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B 1 Threshold 2004

FEASIBILITY OF GRANITE POWDER AS A MOULDING SAND FOR ALUMINIUM ALLOY CASTINGS IN FULL MOULDING

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60 views14 pages

B 1 Threshold 2004

FEASIBILITY OF GRANITE POWDER AS A MOULDING SAND FOR ALUMINIUM ALLOY CASTINGS IN FULL MOULDING

Uploaded by

vikramvetal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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FEASIBILITY OF GRANITE POWDER

AS A MOULDING SAND FOR


ALUMINIUM ALLOY CASTINGS
IN FULL MOULDING

ABSTRACT

We all know generally that granite powder is waste material from the stone crushing
units.

Instead of dumping it as wastage it can be used for so many purposes one such
application is in mould making. In the present study we have examined the granite powder
as moulding material (moulding sand) in the Full Moulding Process as substitute to the
Ferro-silicon material and by this, we can reduce the cost for mould making.

We have conducted the experiments and found that this granite powder can be used
as substitute to Ferro-silicon material as moulding material in full moulding process.

INTRODUCTION

Full moulding process:


In full moulding method, the pattern, made complete with gates and risers is
prepared from expanded polystyrene slabs by machining and fabrication then coated with a
suitable mould wash, and finally embedded in a no-back type of sand. Organic no-back
sad such as furan or allaged isocyanate, may be used for small sized castings and CO2,
Ferro-silicon, or fluid sand for medium and large sized castings. While the pattern is inside
the mould, molten metal is poured through sprue. The heat of the molten metal is
sufficient to gasify the pattern and progressive displacement of pattern material by the
molten metal takes place. The amount of gas produced is so small that it can easily escape
through

the sand without causing any back pressure. To allow easy gasification of the

pattern. The temperature of the metal when it is poured should be about 25 to 50 0C higher
than that required for sand casting.

Un-bonded sand, viz, sand grains only without any binder or moisture has also been
successfully used for full moulding casting. Proper selection of grain shape and size,
correct gating system design, correct pouring temperature and pouring rate are important
considerations in un-bonded sand practice, these have to be established by trial and
experimental.

It is thus possible to quickly and inexpensively cast shapes with high dimensional
accuracy and metallurgical quality. As there is no air in the mould at any time, defects such
as blowholes and pinholes are prevented.

Pattern

removal is not required and so

dimensions are better maintained and detects due to the occurrence of a parting line are
eliminated. Further, there is no limitation as regards size, shape, or complexity. The
method is best suited for one off castings required at short notice or for prototype castings.
It can be used for both ferrous and commonly cast non-ferrous metals.
This method, which can be varied to suit large scale production of small castings, is
an economical substitute for investment casting where the pattern is prepared from preexpanded polystyrene granules. Such granules are injected or gravity filled in thin walled
aluminium or copper dies and heated either under steam or in hot water. Heat caused
granules to fully expand production is very quick as a large number of patterns can be
moulded together. The method can be mechanised.

ADVANTAGES:
1.

For one of a kind or non-machine moulded castings the process required less time.

2.

Allowances are unnecessary in removing the pattern from the sand.

3.

Finish is uniform and reasonably smooth.

4.

A complex wooden pattern with loose pieces is unnecessary.

5.

Cores are seldom required.

6.

Moulding is greatly simplified.

DISADVANTAGES:
1.

The pattern is destroyed in the process.

2.

Patterns are more delicated to handle

3.

There is no opportunity to inspect the finish cavity.

Pattern materials for Full Moulding:

Polystyrene of the moplastic variety of plastics which tend to become soft and
subsequently gasify on heating, the most common is polystyrene from.

This material is available in different densities in formed (expanded) from. It can


be easily shaped, machined and fabricated by gluing to form the pattern. When the molten
metal is poured, the heat of the molten metal causes gasification of the pattern. The ash
content of the pattern material is extremely low and the gas developed during burning is
easily permeate through the sand.

EXPERIMENTATION

To study feasibility of granite powder as a moulding sand in fullmoulding, we


conducted the experiments with silica sand and granite powder for mould making.

Grain fineness number of silica sand particles and granite powder were calculated
using sand sieve analysis test. The readings and results of silica sand grains and granite
powder are tabulated in table (1) and (2) respectively. The schematic diagram of sand sieve
analysis equipment was show in figure (1) and (2) respectively.
Experiments were conducted to study the feasibility of granite powder.
The material selected for making the pattern is polystyrene material (Thermocol).
In the first experiment, the mould was prepared with granite powder only . Every
care was taken during the moulding process. The melting of aluminium aimed at most
favourable results by taking the following measures.

1.

Started the melting practice with clean material.

2.

Used the clean melting practice.

3.

Kept the temperature of melt low until pouring is imminent.

4.

Maintained minimum holding time in the molten condition.

5.

Avoided water vapor or hydrogen bearing gases, as far as possible.

6.

Used adequate fluxing practice. In these experiments Zinc Chloride was used as
flux for separation of slag.

7.

Skimmed only when the molten was ready to pour.

8.

Avoided turbulece when pouring the molten aluminium to minimise drosing and
hydrogen pickup.

9.

Maintained proper pouring temperature and poring practice.

The molten metal, which was melted according to above guide lines was poured
9into the mould and allowed it to cool).

In the second experiment, the mould was prepared with silica sand grains. The
moulding melting and pouring procedures were adopted as described in the first experiment.

TABLE - 1
SIEVE ANALYSIS FOR SILICA SAND GRAINS

I.S.Sieve
opening
number
a
1700
850
600
425
300
212
150
106
75
53
Pan

Weight in
grms on
sieve
b
0
0.5
0.5
1.0
1.5
4.0
7.0
8.0
20.5
3.0
4.0

%Retained

Cumulative
%

Multiplying
Factor

Product

c
0
1
1
2
3
8
14
16
41
6
8
c=100

d
0
1
2
4
7
15
29
45
86
92
100

e
5
10
20
30
40
50
70
100
140
200
300

f=cxe
0
10
20
60
120
400
980
1600
5740
1200
2400
f=12530

G. F. N.

f 12530 125.30 126


c 100

TABLE - 2
SIEVE ANALYSIS FOR SILICA SAND GRAINS

I.S.Sieve
opening
number
a
1700
850

Weight in
grms on
sieve
b
0
0

%Retained

Cumulative
%

Multiplying
Factor

Product

c
0
0

d
0
0

e
5
10

f=cxe
0
0

600
425
300
212
150
106
75
53
Pan

0.5
1.5
1.5
2.0
7.0
9.0
18.5
6.0
4.0

1
3
3
4
14
18
37
12
8
c=100

G. F. N.

1
4
7
11
25
43
80
90
100

f 13190 131.9 132


c 100

20
30
40
50
70
100
140
200
300

20
90
120
200
980
1800
5180
2400
2400
f=13190

CONCLUSIONS:

In our experiments the granite powder (A wastage from the stone crushing units) is
very much useful as moulding material for full moulding process. It was also found that with
this granite powder we can obtain better results than silica sand grainy in full moulding
process particularly in open bed method.

BIBLIOGRAPHY

1.

FOUNDRY TECHNOLOGY

2.

A PROJECT REPORT ON EFFECT

-P.L.JAIN

OF MOULDING ADDITIVES ON
ALUMINIUM CASTING

-Under the guidance of Sri. T.V. Ramanna Rao


M.Tech.

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