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Foundry Technology

Foundry technology involves making molds through processes like green sand molding or shell molding, melting metals, and pouring the molten metal into molds to produce castings; common casting methods include sand casting, die casting, and investment casting; castings can be used to produce a variety of large or small parts through expendable or permanent mold casting processes.

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31 views16 pages

Foundry Technology

Foundry technology involves making molds through processes like green sand molding or shell molding, melting metals, and pouring the molten metal into molds to produce castings; common casting methods include sand casting, die casting, and investment casting; castings can be used to produce a variety of large or small parts through expendable or permanent mold casting processes.

Uploaded by

nikhil110705
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© © All Rights Reserved
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Foundry Technology

Foundry Technology
Foundry Technology involves molding, melting and casting of parts; by
pouring the molten metal alloy into the mold cavity. Foundry is a process of
shaping the metal components in their molten stage.

Practical application
• Casting is the cheapest and most direct way of producing the shape of the
component.
• Casting is best suited to work where components required is in low
quantity.
• Complicated shapes having internal openings and complex section
variation can be produced quickly and cheaply by casting.
Foundry Technology
Steps in foundry process
1. Making the required pattern
2. Moulding process to produce the cavity in sand using pattern.
3. Pouring the molten metal into the cavity to get casting.
Classification of foundries;
• Steel foundry
• C. I. foundry
• Light alloy foundry
• Brass foundry
• Shell moulding foundry
• Die casting foundry
Metal Casting
Process in which molten metal
flows by gravity or other force
into a mold where it solidifies
in the shape of the mold cavity
• Steps in casting :
1. Mold preparation
2. Melting metal
3. Pouring it into mold
4. Solidification
Foundry Technology
Pattern:
In casting, a pattern is a replica of the object to be cast, used to form the sand
mould cavity into which molten metal is poured during the casting process. Once
the pattern has been used to form the sand mould cavity, the pattern is then
removed, Molten metal is then poured into the sand mould cavity to produce the
casting.
Foundry Technology
Types of foundry sand
• Natural sand: Sand containing the silica grains and clay bond as found. It varies in
grain size and clay content. Collected from naturalrecourses.
• Synthetic sand: It is an artificial sand obtained by mixing relatively clay free sand,
binder (water and bentonite). It is better moulding sand as its properties can be
easily controlled.
• Facing sand: It is the fine grade sand used against the face of the pattern and
finally governs the surface finish of the casting.
• Parting sand: It is fine dry sand + brick dust used to preserve the joint face
between the cope and the drag.
• Green sand: moulding is the most common moulding process
• Dry sand mould: Dry sand mould refer to a mould which is artificially dried before
the molten metal is poured into it.
Foundry Technology
Moulding methods:
• Bench moulding: In this method the moulding is carried out on convenient
bench and moulds are relatively small.
• Floor moulding: In this method the moulding is carried out in medium and
large moulds are carried out on the floor.
• Plate moulding: For large quantity production and for very heavy casting
two plates may be used with pattern.
• Pit moulding: In this method the moulding is carried out in the pits and
generally very large moulds are made.
• Machine moulding: A machine is used to prepare moulds of small and
medium. This method is faster and gives uniform moulding.
Process Flow
• Pattern and Mould preparation.
• Melting and Pouring
• Solidification and cooling.
• Removal, Finishing, cleaning and inspection.
Advantages and Limitations of Casting
Advantages
• Can create complex part geometries
• Can create both external and internal shapes
• Some casting processes are net shape; others are near net shape
• Can produce very large parts
• Some casting methods are suited to mass production.

Limitations
• Limitations on mechanical properties
• Poor dimensional accuracy and surface finish for some processes; e.g., sand
casting
• Safety hazards to workers due to hot molten metals
• Environmental issues
Examples of Cast products
Big parts: Engine blocks and heads for automotive vehicles, machine frames, railway
wheels, pipes, church bells, big statues, and pump housings.
Small parts: dental crowns, jewellery, small statues, and frying pans.
Casting Processes
1. Expendable mold processes - mold is sacrificed to remove part
• Advantage: more complex shapes possible
• Disadvantage: production rates often limited by time to make
mold rather than casting itself
2. Permanent mold processes - mold is made of metal and can be
used to make many castings
• Advantage: higher production rates
• Disadvantage: geometries limited by need to open mold
Classification of Casting Processes
Conventional Molding Processes
• Green sand molding • Dry sand molding

Chemical sand molding processes


• Shell Molding • Sodium silicate Molding

Permanent Mold Processes


• Gravity die casting • Pressure die casting

Special Casting Processes


• Investment Casting • Evaporative pattern • Centrifugal casting
Casting Terminology
Casting Terminology
Flask: The box containing the mold
Pattern : The replica of the final object to be made.
Cope: The top half of any part of a 2-part mold
Drag: The bottom half of any part of a 2-part mold
Core: A shape inserted into the mold to form internal cavities
Core Print: A region used to support the core
Mold Cavity: The hollow mold area in which metal solidifies
Riser: An extra cavity to store additional metal to prevent shrinkage
Gating System: Channels used to deliver metal into the mold cavity
Casting Terminology
Sprue: Vertical channel
Runners: Horizontal channels
Parting Line / Parting Surface: Interface that separates the cope
and drag of a 2-part mold
Draft: Taper on a pattern or casting that allows removal from the
mold
Core Box: Mold or die used to produce cores
Casting: The process and product of solidifying metal in a mold
Casting Process

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