used for large castings. Parting sand:- which is clay free, fine-grained silica sand is used to keep the green sand from sticking to the pattem and also to prevent the cope and drags from clinging. ” patterns: - A pattern is the model of the desired casting, which when packed in a suitable material, produces a cavity called the mould. The cavity when filled with molten metal produces the desired casting after solidification. FOUNDRY TOOLS AND EQUIPMENT: - The tools and equipment needed for moulding are as follows: - 1. Shovel: - It consists of iron pan fitted with a wooden handle. It is used for mixing and tempering the moulding sand and for transférring the sand into the flask. It is made of steel blade with a wooden handle. 2. Hand riddle: - It consists of a wooden frame fitted with a screen of standard wire mesh at its bottom. It is used for hand ridding of sand to remove foreign material from it. = It is used for packing or ramming the sand around the pattern. One of its ends, called 3. Rammer the peen and, is wedge shaped and is used for packing sand in spaces, pockets and corners, in the early stages of ramming. The other end, called the butt and, has a flat surface and used for compacting the sand towards the end of moulding. ‘ Strike off bar: - It is a piece of metal or wood with straight edge. It is used to remove the excess sa "d from the mould after ramming, to provide a leveled surface. S. YENt Rod: - it is a thin steel rod or wire carrying a pointed edge at one end and a wooden handle ora n bent loop at the other. After ramming and striking off the excess sand it is used to make small a>CENTRAL WORKSHOP NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA FOUNDRY SHOP WORKSHOP MANUAL ges called vents, In the sand mould to allow the exit of gases and steam during casting. qrowels: - It is used to smoothen the surface of the body. It may also be used for repairing the maced portion of the mould. Trowels are made in many different styles and sizes, each one govt for a particular job. Sick -Itis a small double-ended tool having a flat on one end and a spoon on the other. It is used «mending and finishing small surfaces of the mould, Lifters or cleaners: - Lifter is made of thin Sections of steel of various widths and lengths, with one bent at right angles. These are used for cleaning and finishing the bottom and sides of the deep 4 narrow pockets of the mould. Draw spike: - It's a tapered steel rod having a loop or ring at its one end and a sharp point at the ter. It is used to remove or draw Patterns from the mould. Mallet: tis a similar wooden mallet as that used in carpentry work. In foundry work it is used ‘riving the draw spike into the pattern and rapping it. Swab: - It is a hemp fiber brush used for moistening the edges of sand mould, which are in {Pctwith the pattern surface, before withdrawing the pattern. Itis also used for coating the liquid ‘king on the mould faces in dry sand moulds. S2tue pin: - it is tapered wooden pin used to make a hole in the Cope sand through which the hen metal is poured into the mould. Riser Pin:-Itisa straight wooden pin used to make a hole in the cope sand, over the mould cavity the molten metal to rise and feed the casting to compensate the shrinkage that takes place during ification, Ste cutter: itis semi-circular piece of tin sheet, used to cut gates in the mould. Gates are ant f °F €25y flow of molten metal into the mould.‘Swab mallet a Sprue pin BellowCENTRAL WORKSHOP : NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA & ts § FOUNDRY sHop Rh WORKSHOP MANUAL tsa soft Brush and is used for sweeping away the mould sand form the mould od patter pon hand tool, used to blow air to remove the loose sand particles from the mould - It is @ wooden board with smooth surface. it supports the flasks and the | while the mould is being made, yosicing Flask: ~Itis a box, made of wood or metal, ‘Open at both ends. The sand is rammed in | | | prvi the pattern to produce a mould, Usually, it is made of two parts. Cope is the top half of pe fisk having guides for the aligning pins to enter. Drag is the bottom half of the flask, having bes ins. /ARATION OF MOULD : folowing are the steps used in making a simple mould using a single piece pattern. Pace the pattern on the moulding board, with its flat side on the board. ace the drag over the board, after giving a clay wash inside. Sprinkle the pattern and the mould board, with parting sand. Alow loose sand, preferably through a riddle over the pattern, until it is covered to a depth of 2 to Jem, ‘ack the moulding sand around the pattern and into the corners of the flask, with fingers. ace some more sand in the flask and = the pattern with a rammer, using the peen end and ‘hen butt end, ‘tke of the excess sand from the top surface of the drag with the strike-off bar. "unthe dag upside down. Povo the loose sand particles with the bellows and smoothen the upper surface. ~~(b) Filing the cop Pouring basin SUA » @) the completed mo ' yale}CENTRAL WORKSHOP NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA | FOUNDRY SHOP WORKSHOP MANUAL Place the cope on top of the drag in position. Locate riser pin on the higher point of the pattern. Place the sprue pin at about S to 6 cm, from the pattern on the other side of the riser pin. sprinkle the upper surface with parting sand. | Repeat steps 3 to 7, appropriately. Make holes with the vent rod to about 1 cm. from the pattern, Remove the sprue and riser pins by carefully drawing the mount. Make a funnel shape hole at the ‘of sprue hole, called the pouring cup. Lift the cope and place it aside on its edge. Insert the draw pin into the pattern. Wet the edges around the pattern. Loosen the pattern by ping. Then draw the pattern straight up. Adjust and repair the mould by adding bits of sand, if necessary. Cut gate in the drag from the spure to the mould, Blow-off any loose sand particles in the mould. Close the mould by replacing the cope and placing weights on it.CENTRAL WORKSHOP NATIONAL INSTITUTE oF TECHNOLOGY, KURUKSHETRA FOUNDRY sHop WORKSHOop MANUAL - To study the composition of Moulding sand, its Properties, moulding method, melting | = casting process and casting defects, pi lens» Foundry practice deals with Process of making castings in moulds formed either in sand or some other material. This is found to bea cheapest ‘method of metal shaping. Further, casting mnaybemade to fairly close dimensional tolerances by choosing proper moulding and casting process. gasitation of Molding sand:- {a) According to Nature of its origin [b) According to use & composition According to Nature of its origin 1) Natural and 1) Synthetic sand, Matural sand: - Moulding sand found in nature called natural resources like river beds or are dug from water furnish the bond for green sand. Green sand Fetains the shape Biven to it. The | 4 , | Me Breen sang implies damp or undried sand, ould made from this Sand is used immediate to pour the maten metal itis not a Breen colored | Th * MOUIds Using this sand are called as green moulds. Green sand is collected from natural | Mees. hy | 'as the advantage of maintaining moisture content along time. 10CENTRAL WoRKsHOP NATIONAL INSTITUTE oF TECHNOLOGY, KURUKSHETRA. FOUNDRY sHop WORKSHOP MANUAL noulding sand. To make core sand, core oil Which is composed to linseed oil, resin and other binding naterials is mixed with the silica sand.add with other Para of core sand. 11Auto Sand’ Riddle. 12CENTRAL WORKSHOP NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA FOUNDRY SHOP WORKSHOP MANUAL | sno ack sand should however be cleaned off the foreign matter like fins, nails etc. has adequate Breen strength to return its shape before baking. It has an adequate permeatality nee generated during pouring. It has high collapsibilty so that the cores gives way easily 2% . s. High collapsibility avoids the introduction of hot tears and cracks in the cast z cools and shrink maitves sa Sand: - Silica sand in the form of granular quartz is the chief constituent ‘of the moulding sand. It fractoriness chemical resistivity and permeability «80 to 90% sillca oxide. The silicon oxide imports re! in the mixture of moulding sand. It holds the sand together. {(ay:- Clay constitutes an important ingredient it .e two factors the amount and quality. The increase in amount of bonding quality of clay depends upon thé joulding sand. Normally the amount of clay found in silica sand varies ceases the permeability of the m 6 to 10%, \oiture:- Clay imparts strength and bonding action to the sand in the presence of moisture. 13ig ation is the best if the quantity of water added is just sufficient to form the microfilm excess water will affect the strength of moulding sand, nsCENTRAL WORKSHOP NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA FOUNDRY SHOP WORKSHOP MANUAL | + Plasticity - By this property the shape of the mould is not disturb even after taking the pattern | ‘om sand. + Refractoriness: - It is property of the ‘Moulding sand to with stand the high temperature of molten vetal without fusing or breaking down, reparation of Moulding sand: “eparation of moulding sand consists of two operations ) Sand Tempering. ) Sand Conditioning. nd Tempering: - The process by which the water is added to the sand in the required quantity is own as sand tempering. To develop optimum Properties in the moulding sand it is necessary that ch grain be coated uniformly with clay and the clay be tempered with water, ind Conditioning: - The process by which the moulding sand is made suitable for ramming in flasks known as sand conditioning. The moulding sand should be properly conditioned before use to tain good castings. order to obtain good castings, the sand used for moulding must be correctly conditioned, Proper \d conditioning and preparation helps as follows:- The binder is uniformly distributed around the sand grains, ‘he moisture is evenly disbursed in the sand mixture and the moisture content Properly controlled. ‘he sand gets aerated, expose to action of air, causing the sand Brains to separate and Ncrease the flowbility of sand. he foreign particles are separated from the sand, 15CRUCIOLE ONTAININ FIRE BRICKS CONTAINING METAL UNING. CONCRETE ee | [HINING SHELL | cover Pirie (ease | en CHIMNEY "a oo tq: ATMOSPHERE REFRACTORY LINING 16CENTRAL WORKSHOP NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA FOUNDRY SHOP WORKSHOP MANUAL machine moulding comes out to be an automatic choice from all point of view. Steen sand Moulding: - Green sand moulding is a type of moulding in which the mould is in moist errous alloys. It is suitable for small, medium, and often-large castings. uy sand Moulding: - it is similar to green sand mould 17Brick and cast iron bring Fig. 42. A cupola furnace. 18 ‘DoorCENTRAL WORKSHOP NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA FOUNDRY SHOP WORKSHOP MANUAL e molten metal its installation, pos ot pourine considerations Le. intial investment, to be made a5 cast of equipment, . seecost and cost of fuel to be consumed ete. types of frnaces used in foundries for melting of ferrous and non ferrous metals and alloys in _piollows: = These are the simplest of all the furnaces used in foundries. It is mostly used in gorthe small foundries where melting is not continuous and a large variety of metals is too ited in called crucible, small quantities, In these furnaces the entire melting of metal takes place inside a meting | which is made of clay and graphite. These furnaces can be classified into groups | | ollows; {ote fired furnace: - These furnaces are generally installed in a formed pit and are used for small atties of ferrous metals (pig iron) for producing iron casting and also for non-ferrous metals and | Js Tey are provided with refractory lining inside and chimney at the top. Coke is used as fuel. | hnatural as well as artificial draughts can be used. Broken pieces of metal are placed in crucible. coke is fired in the furnace and crucible placed on it. i1& Gas fired furnaces: - These furnaces utilize oil or gas a fuel. In fact a mixture of gas & air or and air is fed into the furnace, which burns inside to produce the desired temperature. The ture usually enters tangentially and encircles the crucible while burning. se furnaces may be of stationary of telting type. {upola: - For melting or cast iron in foundry the cupola furnace is used. The figure illustrates @ ical cyli ade of 55 sectional view of cupola. It has a construction in the form of hollow vertical cylinder mi mg mild steel plates. In large cupolas lower position is made of comparatively thicker plates so as ake it strong enough to hold the upper structure and fire brick lining. Such cupolas are further ingthened by providing the brick retainer’s rings to suit heights. 19CENTRAL WORKSHOP NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA FOUNDRY sHop WORKSHOP MANUAL door Is supported by rop so that it May not collapse due to large weight of charge and pe bottom gue ete. tearries when cupola is not need for further operation, the charge feeding is stopped, air is ¢ aft and the prop removed, ” ps bets connected to the furnace blower by means of a blast pipe. The amount of air required is xceinto the chamber by blower, which enters the furnace through opening called buyers. The size dno of buyers depends upon the amount of air required. Charging door is located at suitable fight above the charging platform, called as copulates, sting Defects: The various which commonly occur in casting their possible Causes and effective medies are as follows:- swtioles:- They appears as cavities in a casting when they are visible on the upper surface of the Sing they are called as open blows they are concealed in the casting and are not visible from ‘side, the are known as blow holes. They are due to entrapped bubbles of Bases in the metal and exposed only after machining, The causes due t ' Excess moisture content in moulding sand, Jeading to the production of too ‘much of steam and thereby rendering the permeability of mould as inadequate, § Cores not sufficiently baked, + Use of highty moistened chills, chaplets or other metal or other metal inserts giving rise to high amount of steam and gases, » Eicessive used of Organic binders, resulting production of high amount of gases, 20CENTRAL WoRKSHOP NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA FOUNDRY sHoP WORKSHOP MANUAL nd moulds Inadeg inet aveduately vented resulting in thei low permeability. Jk Mowkle rammed very hard further addition to low permeability. onevten J, Moisture content In the moulding sand should be properly controlled. 1 Cores should be adequately baked. substance. | 1 Organk binders should be used with restraints, {Cores ane moulds should be adequately vented, & Moulds should not be rammed excessively hard, MROSITY: - This defect occurs in the castings in the form of Pinhole, porosity or gas porosity. It is fused by gases absorbed by the molten ‘metal. During very small voids through out the casting called ‘holes, Gas porosity becomes more pronounced with higher melting temperature and slower Huttation of metal. To avoid such defects proper melting temperature should be maintained casting tould be made to solidify quickly by proper gating and risers ring, Permeability of mould should be ‘eased! and moisture content of the mould should be kept as low as possible, HRINKAGE: - During solidification of metal, these is a volumetric shrinkage. It is caused in the Bin in the casting mainly by uncontrolled and haphazard solidification ofthe metal. t may be due ‘the improperly sized gating system, inadequate risers, or poor design of casting involving abrupt lanes of sectional thickness. Shrinkage may also be produced if the pouring temperature is too h thus resulting directional solidification does not takes place. The defect can be eliminated by applying * Principles of directional solidification in mould design ions of all mould such that some part 'SRUNS AND COLD SHUTS: - When molten meta falls to reach sections of al Gu some pa ee 21CENTRAL WORKSHOP NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA FOUNDRY sHop WORKSHOP MANUAL _ yptiied resulting 19 incomplete casting. When two streams of molten metal approach each ne mould from opposite directions establish a physical contact between them is termed as out Both these defects occur due to lack of fluidity in molten metal and faulty design in ang very thin sections. As such they can be eliminated by improving the design and adjusting pune temperature to ensure proper fluidity. pease: Its and undesirable deformation in the casting which may occer during or after the gication, The deformation takes place due to internal stresses developed in the casting due to trent solidification in different sections. inte eliminated by modifying the casting design to break the continuity of the large flat surfaces | [facilitate proper directional solidification. Bu:- A swell isan enlargement of mould cavity by metal pressure resulting in localized or overall | agement of the casting. It may be caused by insufficient removing of the sand. It can be hinated by proper ramming increased strength of mould and core. SION: - It causes due to low refractoriness in moulding, faculty gating, too high pouring | ‘perature and poor facing sand. ‘anbe eliminated by improving the refractoriness of sand, modifying gating system, using proper wring temperature and improving quality of facing sand. 22