Assignment No # 1

Topic:
Introduction TO New Foundry Techniques
Subject:
Foundry Engineering (Met 208)
Session:
2018-22
Submitted By:
Muhammad Hasnain Gul
Roll No:
MME-18-31
Introduction TO Foundry
 A foundry is a factory that produces metal castings.
 Foundry is the concept of machinery equipment’s,
man power and other power resources.
 Metals are cast into shapes by melting them into a
liquid, pouring the metal in a mold and removing the
mold material or casting after the metal has
solidified as it cools.
 The most common metals processed area
aluminium, bronze, zinc and cast iron.
 Foundry contain mainly metal casting, furnaces,
molding and other process.
 New technologies and techniques enter in foundry
and factories.
Types OF Foundry
Foundry processes can be divided into two types.
 Ferrous Foundries
 Non-Ferrous Foundries
Foundry processes involve making the mould and the
core, melting and pouring the metal into the mould and
finally removing the mould and core and finishing the
product.

Foundry Technique & Technology

Foundry technology is the art and science of the
processes and materials used in manufacturing castings
from metal and alloys.
In metalworking, casting involves pouring liquid metal
into a mold, which contains a hollow cavity of desired
shape and then allowing it to cool and solidify.
Casting is most often used for making complex shapes
that would be difficult or uneconomical to make by other
methods.
Importance OF Foundry Techniques
& Technology
 Foundry processes are continuously developing to
improve the quality of products and production
efficiency, and take advantage of new technologies.
 Breakthroughs in development have enabled
significant advances in metal casting at key
moments in the industry’s history.

Advantages OF Foundry Techniques

& Technologies
When different techniques and technologies entered in
factory then lot of benefits are creates for all of us.
 Less work
 Less time
 Low cost machine
 Less man power
 Good productivity
Disadvantages OF Foundry
Techniques & Technologies
There are following disadvantages of foundry techniques
and technologies.
 More work.
 Lot of man power required.
 Lot of money for buy machines.
 Lot of space occupy old type factory.
Advanced Foundry Technology
Parts or components for:
 Construction machinery
 Housings
 Gear manufacture
 Plastics processing machinery
 Agricultural machinery
 Impellers, rollers
 Machine bases and beds
 Pulleys
 Textile technology
 Gear cutting machines
 Machine tools
Advance Foundry Techniques
Some of the latest techniques are described in the
following:
 Molding Techniques
- Injection Molding
- Blow Molding
- Compression Molding
 Casting Techniques
- Investment Casting
- Die Casting
- Lost Foam Casting
- Centrifugal casting
 Pattern Making and Core Making Techniques

 Molding Techniques
The first major stage in founding is the production of
mould with its impression of the casting and its planned
provision for metal flow and feeding.
The basic techniques of molding and core production
will be reviewed:
- Injection Molding
 Injection molding is a manufacturing process for
producing parts by injecting molten material into
a mould.
 Material for the part is fed into a heated barrel,
mixed (using a helical shaped screw), and injected
into a mould cavity, where it cools and hardens to
the configuration of the cavity. It is the latest process
developed in the industry of foundry.
 Injection molding can be performed with a host of
materials mainly including metals, glasses and most
commonly thermoplastic and thermosetting
polymers.

Injection Molding Machine

- Blow Molding
 Blow molding is a manufacturing process for forming
and joining together hollow plastic parts.
 It is also used for forming glass bottles or other
hollow shapes.
 In general, there are three main types of blow
molding: extrusion blow molding, injection blow
molding, and injection stretch blow molding.

Blow Molding Machine

- Compression Molding
 Compression Molding is a method of molding in
which the molding material generally preheated, is
first placed in an open, heated mould cavity.
 The mould is closed with a top force or plug

member, pressure is applied to force the material

into contact with all mould areas,
while heat and pressure are maintained until the
molding material has cured.
 Compression molding is a high-volume, high-
pressure method suitable for molding complex, high-
strength fiberglass reinforcement.
 Advanced composite thermoplastic materials can
also be molded by this technique.
  Casting Techniques
Casting is a process in which a liquid metal is poured into
a mold to solidify.
Different casting techniques are used but modern and
advanced are following:

- Investment Casting
 Investment casting is an industrial process based on
and also called lost-wax casting, one of the oldest
known metal-forming techniques. Lost-foam casting
is a modern form of investment casting that
eliminates certain steps in the process.
 The process is generally used for small castings, but
has been used to produce complete aircraft door
frames, steel castings of up to 300 kg(660 lbs) and
aluminium castings of up to 33kg(66 lbs).
 It is generally more expensive per unit than die
casting or sand casting but has lower equipment
costs.
 It can produce complicated shapes that would be
difficult or impossible with die casting, it requires
little surface finishing and only minor machining.
 Investment Casting Process

- Die Casting
 Die casting is a metal casting process that is
characterized by forcing molten metal under high
pressure into a mould cavity.
 The mould cavity is created using two hardened tool
steel dies which have been machined into shape and
work similarly to an injection mould during the
process.
 The essential feature of die casting is the use of
permanent metal mold, into which molten alloy is
directly poured or injected under pressure, giving
rise to the separate processes of gravity and
pressure die casting.
 Gravity die casting, also referred to as permanent
mould casting, has many features in common with
other processes of metal founding including sand
casting, both in production technique and in type of
product.

Die Casting Process

- Lost Foam Casting

 Lost-foam casting is a type of evaporative-pattern
casting process that is similar to investment casting
except foam is used for the pattern instead of wax.
 Lost Foam Casting Process

- Centrifugal Casting
 Centrifugal casting or rotocasting is
a casting technique that is typically used thin-walled
cylinders.
 It is typically used to cast materials such as metals,
glass, and concrete. A high quality is attainable by
control of metallurgy and crystal structure.
 The essential feature of centrifugal casting is the
introduction of molten metal into a mould which is
rotated during solidification of the casting.
 The centrifugal force can thus play a part in shaping
and in feeding according to the variation of the
process employed.
 Centrifugal Casting Process

 Pattern Making and Core Making

Techniques
 In casting, a pattern is a replica of the object to be
cast, used to prepare the cavity into which molten
material will be poured during the casting process. 
 Patterns used in sand casting may be made of wood,
metal, plastics or other materials.
 Core making is the process which forms the interior
part of the casting. The mould provides a space for
 the molten metal to go, while the core keeps the
metal from filling the entire space.
 Cores can be used to extend mould projections to
create extra mould sections, or to block out and
create negative drafts.
 Some modern techniques are also developed for
core and pattern making.

Molding and Core-Making

 Power operated molding machines
 High pressure molding machines
 Core-blowing machine
 Core drawing machines
 Continuous core making machines
Advance Foundry Technology
Material Handling System
 Material handling equipment is equipment that
relate to movement, storage, control and protection
of materials, goods and products throughout the
process of manufacturing, distribution, consumption
and disposal.
 Material handling equipment is the mechanical
equipment involved in the complete system.
 Material handling equipment is generally separated
into four main categories: storage and handling
equipment, engineering systems, industrial trucks,
and bulk material handling.
Sand Preparation and Control
 Continuous mixer
 Mold ability controller-slotted vibratory feeder
 Integrated Systems
-Sand preparation with mixed resin sand
continuously discharging into a molding box placed
on vibratory compaction table, a pattern loop-mould
stripping device and a shake out with a reclamation
plant.
Melting, Pouring and shakeout
equipments
 Machineries are deployed depends on factors such
as:
-Type and condition of equipment
-Economical feasibility
-Availability of floor space
 Automatic pouring system
  Crane, lift truck, turnover truck, belt conveyor
 Vibrating type shakeout, Bumber type shakeout

Control of dust and fumes

 Fine particles of saw dust in the pattern shop.
 When sand is mixed and prepared during molding,
shake out, feting operation.
 Fumes during melting, metal transfer, pouring
operation.
 Cyclone, Filter, Electrostatic precipitator, Mechanical
collectors, Scrubbers, after burners.
Robotic Automation
 Many operations that are performed in a foundry
are ideally suited for robotic automation, because
they are:
 Three D’s - dirty, dangerous and dull.
 Three H’s – hot, heavy and hazardous.

‘Unimate’
The first industrial robot
 In 1954, inventor George Devol developed a
machine, which he called ‘programmed article
transfer’ and later it was commercialized under the
name ‘Unimate’.
 ‘Unimate’ was installed in a die casting operation in
1961 at Ford Motor Company and its main job was
to unload hot casting from die- casting machine.

Computers in foundries
 Product design and Analysis
-Transferring geometric information from human
mind to a computer
 -FEM (Simulation of stress, Strain, Heat transfer,
Fatique, Fracture)
-CAM (Simulate machining Operation, Accurate and
automatic calculation of geometric properties)
 Casting design and simulation
-Convert part design to tooling design, showing
orientation in the mould, parting line, application of draft
and allowances, core boxes.

Software packages for foundry use

 Magmasoft – Optimization casting and foundry
processes.
 AutoCAST – Knowledge based system for cast
design decision and cast model creation.
 ProCAST – Developed by UES software
- Simulating solidification process
 CastCAE – Mould filling and solidification
simulation
 MeshCAST – Fully automatic 3D mesh generation