Foundry-Basics

By

Rao Muhammad Zeeshan, (Mechanical Associate Engineer)

Instructor atWah British Institute of technology, Taxila

What is a Foundry?

• Casting is one of the oldest industrial processes • There are different casting processes.

The focus here is: “GREEN SAND” CASTING

A foundry is:a factory that pours molten metal into molds, producing cast metal objects.

Some typical cast

metal objects:

Turbine blades in jet engines

Engine blocks,axlesAluminum

pots

SAND-CASTING

Sand, mixed with clay binder &

water (so it will hold its shape) plus coal dust to

improve surface finish

Patterna copy of the shape you want to produce, made of wood, plastic or metal

Basic materials & equipment for green sand-casting

Container of molten metalfilled from furnace Top and bottom mold forms

made of metal, open at top and bottom

Rammertool to compact the sand; often a pressing machine is used

SAND-CASTING

MOLDING:Sand placed

into bottom mold form &

compacted

MOLDING: Pattern placed into mold

A very basic summary of the sand casting process. . .

First of all, mix the sand.

21THEN

SAND-CASTINGMOLDING: Add the top mold form

3

4 MOLDING: Fill top form with compacted sand.

RUNNER: A tube or pipe provides a path to pour the metal in

Pattern is still inside!

RISER: A tube or pipe provides a path to exhaust gases

SAND-CASTING

MOLDING: Take the top mold off and remove pattern & pipe

5

6 MOLDING: Replace the top mold and fasten socket!

Pouring hole

In the middle of the sand is a cavity shaped like the pattern!

SAND-CASTING

7 CASTING: Pour the metal (container is filled from furnace immediately before you are ready to pour)

8 Wait for the metal to cool(depending on the size of the casting)

SAND-CASTING

8 SHAKE OUT: Break apart the two halves of the mold & take out the part—usually requires vibrating or striking the mold to break apart the sand

CLEANING. Sand is cleaned off the part

9

A copy of the pattern has now been made in metal

10 Mold forms are reused

11Sand is broken up, screened to remove debris and clumps, and sent for remixing

SAND-CASTING

Sand-casting is simple in concept, but demanding in execution. It is a process essential to making basic and advanced products. . . it is also hazardous and energy-intensive!

Sand Casting: Parts of a Sand Mold (expendable mold)Key terms: Flask, Cope, Drag, Spur, Runner, Gate, Riser, Mold Cavity, Core, Parting Line, Draft (not shown).

Casting Terminology

Parting line

Sand Casting Configuration

Patterns

What is pattern?• Approximate duplicate of product • Patterns are made in the shape of the casting• Pattern Materials: Wood, Plastic or metal.• One piece or multiple piece pattern

Types of PatternsTypes of patterns used in sand casting: (a) solid pattern(b) split pattern(c) match‑palate pattern(d) cope and drag pattern

Pattern Making

One piece or Solid Pattern

Cope & Drag PatternMatch Plate Pattern

Split Pattern

Pattern AllowancesShrinkage AllowancePatterns are made larger than the casting to compensate contraction of the liquid while freezing.For internal cavities the allowances should be negative.

Machining AllowanceAllowance required to remove the rough cast surface. 2 to 25 mm (0.1 to 1’)

Draft Allowance To facilitate ease of removal, usually ½ to 2 deg.

Shrinkage allowance

Normal shrinkage: Cast iron 0.83 to 1.3%Aluminum - 1.3%

Cores

• Cores are used to create internal cavities.

• Should have similar properties as the mold.

• Shaken out after casting is produced.

Casting Process

1

Mould

2

3

Dolly

4

5

Sprue Pins

6

7

8

9

10

11

12

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