APPARATUS

Material

Function

Aluminium

Material that use to create the

product.

Green sand

As core material to create the

mold.`

Parting agent

used to make sure the mold

does not attach with the
pattern and easy to remove
the mold from the pattern.

Equipment

Flask

Function

used to produced drag and

cope which putted the green
sand inside of it.

Pattern

used to pattern the

shape of the product.

Furnace

used to make the molten

metal of aluminium.

Crucible

used to transfer the molten

metal of aluminium after it
was produced from the
furnace and then poured into
the mold.

Sands separator

used to separate a bulk of

sand to the finer particle

Sand Muller

also known as sands mixer

that was used to produce
green sand which contained
silica sand, bentonite, coal
dust and water

Sand rammer machine

used to compress and

compacted the green sand
into the mold. On the
machine, it has air
compressor to clean the
excesses green sand on the
machine and vibrator to
make green sand filled up the
space in the flask.

Hand Tools

Spure pin

Function

used to make a hole to flow

the molten metal of
aluminium into the mold.

Heart trowel

used to dig the green sand to

make hole and pulled out the
spure pin from the mold.

Trowel

used to transfer the green

sand into the lifter.

Lifter

used for removing the sand

particles from the mould
repaired the mold.

Scriber

used to make air vent at the

upper of the cope.

Aluminium plate

used to hold the flask and the

mold in order to make sure
the mold does not break

INDUSTRIAL APPARATUS

Figure 4.17: Double arm resin sand mixer

Figure 4.17 showed that the machine mixed in the short time and the rotation of the double
arms was flexible. The operation and maintenance were easy and simply besides improved
the quality of molding sand to get good economic efficiency. It used plc control, running
stable and reliable.

Figure 4.18: Automatic pouring machine FVNX

Figure 4.18 showed that it transfer from hot molten metals and bringing the melt securely to
the mold.

Figure 4.19: High precision rubber compression molding machine

Figure 4.19 used for various requirements like rubber, Bakelite, melamine dishes and urea
product forming use.
EXPERIMENTAL PROCEDURE

1. In order to ensure that green sand mold easy to split from pattern, parting agent was
put around the pattern in the drag part as shown in figure 5.1.

Figure 5.1: Parting agent stew process

2. Then green sand was filled in the drag part. Green sand was filled until it fulfills the
drag part as shown in figure 5.2.

Figure 5.2: Green sand was filled in drag part

3. Then, the green sand being compacted by using sand rammer. It is being rammed for
five seconds in order to ensure green sand was compressed.
4. Beside, to ensure that green sand was compacted it also was compressed by a
compressor as shown in figure 5.3.

Figure 5.3: Mold was compress by compressor

5. After it was compressed, the green sand mold will going through vibrating process to
ensure that the pattern and flask were easier to remove from green sand mold.
6. After the drag part were finished, the cope take place. Sprue was build by using sprue
pin in cope part as shown in figure 5.4.

Figure 5.4: Sprue pin was marked

7. After that, green sand was fulfilled the cope part and it was compress by compressor
to ensure that green sand was really compacted.
8. Then, green sand mold in cope part will going through vibrating process to ensure that
sprue and flask were easier to remove from green sand mold.
9. Next, air vent was build in the cope part to make sure there is air ventilation in the
mold to minimize the defect in casting. Air vent was build by using scriber as shown
in figure 5.5. Besides, pouring cup;;p was build by using trowel to make pouring
process more easier.

Figure 5.5: Air vent was build by using scriber

10. After that, flasks were removed from mold, cope and drag part were joining together
as shown in figure 5.6.

Figure 5.6: Cope and drag part were joined together

11. Next, the mold was compacted parting line with a green sand as shown in figure 5.7 to
ensure that there is no leaking between cope and drag. Besides, it also to make sure
that there is no molten metal flow out from the mold.

Figure 5.7: Green sand was put at parting line

12. Then, aluminum metal was heated until it reaches melting temperature. After that,
molten metal were pour into crucible as shown in figure 5.8 to easier the process of
pouring molten metal into the mold.

Figure 5.8: Molten aluminum was poured into crucible

13. The mold was left around 24 hours in a room temperature for ensure that the
aluminum is fully solidified.
14. After that, the mold was broke and the product was cleaned.

15. Finally, the product of casting process can be observed as shown in figure 5.9. All the
defects were known by observing the product.