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Kingdom of Saudi Arabia Ministry of Higher Education

Umm Al-Qura University College of Engineering and Islamic Architecture

Mechanical Engineering Department

Sand Molding Arrangement , Design and Production B.sc Project

Prepared By : 1-Ahmad Mohammad Tarmom. 2-Naief Ali Al-Malki

3-Abdullah Abdurrahman Al-Faqasi 4-Meshari Eidhah Al-Juaid

5-Faisal Mohammad Bashaikh 6-Assaf Saleh Al-Khathami

7- Ali Ahmad Al-Omari

Supervised By : Dr. Ahmed Hassan

Casting is a liquidus for process, includes

melting the metal, pouring it in a pre-shaped mould and allowing it to solidify.

Sand casting process is a metal process in which natural sand, containing a proportion of clay to bind the grains of sand together and water, or a

pure silica sand with an artificial binder added to it, is contained in a flask

ABSTRACT

(the name given to a pair of matching molding boxes) and compressed by

hand, or mechanical ramming, around a pattern.

In this project a sand molding arrangement was designed and

produced to simulate the automatic sand molding machine.

INTRODUCTION

MOLDING MACHINES

EXPERMENTAL WORK

CONCULOUSION

CHAPTER ONE

INTRODUCTION

INTRODUCTION

Sand Casting

Types Of Sand Mold

Uses and Advantages

Disadvantages of Sand

Casting

INTRODUCTION

* Casting is a liquidus for process, includes : melting the metal, pouring it in a pre-shaped mould and allowing it to solidify.

Sand Casting

* Sand casti ng process is a metal casti ng process in which a natural sand , containing a proporti on of clay and water to bind the grains of sand together.

When two fl asks are parted, the patt ern and the dowels forming the sprue system are removed, a negati ve mould shape is left in the sand. The molten metal is poured into this cavity.

Types Of Sand Molds

Types Of Sand Molds

Green sand mold:

It is the most common mold

Green mold sand is a

mixture of sand,

clay, and water Green sand

molding is the least expensive

method "of making 'molds.

Cold-box mold:

In this process, various organic and inorganic

binders are blended into the sand to

bond tae grains chemically for

greater strength

No-back mold :

In this process, a synthetic

liquid resin is mixed with the

sand, and mixture

hardens at room

temperature Because

molding of the mold in this

and the cold-box process takes place

without heat

Uses and Advantages

It can be used to produce complex and huge shapes, such as cast-iron engine

blocks and very large propellers for ocean liners.

Sand casting can be economical for relatively small production runs, and

equipments cost are generally low

Disadvantages of Sand Casting

1- The surface finish obtained is largely a function of the materials used in making the mold.

2- Dimensional accuracy is not so good as that of other casting processes.

CHAPTER Two

Sand Molding Machines

Sand Molding Machines

Introduction.

Advantages of Sand Molding

Machines

Automatic Molding Methods

Introduction

•The objective of automatic molding is to produce accurate parts able to withstand lifting and handling .

• Molding Machine enables moulds to be produced at high rates .

• The principal feature of molding machine is the use of power operated mechanisms for mould compaction; this mechanization can extend in varying degrees to pattern withdrawal and mould part manipulation

Advantages of Sand Molding

Machines

•1- Eliminate labor cost.

• 2-Offer high quality casting by improving the application and distribution of forces.

• 3-Manipulate the mold in a carefully controlled fashion .

• 4-Increase the rate of production

Automatic Molding Methods

Automatic Molding Methods

Jolt and squeeze

compaction

vertical flaskless molding

Impact molding

Jolt and squeeze compaction

Vertical Flaskless Molding

Impact Molding

CHAPTER THREE

Experimental Work

Experimental Work

Introduction.

Project Parts

Assembly and

Operation

Process Procedure

Introduction

•Sand molding process was a hand process. And it is developed to be an automatic process.

•In this project a sand molding arrangement was designed and produced to simulate the automatic sand molding machine

Project Part

Project PartsPneumatic cylinder and its

squeeze

heads

Frame

structure

Flasks Pattern

Riser,

sprue and runn

er

Plate

Pneumatic cylinder and its squeeze heads

lWe select pneumatic cylinder with bore

D = 10 cm

that is available Commercially and to be more efficient , while the stroke is taken

L= 10 cm .

Frame structure

Flasks

Pattern

Riser, sprue and runner

Plate

Assembly and Operation

Process Procedure

•1- All parts are assembled on the plates including the flasks for making cope and drag . •2- The flasks were filled with sand

•3- The two assembled flasks then placed under the squeeze head of the arrangement one by one.

•4- The sand was compacted using the repeated impact of the squeeze head

•5- After squeezing, the plate with pattern, sprue and riser removed .

• 6- The flasks (cope and drag ) were bolted together .

•7- The molten metal is poured through the sprue to fill the mold .

• 8- The molten metal is left to cool, the casting extracted from the sand mold and cleaned

Conclusion

4.1 Conclusions :

1 - T h e s a n d m o l d o b t a i n e d h a v e a g o o d f o rc e d i s t r i b u t i o n b e t t e r t h a n t h e m a n u a l l y r a m m e d

2 - T h e s a n d m o l d i n g p ro c e s s t a k e s m a l l t i m e c o m p a re d w i t h t h e m a n u a l l y o n e .

3 - T h i s m e a n t h a t t h e p ro d u c t i o n r a t e i s i n c re a s e d . 4 - T h i s a r r a n g e m e n t w i l l b e g o o d e x a m p l e f o r t h e s a n d m o l d i n g m a c h i n e f o r t h e

s t u d e n t s o f t h e f o u n d r y c o u r s e .

Recommendation

4.2 Recommendation :

1 - T h e f o rc e t h a t f o r m t h e m o l d i s a s s u m e d d e p e n d i n g o n e x p e r i e n c e a n d n e e d s e v e r a l e x p e r i m e n t s t o f i n d t h e o p t i m u m f o rc e .

2 - T h e o p e r a t i n g v a l v e s i s w o r k i n g m a n u a l l y a n d c a n b e c h a n g e d t o o p e r a t e a u t o m a t i c a l l y .

3 - U s e t h e c o m p re s s o r w i t h h i g h e r p re s s u re r a t e w i l l h e l p t o re d u c e t h e m o l d i n g t i m e .

THANK You