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    5674620

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    Amrik Singh
    A foundry is a factory that produces cast metal objects by pouring molten metal into molds. The document provides details on sand casting, a common casting process. Sand is mixed with binders and compacted around a pattern to form molds. Molten metal is then poured into the molds, taking the shape of the pattern. After cooling, the molds are broken apart to release the cast parts. Sand casting allows for complex shapes but requires careful mold preparation and metal pouring.

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    5674620

    Uploaded by

    Amrik Singh
    72 views30 pages
    A foundry is a factory that produces cast metal objects by pouring molten metal into molds. The document provides details on sand casting, a common casting process. Sand is mixed with binders and compacted around a pattern to form molds. Molten metal is then poured into the molds, taking the shape of the pattern. After cooling, the molds are broken apart to release the cast parts. Sand casting allows for complex shapes but requires careful mold preparation and metal pouring.

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    A foundry is a factory that produces cast metal objects by pouring molten metal into molds. The document provides details on sand casting, a common casting process. Sand is mixed with binders and compacted around a pattern to form molds. Molten metal is then poured into the molds, taking the shape of the pattern. After cooling, the molds are broken apart to release the cast parts. Sand casting allows for complex shapes but requires careful mold preparation and metal pouring.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    72 views30 pages

    5674620

    Uploaded by

    Amrik Singh
    A foundry is a factory that produces cast metal objects by pouring molten metal into molds. The document provides details on sand casting, a common casting process. Sand is mixed with binders and compacted around a pattern to form molds. Molten metal is then poured into the molds, taking the shape of the pattern. After cooling, the molds are broken apart to release the cast parts. Sand casting allows for complex shapes but requires careful mold preparation and metal pouring.

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    © All Rights Reserved
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    Download as ppt, pdf, or txt
    of 30

    Foundry-Basics

    By
    Mr.B.Ramesh, M.E., (Ph.D.),
    Research Scholar, CEG, Anna University, Chennai.
    Associate Professor,
    Department of Mechanical Engineering,,
    St. Josephs College of Engineering,
    Jeppiaar Trust, Chennai-119



    What is a Foundry?

    Casting is one of the oldest industrial processes
    There are different casting processes.
    The focus here is: GREEN SAND CASTING
    A foundry is:
    a factory that pours molten metal into molds,
    producing cast metal objects.
    Some
    typical cast
    metal
    objects:
    Turbine blades
    in jet engines
    Engine blocks,
    axles
    Aluminum
    pots
    SAND-CASTING
    Sand,
    mixed with clay binder &
    water (so it will hold its
    shape) plus coal dust to
    improve surface finish
    Pattern
    (a copy of the shape
    you want to produce,
    made of wood, plastic
    or metal)
    Basic materials & equipment for green sand-casting
    Container of molten metal
    (filled from furnace)
    Top and bottom mold forms
    (made of metal, open at top and
    bottom)
    Rammer (tool to compact the sand;
    often a pressing machine is used)
    SAND-CASTING
    MOLDING:
    Sand placed
    into bottom mold
    form &
    compacted
    MOLDING:
    Pattern placed into mold
    A very basic summary of the sand casting process. . .

    First of all,
    mix the sand.
    2
    1
    THEN
    SAND-CASTING
    MOLDING: Add
    the top mold
    form
    3
    4
    MOLDING: Fill top form
    with compacted sand.
    A tube or pipe provides
    a path to pour the
    metal in
    Pattern is still inside!
    SAND-CASTING
    MOLDING: Take
    the top mold off
    and remove
    pattern & pipe or
    post
    5
    6
    MOLDING: Replace the
    top mold and fasten
    securely!
    Pouring
    hole
    In the middle of the
    sand is a cavity
    shaped like the
    pattern!
    SAND-CASTING
    7
    CASTING:
    Pour the metal (container is
    filled from furnace immediately
    before you are ready to pour)
    8
    Wait for the metal to cool
    (minutes to days,
    depending on the size of
    the casting)
    SAND-CASTING
    8
    SHAKE OUT: Break apart the two
    halves of the mold & take out the
    partusually requires vibrating or
    striking the mold to break apart the
    sand
    CLEANING. Sand is
    cleaned off the part, the
    tab where metal flowed
    in must be removed.
    9
    A copy of the pattern
    has now been made
    in metal
    10
    Mold forms are reused
    11
    Sand is broken up,
    screened to remove
    debris and clumps, and
    sent for remixing
    SAND-CASTING
    Sand-casting is simple
    in concept, but
    demanding in
    execution. It is a
    process essential to
    making basic and
    advanced products. . .
    it is also hazardous
    and energy-intensive!
    Sand Casting: Parts of a Sand Mold (expendable mold)
    Key terms:
    Flask, Cope, Drag, Sprue, Runner, Gate, Riser, Mold Cavity, Core, Parting
    Line, Draft (not shown).
    Casting Terminology
    Parting line
    Sand Casting Configuration
    Patterns
    What is pattern?
    Approximate duplicate of product

    Patterns are made in the shape of the casting
    Pattern Materials: Wood, Plastic or metal.
    One piece or multiple piece pattern





    Types of Patterns
    Types of patterns used in sand casting:
    (a) solid pattern
    (b) split pattern
    (c) match-plate pattern
    (d) cope and drag pattern


    Pattern Making
    One piece or Solid Pattern
    Cope & Drag Pattern Match Plate Pattern
    Split Pattern
    Pattern Allowances
    Shrinkage Allowance
    Patterns are made larger than the casting to compensate
    contraction of the liquid while freezing.
    For internal cavities the allowances should be negative.

    Machining Allowance
    Allowance required to remove the rough cast surface. 2 to 25 mm
    (0.1 to 1)

    Draft Allowance
    To facilitate ease of removal, usually to 2 deg.

    Shrinkage allowance

    Normal shrinkage: Cast iron 0.83 to 1.3%
    Aluminum - 1.3%


    Cores
    Cores
    Cores are used to create internal cavities.
    Should have similar properties as the mold.
    Shaken out after casting is produced.
    Process
    1
    Mould
    2
    3
    Dolly
    4
    5
    Sprue
    Pins
    6
    7
    8
    9
    10
    11
    12
    13

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