ob NoL1] Date

tools
to foundry
Name of the Job Introdue-tion

and materials

of the ins
View
Objective To aet a overal
too ls
and outs of foundr found
and imporance o ur
dag to dy ife

deals with
Foundr: I+ which
i the indust
and the pourin9
ofmetals
the meting
melting

molten metals into hHh mo ds obtained

of
from patterns. Then this pro cess of castinm

made from the prov jded patte

requirecd jeb

frem ha elient

Foundry tools Riadles rammer r o wel s|ick

spoon
belio ws ifters Swab, vent wire
ra spi ke aate cutter 5prne cutter s hove

runnes> riser, drag an d cope moldin9 board,

urnace ete.
FoundrH Materials Molding and sand binder,
Sand

addiives, casting materials. parti

Sandfucing sand ete

Safety in Foundr shop

Wearina a
pair ot aaales aloves and
apron uwith shoes
Do not 8et the sandto wet The are

enem to molten metal (water)

Never look over tha mod
during pouring
becawe tha metal might spurt aut of t mold:

Hande the Auipmats carefulla

hea qmd Some
poit
Importan ce ot toundr2 The convenience enj°{ ed nin
+he modern home and
SoCiety
argel depends on foundry Al he metal PToducts
We we are &eneraly ee made
bCasting Including
all
ransportahms, wtensi ls d
machineria^
a
predet of foundr
indutr
 Job No 2 Date

Name of the job: Mold makina

objeetive To know na pro cedures

of making

mold and do according

container used to
Mold I + is hollow
nmateri l
hot liquid
Ive shape to mo ten or

when Cools qnd hardens-

ypes f mold:

reen sand mo ld Mold is elosed and metal poured

on after molding before appre

Ciable drying has ocured

Dry sand mo I+ is harder, Stronger. and

free of mo
lding ganes it produce
more
mensionallyacCurafe Castings Compar ed
with aTeen Sqnd mold

Loam mod Loam molds ar

usedtor larger
work Th mold mqde
"p f large
metalCiron) Parts hick loam mertar.
 w It h Sodium

mixedB
CO2 moldsClean sand
r a m m e d

mixture is
and ha
silicate
around a pattcrn

I m p r e S s i 6 n

an
Creating
Molding:I+ is the procesSs ot
Pattern
of produet
In the s and bed b a

T pes ot moldingi
the die casting
Metal mo lding Mainl used in

of low-meting alls

smal work +his tpe

Bench molling: For
On a bench
molding is done

Floor moding Large castings

with difficuta in

1ts done on loor

hand ling

Pit molding_Done in a pit instead of flask

Mach inemodingL Here almost all operatins are

done without human touch

Tools and equpments

.Ricdle A riddle ot a atandard

mesh sCheen is usedto

remoVe
lum ps oTeigrm par tic le
em he nand Piddie
 used

pamm er 1s

hand
Rammer A
Sand
the
for Poking -the
Pack

used to
mold Butt I -o
he used
to
end
is
sand hna and peen
the
Pa
through
sqnd
the molding
Pack
Rammer
lding tlask:
Cornerr of mo

finishing
It is used for
Trowel
repaurin mod cavlties

and Hande
Over the
as well as for smoothr Blade

of the mold
Trowe
Sand
parhna

Tt is used
. Slick-spoon
molds
Tapaurin Siek Spoon

.Beliows I t is
used tor bloaing

off loose sand fro

old varieties and surface

the

of +he mold

Beliow
 Litter Usedfor Smoo-thing and

clearing8
Clearing our o ose Sand

depression in the mold

LfHer

Swab Used for app ina water

e mold around the

edge of the Pattern Swa

Vent wire It is u sed for making

o
holes in the mold sothe

heat 3 gas can come outF rom insidh2

Vent+ wire

Draw spi ke/screuo The draw spike is

pointed steel ro cwith

loops at one end

ra u spike
G a t e cutter I+ is used to cut

the oppenina that eConnacts

he spruce with -te meld Cavlty

nate cut er.
Sprute cutter I+ is Sed instead
fproviding
runner or rapid 0pk.
 Pn re r

Piser
tore

Sand

coDe
uPical mold yil

Procedure of mo lding

Prepare enough s a n d t
the Hask
Side
.Place drag n he moding board, joint

the oar d

Place Pattern, large side down, in draa

Rid de i n Sand Over Pattern

Fill drag ith san d an d Peen q areune

with ben ch
rammer keeping at eant 2 awa fr
Pattern

Reill drag peen all over

Stri ke off excess

.
s and
Vent around and ver pat ern
wth vent
wire.

Roll hand tulls of lo0se Sand

Over mo ld
 Roll drag over remove
mo l d i n g board

Place cope off drag and shake Partng 5and

Blo billo
Parina sand off patern by
Riddle in sand Over Pattern
and
Refill cope» peen all over, r e n l aqajn

butt al Over

sand off
Remove Cope blew ex ce Ss parhing
the drag .

Cut gate in deep and 1" wide

dra
drag
and remove ana 0ose sSand trom The mo d.

Put board outside f Cope and la it dewn

lat bard underneath.

.Dust blacking in
Ppouning basin

Put on
dr and its
cope orgina PoStim
Uncove basin qnd
Place suitable
Pourin
weight on Cpe t hold t down agains+ the

lift f the mol Hen metal

P:T.0
Chaplet: IH is a allmetal insert or spacer
us ed In proVIde core supPort
molds to

during the casting process

during

Chills A chil s an object wded to promote

solidifiaation in Apeciic Portin of a

metal Cating mold

Discuioyn I i the most important step of faundy

In
In this step we make the bare of aking

a
Pattern I thin ntep is not Correc- semeh,

the Pattern wonf be Correc alsd. We havet e

extra carefu making the mold

 Job No131
Date
Name of the
jeh al tern
Paltern and
And pat tern makina
pat1ern
Objective In his step
step we l Know 50me basics
about pattern, ils materiiols ond ege
eic

Potttern
aftern Tt is the model of desired
castina Twith
cashna
exoctl Same
shape and 6ize with or withouT
the additionn of alloNance and Core
Prints

Types ot pattern:
Sinale pi ece pattern Gated pattern
Split Pattern
Loose Piece pattern
Gated pattern
Mateh plate patten
Box up pattern
Cope drag Pattern
Pattern mater ials
wood Plashc

Metal Wax
 aa
made
Pattern allowance A pattern 1s ways

required
thanthe

litle bit larger

patfern
1s
Called
Size of the desired ncl this
object a

allowance

HPes of pattern allowance

shrin kage
To Compens ate the
Shrinkage allowance
solidificatn
of metal during

and cooling after cash8

in dimensim pro
Finish1ng allowance Tolerance
make
vided in the added to

for machining to surtace

of casting
a pattepn

To acilate the withdranal of

DrafE allowance
rom a mold preper
a Pattern

draft should be applied tohe pattern surtace.

. Distortion or camber allunance 5mall changes in a

pattern to avoid bending

the catinA pro cess due exces slve haat

in

and preMure applied

P:.D
Master pattern Master pattern 15 oa pa-ltern which
shrin
Contrachm
or
has double

Kage allowand

Discussi on In this We learnt about patern

Step,

rom which materias +is made, we

pattern
also learnt about different kinds of

important t o make
allowance Pattern allowance

Pertect desired object in terms f length

width and height

 Job no : L4] Date

Name of the Job Sand Preparation

which wil
Objechve To make the molding7 Sand

the pro cess of

be used af ter wards In

Sand casting or the preparotion of mou ld

cavitd

Molding materials Sand. metals and qlloHS Plaster of

Paris ceramic plastic, wood, araphHe

ete

Moldin Sana The sand which is used malke

mold can be classi hed into man
tpes areen Sand. molasses sand NaaS i0 3 san
Oil sand dry Sand loam sand ete.
Main tne
ComposItion 1S

Osi02 - 807.
Ala03 157
Fe203-137 iv Ha0257.
0thers- 1.27.
i n Sand p operfies

out
Permeabilty- lo pass he a s easi
psess ure

Reractoriness -Tolerance of heat and

Plasticitd To hod the structure of pattern

Collapsibi lity - T breakthe mould atterwards

Chemical resishvtH- Doesn t react with any metal

Re-usee Can be used gain

Adhesiveness To hold he box and pattern

and sand
Cohesivess
Bondina between S and and s and

Some other
elements Silica sands are not directl
net directl
N
use tor molding due to absence
of S ome
Properties like
cadhesiveness Cohesivenes.
For 8 OLwIn aP hoe properthes , we haveto mix
5 ome
elements with silica Sand
Mainly the
these
elements are wo tHpes
Sand binder
sand
additives
 ike-
Sand Binder used for sands
Different binders are

.Clay for areen sand mod

Molasses or molasses s and moH

Na2si03 -

for Na,Si03 Sand moE

or oil sand mod

507. clay +407. silica for oam sand mold

sand additvesS: Sand (sio2) water, cellulose, uood

dust coal dust. Alumina sili ca

tlour ete

Partina sand H IS used be-tween drag and cope

to easi sepqr ate it ateroards

Facing Sand T+ is used in

moldina boardt
give better surtoce
finish to the
castings
Mesh no. The number of holes Per
inch
square
in the standard mesh is in
the riddle is called mesh
mumber
 Sand is verg
Discuson .
Preparation of mod1ng
he firsst
His very
impor tant as

different
used
Step f making a mold Here we

Th
kinds of ingredients in carefu wy
verd
rer
Yequined percentage s also
almos a ccurate
 Job no..L5]
Date

Name ot the Job Core and Core making

Objechve To Overcome the problem while @astirg

a mo ld containing cavity usin C CoPe

be tore cantina

Core Core the

1S Sand body torm b
pattern or Core box which placed in the

mold cavit to
get hold slot or
Cavity in our

required size in
cashna
Pes ot Core:

Horizontal core A cHlindrical torm laid

in the mod Mold

horizontall
The ends of the core rest in Seats
Cor
provided b Core orints on the pattern Horizomtal cere

Vertical ore The core when required to

Mod
be placed along a verhcal
ais known as Verhical core
Cove
Ver tical cove
 has a
C or
Balance Core A balance M. Cor
print and
Core
single
Procduces in Contin Chope
S'nale opening
o lonte Carc

the
Core Print: I+ is the extended Portton of
Impre ssion In
an
Pat tern which forms
T place
night position
the mold which locate the

the drH - Sand core in the mold

Core seat: It is the impression ot the core pr1nt

A
Core box Core box is essental aypef
Pa-t tern made of Wood Or metal in which

Sand in nammed t form a Core

In this step, wwe learnt about the

DiscusSion
pattern, rom which materials 1t 1s made

we also leqrnt about different inds of pattern

allowanee. Pattern allowance 15 done than

than cor
COre

set to 8Ve a Perfecet PTo tected mold

cavitd
 Job No.L6] Date

defes
practice and sting
Name of the job : Ca stinga
to implement
how
Objective In this step, we'l knos

Steps into mak the

all the previous

desined object. We'll make Our objecf in this job-

Casting Tt of meHi metal

the procesS

n in tha2 mo ld
Turnace and pourin

Metal nmelting fur nace It is used for me

Hina
meta The choice of furnace

some tactors ike Cost) avala1biity ete.

dependss on

Tpes of furnace :

Electric turnace - Al
cashna
metal cashn

Crucible furna@e Alumiium Cashng

Castna
Cupola turna ce Cast inon Casthng.

Open hearth furnace - Stee cas hn

cible I+ is a
c
and araphite Composed
Composed po+

where metal 5 malted

Size of crucible: 1-400
Size is fenerally from
is approX
i-
represet
The number

mate capact in pund (lbs) ofAluminjun

li ke
Crucible materials High retractory materials

on, raphite hine cla ete

the temparature
Parometer I+ is used to test

of the Turnace

Meting temparature and density of some metal:

Name of the Meting temparature DensitCgem)

metal

Aluminium CGo'c 2-4 g emS

Crass (Cu+3n) 1000 C 87gem

Bronze (Co+ Sn) 80°c 8 2 cmn3

1050 c 8 a em3
Copper

Cast iron 1350- 1400"e 7.2 sem

1300 1500'c
Steel 78 em3

someCasting defects
Blow hole Rough surface

. Hot tears Shrinkage cavity

 Metal penetrahon .MIss un

Swel
Gnac hole
Core sh:ft
Shift
Scab hole
Cold shut

to be Safe in this step

Diseussi ons we have

Wear
appropriate apron
S0, We have

we have
S hoe when we're Pourin moten metal

To be carejul about the meHing tempara-tures.