Manufacturing Technology Laboratory

Experiment 7
FOUNDARY SHOP- The Sand casting

Submission details

Submitted by: Pratyush Raj

Date of Experiment: 19-Mar-2021
Date of Submission: 26-Mar-2021
On-time/Late Submission (Provide On time submission
details):

Submitted to
Donga Ramesh Kumar
Department of Mechanical Engineering, UPES
Title of the Experiment
Foundry experiment- prepare an aluminium casting using sand mould.

Introduction
In simplified terms, a Foundry is a factory where castings are produced by melting
metal, pouring liquid metal into a mould, then allowing it to solidify. In order to
understand a foundry, you need to understand the casting process. The general
steps involved in casting are patternmaking, molding, melting, pouring, ejection,
cleaning, fettling, and inspection.

Fig.1 A representation of sand casting in Foundry shop(taken from web)

Aim of the Experiment

 To prepare an aluminium casting using sand mould and observe it for defect
identification.
Objective of the experiment
 Create product using sand casting
 Identify the casting defects.

Materials and machine required

 Aluminium scrap
 Open hearth furnace
 Sand
 Wooden pattern
 Moulding box
 Swab, gate cutters etc
 Crucible

1
Theory
 Casting is the process of creating a final product by melting and solidifying it
in a preformed mould.
 Sand casting is one of the casting methods.
 A sand mould is created by patter
 Molten metal is poured inside the mould.
 Casting is taken out for secondary operation.

Parts of the Sand Mold

Sprue: It is a part from which the molten metal poured into cavity. Sprue design is
one of the crucial parts of the mold. When fluid (molten metal) flows into cavity there
is changes in various energy heads (potential, Kinetic, and pressure) but total energy
head will be constant.
Use Bernoulli’s principle to find the height of sprue. For non-pressurised gating
system, both ends of the sprue will be at atmospheric pressure.
Let us take point at the top is 1 and at the bottom. For the pressurized gate, metal is
poured with the pressure.

2
Pattern
Pattern is used to create the cavity of the final part. It is a replica of the final part
having some allowance so that the final part will have the designed dimension.
Patter is having three main allowances that are shrinkage allowances, machine
allowances, shaking allowance. The pattern is making somewhat large in dimension
then final casting to accommodate solid-state shrinkage during solidification of the
cast. machining allowances give us the freedom to machine the cast after casting so
that good finishing can be done. shaking allowances is given for easy removal of the
pattern.

Riser:
Riser is also one of the important of the sand mold.it is provided to serve various
functions. It acts as the indicator of filling of the cavity. It accommodates the liquid
metal shortage during liquid state shrinkage of the casting. It acts as a gas vent also.

Conclusion

 Casting is a primary manufacturing operation.

 Care should be taken while melting and pouring the molten metal.
 Most occurred defects are sand inclusion and incomplete fill.
 Other defects can be porosity, mold shift, rat tail penetration.