DEPARTMENT OF TECHNICAL EDUCATION ANDHRA PRADESH

Name of the Staff Members Designation Branch Institute Year/semester Subject Subject Code Topic Duration Sub. Topic Teaching Aids : : : : : : : : : : : P. Ramulu Work Shop Supdt., Mechanical Engineering Govt. Polytechnic for women, Medak. I year Work shop Technology M-105 Foundry(2/2.14) 100 Minutes Moulding procedure and methods Animation Clips & Images

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Recap
In the previous class we have covered Construction of patterns Colour Code Core Advantages & Properties of Cores

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Recap
In the previous class , you have learnt
Type of metal, number of castings, moulding method,
etc will decide the making of pattern Pattern layout, shaping the pattern are the key steps in

pattern making
Core is meant for providing internal features in castings Horizontal, vertical, hanging, kiss etc are the types of cores.
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Objectives
On completion of this period, you would be able to know about:
Moulding procedure

Types of Moulding processes.

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Moulding Procedure
The Moulding Box consists of Cope and Drag The Pattern is kept inside the Molding Box on Moulding Board. Parting Sand is dusted on Pattern surface. Facing Sand is poured up to a depth of 25 mm Backing Sand is filled. Ramming is done. Excess sand is cut off with Strike off Bar.
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Contd

Moulding Procedure

Fig 55. Moulding Procedure

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Moulding procedure

Drag is turned over. Cope is placed on Drag. Parting Sand is sprinkled over Pattern.

Sprue &Risers are placed in position .

Moulding Sand is filled in the Cope

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Moulding Procedure
Sand is rammed

Excess sand is removed.

Sprue & Riser pins are withdrawn. Cope is lifted off and set aside. Pattern is withdrawn from Drag.

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Moulding Procedure
Finally Cope &Drag clamped together. Metal is melted separately in Electric arc Furnace. This molten Metal is poured into the Mould. When molten metal cools down the Mould is broken.

Casting is separated.

Classification of Moulding Processes

1) According to the Method used
Bench Moulding. Floor Moulding, Pit Moulding. Machine Moulding.

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Bench Moulding
Moulding is done on Bench. The Flasks are kept on Bench. Convenient height of Bench is selected. Employed for small Castings.

Fig 56. Bench Moulding

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Floor Moulding

Moulding is done on Foundry Floor

Used for medium to large Castings.

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Pit Moulding
Moulding is performed in Pit.
Pit is dug on Foundry Floor It acts as Mould (drag). A separate Cope may be Used. Adopted for Large Castings.
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Machine Moulding
Employed for mass production &batch production. Enables higher accuracy. Enables higher output. Various operations are performed by Machines,like a) Ramming. b) Removal of Pattern. c) Gate cutting.
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Classification according to Moulding Materials

Green sand Moulding. Dry sand Moulding. Skin-dry sand Moulding. Loam Moulding. Cement bonded Moulding. Ceramic Moulding.

Shell Moulding.
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Green sand Moulding

In this moulding moist sand with clay is used. Used for small & medium Castings. Drying of the Mould is not necessary. Molten is poured immediately. Green refers to moisture not colour of Sand.

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Advantages
Least expensive. Consumes less time .

Flasks can be reused

Less distortion problem.

Less danger of Hot tear.

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Disadvantages

Sand control is critical Moisture in sand may cause defects. Surface finish is poor. Mould lacks strength.

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Applications
Ferrous and Non Ferrous Alloys can be casted Used for small & medium Castings.

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Dry sand Moulding

Synthetic Sand is mixed with binder & Water. Synthetic Sand does not contain Clay. Mould prepared is baked in Oven at 240 degrees temp. Mould becomes Stronger. Used for medium to large Castings. Metals like Cast Iron & Mild steel are casted.
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Advantages
Stronger than green Sand Moulds. Defects are avoided due to baking. Better surface finish.

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Disadvantages
Cost of production is high.
Slow production rate. Mould distortion. Susceptible to hot tear. Not suitable for light & intricate parts.

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Skin dry Sand moulding.

Synthetic sand with bentonite binder & water is used.
The surface of Mould is dried up to a depth of 15 mm. Drying is done by Carbon dioxide or hot air. Adopted for Ferrous & non-Ferrous alloys of large size.

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Advantages

Less expensive. Requires less time. Stronger than Green Sand Mould.

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Disadvantages

More Expensive.

Mould weaker than Dry sand mould.

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Loam sand Moulding

Mould made with loam sand. Sweep pattern is used to prepare mould. It is rotated in loam Sand to make mould.

Mould is dried to provide strength.

Used for large castings of symmetrical shape.

Large cylindrical, paper mill rolls etc. are casted.

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Loam sand Moulding

Fig 57. Loam Sand Moulding

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Advantages
Large Castings can be casted cheaply.
Symmetrical Castings are made.

Disadvantages
It is slow process and laborious. Skilled moulders are required.
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Summary
In this class , you have learnt
Moulding procedure Types of Moulding processes like Green sand moulding Dry sand moulding Skin dried moulding Loam sand moulding
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Frequently Asked Questions

1.
2.

Explain The Moulding Process?

What are the various types of Moulding processes depending upon type Mould materials?

3.

What are the various type of Moulding processes depending upon Method of Moulding?

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Quiz
1. Sprue is used for ------------------------(Gate) 2. Top part of Moulding Box is called--------------

(Cope )
3. Pit moulding is used for-----------------------sized castings

(Large)

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