Download - sand casting
IPTR 1- REVIEW
ST JOSEPH UNIVERSITY COLLEGE OF ENGINEERING AND TECHNOLOGY
COMPANY NAME : TANGANYIKA PLANTING COMPANY (TPC) Ltd. STUDENT NAME : AMRAN HASHIM ALLY
REGISTRATION NO. : 14171052003
MECHANICAL ENGINEERING
ABSTRACT
My training report is about Workshop activities during industrial maintenance which involves difference mechanical
process such as machining(drilling,milling,turning,threadi
ng ect.),metal fabrication and pattern design and molding(sand casting).
TANGANYIKA PLANTING COMPANY (TPC) Ltd. Is one of the sugar industry in Tanzania which is located at
Moshi established in early 1930s. The company was registered in Tanzania as TPC on 29th June 1973 and shareholders remained the same M/s A.P.Moller of Denmark. Sukari Investment Company Ltd purchased 75% of shares of TPC limited in March 2000, and became the majority shareholders of the company; the government retained the remaining 25%. . The factory crushing capacity has been increased from 125TCH to 160 TCH, the area under sugarcane was extended from about 6000ha to 8000ha. The harvests season at Tpc lasts for 8.5 months from July to mid-March because of the long rains which usually hindering the harvesting and transportation of cane, the sucrose content also falls to the lowest level during the rainy season.
COMPANY DETAILS
SAND CASTINGPATTERN DESIGN AND MOULDING PROCESS
PATTERN DESIGN Pattern making:1. Motor fan2. Bush3. Hollow shaft4. Ejector5. Square nut
MOULDING Molding or moulding ; is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or matrix. This itself may have been made using a pattern or model of the final object
MOLD MATERIALS There are four main components for
making a sand casting mold: base sand, a binder, additives, and a parting compound.
Molding sands, also known as foundry sands, are defined by eight characteristics: refractoriness, chemical inertness, permeability, surface finish, cohesiveness, flow ability, collapsibility, and availability/cost
Binders are added to base sand to bond the sand particles together (i.e. it is the glue that holds the mold together).
A mixture of clay and water is the most commonly used binder. There are two types of clay commonly used: bentonite and kaolinite
PREPARATION OF MOULDING SAND Required to mix1. Non mineral sea sand2. Bentonite3. Water Mixing of water was gradual process for
proper wetness (low wet sand was required) ,the mixture allowed to settle while little water spread.
MOULDING PROCESS Selection of moulding box1. Drag and2. Cope
Selection was base on type of pattern either:1. Split or2. Solid For split one piece was put on drag and another on the cope and
then joined with proper alignment and the molding sand was introduced and compact together to give the shape required
For solid pattern the moulding box was selected which fit the height of the sample.
All before pattern were insert graphite was polished first and the pattern carefully removed
The boxes were placed near high heat to fasten the drainess and proper binding
The boxes was allowed to cool for 5-6 hours .
SAND CASTING SCHEME
EXAMPLE OF SPLIT PATTERN(EJECTOR)
MELTING OF BRASS MATERIALS Furnace used was Diesel and Air furnace First it was lighted for Cleaning of the furnace, by
allow it to get heated for some time and remove the molten slag waste.
Introduction of brass material to the furnace The material was heated between temperature
1600°c to 2000°c The crucible were prepared placed near the
furnace After the brass was properly melted it was
poured into the crucible and then into the mold boxes to give the required shape and allowed to cool and solidify.
DIESEL AND AIR FURNACE
POURING OF MOLTEN BRASS IN THE MOLDS
After cooling the mold was defragmented by carefully removing the sand part
The remaining part was the workpiece required
It was further taken for machining operation
FOLLOWING SAFE PRACTICES Wear heat-safe gloves, apron, and boots Wear cotton or wool clothing Protect your face and eyes Consider a respirator
CONCLUSION I am well satisfied with my training. I have
learned many new technical subjects, acquired a number of new technical skills and improved
another group of existing skills such as: Increased skills in repairing faulty in machine
process Large steps in improving my abilities in
designing and repairing of materials Most important is how team work create high
efficiency and excellent work performance.
THANK YOU