FOUNDRY

1) INTRODUCTION
There are various manufacturing process by which a product can be
made. Each process however has it's own place & can be particularly adopted
to certain specific operations.

Foundry of casting is a process of forming metallic products by melting

the metal, pouring into acavity known as mouid. This product is cleaned &
machined to desired dimensions. Moulds can be made of metals or non
metals butgenerally they are prepared in sand.
The basic steps in making a casting can be set forth as
1) Patten making.
2) Mould and core making

3) Melting andPouring
4) Cleaning and casting.
Pattern Niaking:-This is the first step in casting of a job. This patern is the
model of job and is made up of suitable material like wood or metal. Pattern is
used to make the mould.

Mould andcore making :- Mould is the cavity whict. is formed wish the help
of pattern in a suitable mould material commonly the moulding sand.
Sometimes a hole or a recess is required in casting. This is achieved by
placing a suitable core in the mould shape of core corresponding to the shape
of hole of recess. The cores are usually made up of sands having
compositions much different from moulding sands.

Melting and Pouring :- Once the mouBd is made it is ready to receive molten
metal. At this stage the metal is melted in a suitabl srface depending upon
the amount and the nature of the metal. When the metal is incomplete molten
state it is tapped ina suitable ladle and then poured in the :ould
Cleaning :- After the metal has been poured in the mould, the whole thing is
allowed to cool thus solidifying the metal. When process of solidification is
complete the casting is taken out. The casting of this stage however is not in
the same form in which it is desived to be and it is cleaning is very essential.
The process of cleaning is done in two steps as a) all extra parts like spunces,
gates, risers etc are removed b) surface of casting is cleaned by the sand &
other foreign paticles sticked to its surface.
PATTERN :- Pattern is the model made up of 'suitable metalvial like wood,
plastic, etc. and is used for making the cavity in moulding sand or in sorme
other moulding material.

PATTERN MATERIALS :- Following are the materials which are very

common in pattern making.

(1) wood (2) metal (3) plastic (4) Plaster (5) Wax. But before selecting a
particular material for pattern making the following must be taken into
account.

i) No. of castings to be produced.

ii) Mould materials used.

ii) Type of moulding process.

iv) Min. thickness required.

WOOD :;- Wood is the most common material used for pattern making. The
main characteristics of used which makes it as popular are as follows : (1)
easy to work with (2) readily available (3) Lightness (4) Easily fabricated into
various forms (5) It can be preserved with shellac.

However it has its disadvantages too. It is readily affected by moisture,

it changes its shape when moisture dries out of it. It wears out quickly and if
not properly stored it may warp badly. So wood patterns are preferred only
when small no. of castings are to be produced.
2) TYPES OF PATTERNS:

1)Single piece pattern :A pattern that is made without joints,. parking or any
loose piece in its construction is called a single piece of solid pattern These
pattern are cheaper.

2) Two piece of split pattern : These patterns are made up of two pieces
which are joined. These patterns are at the parting line by means of dowel
pins. The splitting at the particular line is done to facilitate withdrawn of
pattern.

3) Multiple of loose piece pattern: Many patterns which are complicated in

shape cannot be prepared of one or two pieces because of difficulty in
withdrawing pattern. In such a case pattern is made up of loose pattern. Here
the main part is removed first and then the loose or separate parts are taken
Out.

4) Match plate pattern: In this case the pattern is in the twohalves mounted

on opposite sides of a Wooden of metallic plate known as match

plate. The
for
gates are runners are also attached to the plate. This pattern is sued
producing small casting in large quantaties in moulding maciiines. Which give
the initial
Occurate and rapid production. They are expensive to construct but
cost isjustified when quantity production is desired.
parts of the mould are
5) Cope of Drug pattern : In this case cope & drag
heavy to be
prepared separately. This is done when complete mould is too
halves which are
handled by one operation. The pattern is made up of two
moulded on different parts.
patterns become
6) Follow Board pattern: When the use of solid er split
the pattern is
difficult acavity corresponding to exact shape of oie half of
and it acts as a
made in wooden board which is called to Follow board
moulding board too the first moulding operation.
multicavity moulds are
7) Gated pattern: IN this mass production of casting,
used. Such moulds core formed by joining a no. of pattens and gates are
 4

providing a common runners for the molten metals and metallic pieces to form
gates and runners are attached to pattern.

8)Sweep pattern :Sweep patterns are used for forming large circular moulds
by revolvinga sweep attached to a spindle. Actually a sweep is a sample of
Wood or metal and is attached to spindle at one edge and others edge has a
contour depending upon the desired shape of the mould. The principle
advantage of this method is that is eliminates expensive pattern construction.
9) Skeleton pattern : When a large no. of big castings are to be made it is

not economical to make asolid pattern. In such case skeleton pattern canbe
of the
used. This is a ribbed construction of wood which forms the outline
pattern to be made. This frame work is filled and rammed with claysand or
loous and a stripe off board is used to scrap the excesS and out of space
between ribs.

used circular
10) Segmental pattern : Patterns of this type are generaliy
sections. Of
castings for eg. Wheel, rin, gear plank, etc. such patterns are
moved to form each
pattern so arranged as to form a complex mouid by being
the use of
section of mould the movement of segmental pattern is guicded by
control pinot.

3) MOULDING TOOLS ANDEQUIPMENTS:

groups viz
Foundry tools & equipments may be classified into three
hand tools, flasks and mechanical tools.
HAND TOOLS:
moulding sand and
1) Showel :A Showel is used for mixing a tempering
for moving the sand from the pipe to the flask.
circular or a
2) Riddle : Ariddie sometimes called a sereen consists of a
botton. t is
square wooden frarne fitted with standard wire much at the
used for removing foreign particales from moulding sand.
3) Rammers : A hand rammer is a wooden tool used for packing or

ramming sand into the mould. One end called the peen, is wedge
shaped and the opposite and called butt has a flat surface.

4) Trowel: A trowel consists of awooden blade fitted wooden handle.

Trowels are employed in order to 1month or sleek over the surfaceof
the usual trowelmoulds is rectangular.
5) Slick:It is small double ended tool having a flat side on one end.

various
6) Lifters: Lifter are made up of very thin sections of steel of
widths and lengths with the end but at right angle. They are used to
clean and finish the bottom and the sides of deep narrow opening in

the mould.

7) Strike off Bar : It is piece of metal or wood with a straight edge. It is

used to strike off or strickle excess of sand from the mould after
rammingto provide a level surface.
8) Spruce Pins : A spruce pin is a tapered pin pushed through the cope
to the joint of the mould. As the peg is withdrawn it removes the sand
leaving on opening for the metal. This opening is cailed the sprue
through which the metal is poured. The sprue pin forms the riser pin.

9) Bellows : They are used to blow loose particles of sand from the
paüern &also from the mould cavity.
10) Swabs : Asimple swab is a simple brush having long limp fibres, a
bulb swab has arubber swab bulb to hold water & a soft heur brush at

the open end. Swabs are used for moistering the sand ground the
cavity.
11)Gate cutter: It is a small piece of atiny plate. This server as a tool for
cutting gates &runners in the mould.
12) Mallet : Mallet is used to loosen pattern in mould so that it can be
withdrawn without the damage to the mould.
 13) Vent Rod: Avent rod of a wire is used make a series of small holes

to permit the gases to escape. While the molten metal is bring poured.
14)Draw spike or Dowel pins or scrue: Draw spike is apointed steel
rod, with a loop at other end. It is used to draw pattern frorn the mould.
15) Moulding Board : It is a smooth wooden board on which flasks &
pattern are kept when moulding is started.
16) Moulding Boxes:Sand moulds are prepared in specially constructed
boxes called flasks. The purpose of the flask is to impart the necessary
rigidity & strength to the sand in moulding. They are usually made in
two parts, top part is called cope /lower part is drag. If it is 3part, the
centre part is called cheek box.

4)TYPES OF MOULDING SANDS :

1) Natural moulding sand : Natural moulding sands are green sands

and are obtained from river beds are dug from pits. It has two advantage of
maintainingthe mixture for a longer time.
2) Synthetic moulding sand : It is prepared in foundry by mixing a
relatively clay free sand with selected clay. The desired strength and the
bonding properties of these sands are developed by clay matter & moisture
content.

TYPES CF SANDS MOULD

1) Green Sand : it is mixture of silica sand with 18-30% clay having total
water of 6-80%. It is fire, soft, light & porous-mould material prepared in this
sand are called green sand mould.
2) Dry sand:Green sand that has been dried or halved after the mouBd is
made is called dryy sand. They are suitable for long castings.
3) Loangsand : It is mixture of clay a mounting as much as 50% or so
and dries hard. This is particularly employed from loan moulding usually for
large casting.
 7

4) Facing Sand : Itforms the face of the mould. It is used directly next to
pattern and comes in contact with molten metal. Here it must be porous high
strength &refractarinecs. It is made up of silica sand &clay without hddition of
water.

5) Baking Sand : It is also called floor sand & it is used to back up the
facing sand &to fillthe vol of flask.

6) Parting Sand: This sand is sprinkled on the pattern &parting surface

ot the mould so that the sand mass of one flask does not stick So that of other

or to the pattern sand &dry silica sand are used for this purpose.
7) Core Sand:Sand which carries a high silica contract and issued form
making core is known as core sand.

5) PROPERTIESOF MOULDING SAND

Flowability : It refers to its ability to behave like a fluid so that when
1)
rammed it will flow to all positions of mould.
Collapsibility: After the molten metal in the mould gets solidified, the
2)
occurs &
sand mould must be collapsible so that free contraction of the metal
this mould avoid the crackingof the contracting metal.
Adhesiveness : The sand particles must be capable of adhering to
3)
the
each other and also to other body i.e. they sould cling to the sides of
moulding boxes.
Cohesiveness of strength: This is the ability of sand particles to stick
4)
together. The strength of mouldingjand must therefore be sufficient to permit
the mould to be formed to tha desired shape and to retain its shape even after
the hot metal is poured in the mould.

5) Refractoriness: The sand must be capable of withstanding the high

temp of the molten material without fusing. Moulding sands with poor
refractoriness may burn on to castings.
 8

6) Porosity : The sand must be porous enough to allow the gapes of

metal or moisture present within the moulds to be removed freely when the
moulods are poured. This property is called as porosity.

The different types of furnaces depends upon the metal to be nolten. It

can be broadly classified as into two types.

1) Ferrous metals and allay melting furnaces.

2) Non-ferrous metals and alloy metal melting furnaces.
1) Ferrousmetals /alloy melting furnaces are.
a) Blast furnace (b) Bessemer converter (c) Open hearth furnace
d) Cupola (e) Induction furnace.
2) Non-Ferrous metals &alloy melting furnace.
a) Reverbatory furnace b) Pit furnace c) Dil till furnace

d) Metal pot furnace.

The different defects in casting are (1) Shifts (2) Warpage (3) Swell
(4) Blowholes (5) Drop (6) Dirt (7) Sponginess (8) Metal peyetration (9) Sand
holes (10) Pin holes (11) Scabs (12) Shrinknge (13) Hot tears (polis) (14)
Cold shut &mis run (15) Powered short (16) Internal air pocket.

6) SAND ADDITIVES:

(i) Facitg material : They are used to provide a smooth surface on the
coating casing. Different forms of carbon are used because carbon wil! glow
& give ff yases but it will not melt. Charcoal, gas carbon, coke dust.
plumbagoor graphite may be used.
(ii) Fire clay : It consists of hydrated ammoniumsilicate. It offers a good
bond when mixed with burnt sand.

(ii) Clay - wash : It is a mixture of fire clay & water. It is used in the
foundry where a strong bond is required.
(iv) Parting material: They are parting sand which contains no bond. A
non-silica partingcompound is made from powdered phosphate rock.
(v) Binders: Flours, resins, linseed oil, cereal products, dextrine,
molasses etc. are used. Dextrine is the best. It increases air setting strength
toughness &collapsibility &permit prevents sand from drying rapidly.

MELTINGFURNACES FOR EERROUS METALS

1) Cupola : Cupola is used to produce from of desired composition temp
& properties at the req. state in the most economical manner cupola
capacities vary from 1to 15 tonnesof melted iron per hour.
2) Blast Furnace : It is a vertical furnace designed for continuous
operation. The iron inthis furnace pickS up 3.4% carbon.

8) MELTING FURNACE FOR NON-FERROUS METALS

1) Crucible Furnaces : They are also of two types

a) Pit type b) Tilting type.

a) Pit Type : It is a pit below ground level. It is usually fired with coke,
sufficient coke being pocket round & above the crucible pot to melt &
superheat the charge.
b)Tilting Type : They are mounted on two pedestals / rotated by means of a
geared hand wheel. Furnace is fixed by coke, oil orgas.
2) Metal Pot Furnaces:The alloys of Al, Mg, Au, Zn, Pb, cd, Sn can be
melted in a metal pot which is usually made of Cl or steel.

9) CLEANING OF CASTINGS: Castings when tanen out of the mold are

not in same condition in which they are desired. Since they have spruce,
risers, gatrs, etc attached to them. The operaiicn of cuffing off unwanted
parts, cleaning &finishing the casting is known as fettling. This includes.
 10

1) Removal of cares from the castings.

2) Removal of gases, risers, grunners etc frorm the casting.

3 Removal of pins &other unwanted projections from the casting.
4) Removalof adhering sand &oxide scale from surface of casting
5) Repairing castings to fill up blowholes, straighting the warped or
deforming castings.
Dry sand cares may be removed by rapping or knockingwith iron bar.
Gates, risers, spruees & runners, are removed by knocking off or

breaking with hammer, sawing, torch cutting. electric are cutting abrasive
wheel cutting etc.

Sand is removed by wire brushes or small scale or by using tumbling

barells &sand blasting machines. The castings are loaded with jack stars
made of white cost iron. Rotation of the barell caves. The casting to tumble 8
abrade against one another.
Sometimes pickling in suutable acid helps in removing any adhesive
sand from the casting.
 2) OPERATION FOR FLOORMOULDING
Sr. No. Procedure for Moulding Tools & Materials

required
1 Make a ig &pit according to pattern. Sand bed
(Fuoundry fioor)
2 Fix the pattern on the sand bed. Pattern

3 Ramming should be done. Hook / peg & Flat /

But rammer.
(Hook/peg ramming three times, Flat rainring
one time)

4 Remove the additional sand with strical Strical bar

5 Make a layout equal level to pattern &sand bed. Spirit Level.

Check-up the layout of sand bed & apply theTrawel.
parting sand.

7. Put the cope boX on the sand bed. Cope box.

8. Fix the gate pins. (sprue pins) Rur:ner & Riser

Fiithe moulding sand in the cope box. Moulding sand.

10. Ramming should be done. Hook/peg & Flat
rammer.

11. Remove the moulding sand with strical. Strical bar.

12. Sprinkle the parting sand. Parting sand.

13. Venting should be done. (top to bottom /full) Venting wire.

14. Fix the marking pins / side pins. Vedges pins.
15. Take out the gate pins. Runner/ Riser.

16. Lift up the cope box from the sand bed &Aside Foundry flocr.
on the foundry floor.

17. Cleaning should be done parting sand. Brush/Cotton.

 12

Sr. No. Procedure for Moulding Tools & Materials

required
18. Apply the water & take out the pattern from Drawspike, Draw
mould. Scrue.

19 Cut the in gates &cleaning & finishing. Should Cleaner, Travel,

be done of mould cavity. Gate cutter.

20 Apply the plambago powder. Plambago powder,

Dry wash, Graphite,
French chock
powder.

21. Bake & plane the cope on the mould cavity in its
proper Position &mould is ready for pourirg.
 NEW STA.NDARD ENGIIEERItlG. CO.Lo
CONSTRUC TION Df JOLT SOUEEZE STRIPPER
MOUL DING MAHINE MODCL FD-2A/1A
w

CAP

SQUEEZE HEAO

ÇOLUMN
ORAW BAR
ME TAL
JOLTCYLIDER,

-DRAW 3AR
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TON

CYLINDER

PISTON RiNG
FCR 53UEEZE
PISTON RÍNG.
FOR JOLT

LEATHER PACK0NG
FOR DRAW
 FoUNDRy 700L S
Mesh.

Wooden
Pan handle

Frarme
Fig. Il. 1. Shovcl. Fig. 11.2. Riddlc. Fig. 11.9. Trowels.

Peen

Butt

(b) Foor rammer. (c) Peen rammer. (d) Pneumatic rammer.

(a) Hand rammer.
Fig. l}.3. Types of rammer.

PEG
Fig. I1.4. Vent wire. Fig. I1.5. Slick. Fig. l1.6. Lifter.
Brush

HoOK.R.
Simple 6) Bulb
Blb
Beloas

Fig. l1.10. Gate cutter.

Fio | 13 Sorue cutter. Fig, 11.14. Mallet.
(a) Draw spike. (3) Draw sCrew.

Fig. 0.12. Strike-of[-bar.

Fig. 11.6. Clamps. Fig. 1.!5. Gaggers.
 Fig. I1.17. Rapping plates.

wooden moulding tox.

Fig.11.21. Typical

Fig. li.18. Spirit level.

(b) Bull ladle.

(a) Hand or shank ladle.
Retractory.
sleeves
Moncrail Hand wheel
EGG-SMooTHER lor pouring
Trollay Raising and Pouring
lever
jowering
handwheel
Stopper Pouring hcie
Douring (graphite) (graphite)
(e) Bottom stoppered ladle
(c) Crane or moncrail iaile. (d) Tea pct ladle.
Fig. 11.28. Types of ladles.

PI PE SMO0THER
BACHA-90X
Cope

Drag
SAEE-END
SMO0THER Fig. Il.19. Box type of flask. Fig. !1.20. Srap flask.

RoUN DED,E FLANG EEORNER

SQUHRE FLANGE
cORN ER
RoUN DEFDCE
CORNER
)

S9uAR EDGE 2UTTEN

ROUND EDGE, EXTERNAL
CORNER SioUTEER
EXTE RNAL
OR- BULL-CORNER
 BEAD TO0LS_
FLUETED BEp 7. 2) GRDER 700L
bFL ANGG BEPD 7. (4CIRC VLAR BED 70
STRAIGHT BEAD7. (6) sLEAKER DOG, TIIL
1SPOOA 700L .

Lo
rig
 TYPES oF PATERNE
Core

Fig 10.3. Sold pattern.

\Dowel pin
Fig. 10.17. Splitcore box
Strickle board

Fig. 10.4. Splitpattem.

Cor

Core sand
,18. Suickle core box.

(a) (b)
Fig. 10.19. Right and left hand core box.

Loose piece for Loose piece for

right hand core left hand core

Core boX

Fig. 10.20. Loose piece core box.

Core

Fig. 10.16. Half core box,

core box,
Fig. 10.21. Gang
 Strikle board

Rib Loam sand

Fig 10.10.Skeleton pattem.

Plate Pattern

{a) Curved sweep. (b) Sraight sweep

Fig. 10.9. Sweep pattcrn.

Fig. 10.6. Match plate pattem.

-Ch.

Main
patlern k-Dra
Pin

Loose (a) (b)

Piece
: Fig. 107 LooSe piece pattern. Fig. 10.5. Multipiece pattern.
Gate

Fig.
Parting
10.8.
Sp1ndie Gted

pattern.

Fig. 10.l. Shell pattern.

Fig. 10,12. Scgmental pattenn.

 (3)

Head Head

(a) (b)
Fig. 10.14, Lagged up pattern.

SPARK ARRESTER

Fig. 10.13. Follow board pattern.

A
Textbook of Workshop Technolog STACK
LINING
-Hub SHELL
Core-print
METAL CHARGES

riMESTONE,
COKE CHARGES
ZONE "A"
LINING SHELF

COKE DED
ZCNE s
SLAG SPOUT
ZONE

(a) (b) LFoo BorTOM DOOR IN

OROPPED POSITION
Fig. 10.IS. Leít and right hand pattern TAPPING SPQU
80TTOMPLATE
SAND BoTTOM e
FLOOF GAATE PEFRACTORY LIC
BAICK LINING
CAUCIBLE CHIANEY Fig. 6.5 Cupola furnace

nFROM
BLOWEF

Fig. 6.! Pit type coke-fired crcible lurmce

140 Pinciples oi Foundy Technology

POUAING SPOUY

BOTTOM SPQUT
(FOREe RGGNC )

tig. ó oil hre' titing tyle crucible furaac

CRUCIBLE LIFTING TONG.

CRDCIBLE (TELT|NG POT