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    Unit I Foundry All

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    velavansu
    Foundry engineering deals with the casting process, including pattern making, moulding, melting, casting, finishing, and inspection. The main stages are pattern making, moulding and core making, melting and casting, fettling, and testing. A variety of furnaces are used for melting ferrous and non-ferrous metals. Moulds are prepared using sand which is prepared and tested. Different gating systems and casting processes like gravity die casting and shell moulding are used to produce castings. Castings are inspected and cleaned before final testing and use.

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    Unit I Foundry All

    Uploaded by

    velavansu
    285 views58 pages
    Foundry engineering deals with the casting process, including pattern making, moulding, melting, casting, finishing, and inspection. The main stages are pattern making, moulding and core making, melting and casting, fettling, and testing. A variety of furnaces are used for melting ferrous and non-ferrous metals. Moulds are prepared using sand which is prepared and tested. Different gating systems and casting processes like gravity die casting and shell moulding are used to produce castings. Castings are inspected and cleaned before final testing and use.

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    Foundry engineering deals with the casting process, including pattern making, moulding, melting, casting, finishing, and inspection. The main stages are pattern making, moulding and core making, melting and casting, fettling, and testing. A variety of furnaces are used for melting ferrous and non-ferrous metals. Moulds are prepared using sand which is prepared and tested. Different gating systems and casting processes like gravity die casting and shell moulding are used to produce castings. Castings are inspected and cleaned before final testing and use.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    285 views58 pages

    Unit I Foundry All

    Uploaded by

    velavansu
    Foundry engineering deals with the casting process, including pattern making, moulding, melting, casting, finishing, and inspection. The main stages are pattern making, moulding and core making, melting and casting, fettling, and testing. A variety of furnaces are used for melting ferrous and non-ferrous metals. Moulds are prepared using sand which is prepared and tested. Different gating systems and casting processes like gravity die casting and shell moulding are used to produce castings. Castings are inspected and cleaned before final testing and use.

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    of 58

    Introduction

    Foundry Engineering deals with the process of making casting in moulds prepared by patterns Stages:
    1. 2. 3. 4. 5. Pattern making Moulding and core making Melting and casting Fettling Testing and inspection

    Foundry Hand Tools

    Foundry Hand Tools

    Foundry Hand Tools

    Foundry Hand Tools

    Foundry Hand Tools - LADLES

    Foundry Hand Tools- CRUCIBLES

    Melting Equipments
    In order to obtain the proper pouring and melting temperature of the metal several furnaces are used: For ferrous metals:
    Cupola furnaces Open heart furnaces Electric furnaces

    For non-ferrous metals:


    Pit Type Stationary type Tilting Type

    Cupola
    Used for melting for cast iron. Low cost. Better control of temp and chemical composition. Easy tapping. Consumes easily available fuels.

    Electric Furnace
    High Temp. Fast Melting. Controlled atm. For large quantities. High cost and maintenance. Fumes, smoke and noise.

    Oil / Gas fired Rotary Furnace

    Moulding
    Mould is a void or cavity created in a compact sand mass with the help of pattern. Core is a sand shape exactly similar to the cavities to be produced in casting. Generally made differently in a core box. Permanent moulds are made up of ferrous metals and alloys, normally used for casting of low melting point material, costly Temporary refractory moulds are made of refractory sands and resin, for high melting points and bigger objects, Cheap.

    Main constituents of Moulding sand


    Principle Constituents: Silica Sand
    Major Portion, 80-82 % High Softening Temperature and thermal Stability, chemical resistively and permeability. Found in banks and bottom of rivers.

    Binders
    Imparts sufficient strength and cohesiveness, but decreases permeability of sand. Organic, in-organic and Clay are used.

    Additives Water

    Additives of Moulding sand

    Additives of Moulding sand

    Sand Grains

    Properties of Moulding Sand


    Porosity or Permeability Flowability or Plasticity Refractoriness Adhesiveness Cohesiveness Collapsibility Durability Fitness Bench life Co-efficient of expansion Chemically Neutral Reusable, Cheap and Easily available

    Classification of Moulding Sand

    Special Sand

    Special Sand

    Special Sand

    Preparation Moulding Sand

    Sand Testing

    Moulding Process
    According to the method Used: 1. Floor Moulding Foundry floor acts as drag and may be covered with cope or may be casted open. Used for all medium and large casting 2. Bench Moulding For small and light moulds Done in cope and drag 3. Pit Moulding Moulding for extremely large casting is done in pit Pit acts as drag and separate cope can be used to make gates and runners

    Moulding Process
    4. Machine Moulding All the jobs of ramming, moulding and gate making, drawing of pattern is done by machines. Produces identical and consistent castings Preferred for the mass production

    Moulding Process

    Moulding Process

    Moulding Process

    Moulding Process

    Gating System
    Gating System means all the passages through which the molten metal enters the mould cavity. Includes: Pouring basin Runner Gate Riser It has great impact upon the quality of the casting produced.

    Requirement of Gating System


    Low flow velocity of molten metal. Insure complete filling of cavity. Prevent absorption of moisture while flow. Prevent formation of oxides. Prevent entry of slag, dross etc. Assist directional solidification. Should be practical and economical.

    Types of Gates
    1. 2. 3. 4. Top Gate Bottom Gate Parting Gate Step Gate

    Types of Gates

    Special Casting Processes

    Gravity Die or Permanent Mould Casting


    Molten metal is poured under gravity only. Uses permanent moulds; can be reused many times Made of grey cast iron; inner surface coated with refractories. Made in two halves with built-in gating system.

    Centrifugal Casting
    Mould is rotated rapidly about its central axis as the metal is pored into it. Centrifugal force plays major role in shaping and feeding of the casting. C.F. helps to distribute the molten metal evenly to all surfaces and separates the slag from out flowing molten metal. Three types:
    1. True Centrifugal 2. Semi Centrifugal 3. Centrifuge

    True Centrifugal Casting

    True Centrifugal Casting

    Semi Centrifugal and Centrifuge Casting

    Carbon dioxide Moulding


    This process is basically a hardening process for the moulds and cores. As Co2 gas is passed through a sand mixture containing sodium silicate, the sand immediately becomes extremely strong bonded as sodium silicate becomes a stiff gel giving the necessary strength to the mould. Pure dry silica is mixed with 3-5% sodium silicate and water; and is rammed in the moulding box. Co2 is forced into mould at high pressure. Additional hardening may be done by baking.

    Carbon dioxide Moulding

    Carbon dioxide Moulding

    Shell Moulding
    The sand mixed with thermosetting resign is allowed to come into contact with heated metallic pattern plate. A thin and strong shell of mould is formed around the pattern. The shell is removed from the pattern and paced in cope and drag with backing material and molten metal is poured for casting.

    Shell Moulding

    Rotational Shell Moulding

    Shell Moulding

    Casting Defects

    Casting Defects
    1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Blow holes Porosity Shrinkage Hot tears Drop Metal Penetration Fusion Shot metal Shift Swells Hard Spots Warpage

    Casting Defects

    Casting Defects

    Casting Defects

    Casting Defects

    Casting Defects

    Casting Defects

    Cleaning of Casting (Fettling)


    After casting has solidified it is removed form the mould and is cleaned to remove the runner risers cores etc. 1. Rough Cleaning 2. Surface cleaning
    Wire brush Sand blasting Shot Blasting

    3. Finishing 4. Inspection of casting


    Destructive and Non-Destructive

    Inspection of casting
    Destructive Cutting samples and examining properties Tensile, Compression and Torsion Testing Non-Destructive Visual Inspection Dimensional Inspection Pressure Testing Radiographic Inspection Magnetic Inspection

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