Department of Materials and Metallurgical Engineering

Bangladesh University of Engineering and Technology, Dhaka

MME346 Foundry Engineering Sessional

1.50 Credits 100 Marks 3.00 Hours/Week

Experiment 1
An Introduction to the Moulding and Casting Processes

AIM OF EXPERIMENT
1. To have hands on experience on the overall casting process including mould making,
melting, pouring, shake out and visual inspection of casting.

STUDENT EXPECTATIONS / LEARNING OBJECTIVE

1. Identify different parts of a mould and understand their importance
2. Understand the different proportions of mould ingredients and preparation of sand systems
3. Understand the use of pattern and core in making the casting
4. Understand necessity of using different types of pattern allowances and core prints
5. Selection of parting line and placement of pattern
6. Preparation, closing and visual inspection of mould
7. Different kind of furnaces used in the foundry
8. Selection and operation of different kind of melting furnaces and safety measure during
operation of furnace.
9. Understand melting procedures
10. Cooling of molten material

THE CASTING AND ALLOY COMPOSITION

A cylindrical object is to be cast using greensand moulding system. The alloy to be used is
commercially pure aluminium (LM0) alloy. The pouring temperature is 700 °C.

EXPERIMENTAL PROCEDURE
1. Observe the pattern
Observe the casting object and the pattern to be used for making the mould. See the
differences between the casting and the pattern. Is it symmetrical about a plane or line? If
so, that plane can be a parting plane. Observe the actual practice on the shop floor for a
given pattern to justify the selection of parting line. Remember that the more critical parts
are to be located in the drag. Make a drawing of a simple pattern and select, giving a
proper logic, the parting line.
2. Making a mould
Observe the making of mould and core for the casting. Especially notice the plumbing
system used for the flow of liquid metal to the mould cavity.
List the (a) equipment used – hand moulding, pneumatic rammer or machine moulding
(b) the materials required for making the moulding sand and their proportions. Report the
steps in making a mould.
The plumbing system consists of the sprue, the runner and ingates and the feeder. In
match plate pattern or cope-and-drag pattern, the feeder and gates are already attached
with the pattern. There is logic in selecting the locations of the (i) Sprue – through which
liquid metal enters the mould, (ii) the runner and gates. Runner, is cut in the mould,
usually along the parting plane between cope and drag in such a way that the liquid metal
is distributed evenly throughout the mould. The feeder(s) acts as reservoir of liquid metal
to compensate for the shrinkage during solidification. Ingates and feeders are placed on
or near such heavy sections. The Report should indicate a view of the location of the
feeder, runner and the ingates.
3. Making a core
If a core is required, observe the sand system used to prepare the core and its difference
to those used for preparing the mould. Note how moulder makes sure that the core is set
properly. Chaplets, which are metal pieces with a stud joining flat pieces, are used to hold
the core in position.
4. Mould finishing
Observe the finishing step. Usually, the mould and core are given a coating to obtain
good surface finish. The assembly step of cope and drag parts of the mould are important.
For a mould with core, observe how moulder makes sure that the core is set properly.
Chaplets, which are metal pieces with a stud joining flat pieces, are used to hold the core
in position. Note how the cope and drag, after setting are clamped to hold tight and in
addition, if there is the practice of putting weight on the mould box so that the buoyancy
of the liquid metal does not shift the cope. Report how venting is done and write on
purpose of venting.
5. Melting and pouring of liquid metal
Observe the melting process and the furnace used for melting the material. Describe the
preparation before beginning of charging and the charge sequence. Note whether any de-
oxidisers are used to reduce the oxygen level. Observe how the melt is tapped – ladle
description and capacity, whether any holding ladle is used etc. So whether the melt is
treated for slag removal, removal of dissolved gas, or addition of (i) inoculants for cast
irons, (ii) grain refiners for non-ferrous alloys after tapping.
Observe pouring. See whether a pouring basing or a conical cup is used for pouring and if
there is any interruption during pouring.
6. Shake out
Remove the casting after cooling and visually inspect the casting and identify the defects,
if any, present in the casting.
7. Prepare the report.

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DISCUSS THE FOLLOWING IN YOUR REPORT
1. The basic steps involved making a casting.
2. Identify the steps where, in your opinion, the science should be applied.

INDIVIDUAL ASSESSMENT
We recognise that students have different learning styles and needs. The following will help
students to assess their progress

Learning Objective Learning Outcome Yes/No

Mould materials Knowledge of mould materials

Core materials
Application of tools
Moulding process
Sand system
Preparation of sand mix
Mould making
Gating and feeding systems
Mould inspection
Melting furnaces
Selection of meting furnaces
Charge materials of melting
furnaces
Operation of melting furnaces
Melting of materials
Handling of liquid material
Pouring of molten material
Pouring temperature of molten
material
Knowledge of core materials
Uses of tools
Different moulding methods
Different types of sand mix
Use of sand mixer and muller
Steps involved in mould making
Necessity of gating and feeding systems; Importance
of a good design of gating and feeding systems
Steps involved in mould making; Soundness of
mould
Understanding of different kind of melting furnaces
Use of furnace for a particular material
Understanding of charge materials for different kind
of furnaces
Working procedures of furnaces
Melting characteristics of particular charge material
How to transfer liquid metal from furnace to ladle
and ladle to mould
Control over pouring time and rate of filling the
mould
Optimum temperature to fill mould cavity

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