Session 2020-2024

Foundry Engineering-II

Submitted to:

Prof.Dr.Atif Makhdoom
Group no :
07
Submitted by:
Eman Hussain (20mme-S1-314)
M.Nauman Butt (20mme-S1-315)
Taimoor Khawar (20mme-S1-325)
Talha Rasheed Awan (20mme-S1-324)

Institute of Metallurgy and Materials Engineering

Faculty of Chemical and Materials Engineering
University of the Punjab Lahore
Problem Statement :

To calculate and perform four-piece casting of solid cylinder using

aluminum alloy.

PROJECT MANAGEMENT STRATEGY:

Calculations:
• Riser calculations.
• Riser design
• Molding techniques, rechecking the calculations and design and selectionof the
best design for casting.
Experimentation:
• Pattern making.
• Sand and mold making.
• Melting and pouring.
• Defects of casting.
Introduction:
The origin of casting started from ancient civilization and its most common product
was cast iron. With the discovery of new metals concept of alloys begins. Modern
casting includes the latest machine and equipment to produce the best product
which is defect free. [1]

It is defined as;

“It is a process of heating the metal to its molten state and then pouring it into the
mold and the solidify it to desire shape inside it.”
Metal casting process :
The casting process is divided into two categories:[2]

Expendable mold casting :

The casting in which mold is sacrificed to get the final product is known as
expendable mold casting. In this casting, process complex shapes and designs are
possible, but its production is quite slow.[2]

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Non-expendable casting :
Those castings in which mold is not sacrificed to get the final product is known as
nonexpendable casting. In this casting, process manufacture has a high production
rate. However, it has limitations on complex designs.[3]

Parts of gating system :

By gating system, we mean all those elements which help to transfer molten metal
into the mold cavity. The following are the essential parts of gating system.[3]

Pouring basin:
Its main purpose to collect the molten metal from the ladle. It can be circular and
rectangular. In sand casting, pouring basin is usually made with the help of yonkey
lifter. [4]

Sprue:
It collects molten metal from the pouring basin and further transfers it to other parts
of the gating system like runner bar, sprue well and ingate etc. its shape can be
cylindrical and tapered.[4]

Sprue well:
Its main responsibilities is to reduce turbulence in the casting process and
transferring molten to the runner bar. It is located at the bottom of the sprue.[5]

Runner bar and ingates:

Molten metal from sprue well is transfer to long length rectangular or trapezoid
shape bar is called runner bar. Usually, the runner bar is designed in such a way to
overcome slag entrapment in the casting. Ingates are smaller in size as compare to
runner bar. It can be square and rectangle.[4]

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Riser:
The purpose of the riser is to overcome or compensate for the shrinkage which cause
a defect in the casting. It is important to know that riser must be solidified at the last
of the casting.[6]

Complete components of a gating System

Source : google

Types of Riser in casting :

There are two types of risers that are using in the casting process:[7]

Open riser

Those risers which are open to the atmosphere is known as top riser or open riser.
Its size is greater than the blind riser however is easy to mold as compared to the
blind riser.[6]

Blind riser

Those risers which are not open to the atmosphere is known as blind riser. Its size
is smaller than open riser however it is difficult to mold as compared to the open
riser. The solidification of the blind riser is slow as compared to the open riser.[6]

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 Source : Google (Open vs Blind Riser)

Basic rules for designing riser

There are six basic rules for designing a riser:[5]

• The riser must solidify after the casting.

• The volume of the riser must be large enough to compensate for the liquid to
liquid shrinkage.
• The hot spot must not be located between the riser and casting.
• The riser must be placed on that section that has the highest modulus in casting.
• There must be sufficient pressure to drive the liquid metal into locations in
the mold where it is needed.
• The pressure head from the riser should suppress cavity formation and
encourage complete cavity filling.

Observation and Calculations:

As riser is necessary to prevent the volume shrinkage of the casting. According to

modulus method the riser was calculated by considering:[5]

Mr = 1.2 Mc

Mr = Modulus of riser
Mc = Modulus of casting
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Modulus of casting was calculated by dividing the casting into the simplest shapes. And
by calculating their Volumes and areas Modulus of casting was calculated.[5]

After calculating modulus of casting the modulus of riser is obtained by using the above
relation.Now as we have to made a cylindrical riser then then we can calculate the area
and volume of riser in terms of its height and diameter then by assuming the ratio of
height/ diameter the riser was calculated.[6]
Now we as we know about the volume of our casting and also we know about the
density of aluminum. So by using their relation we can calculate the amount of metal
used for our casting as well as for riser.[7]
Aluminum shrinks 5% by volume then the riser has to feed the 5% of total weight of
casting which can be calculated easily.

Riser Calculations of solid cylinder

Length = 10.2cm
diameter = 5.16cm
radius = r = 2.58cm

Figure 01 : pattern dimentions

Volume = V = πR2h

V = 3.14x10.2(2.582)

V = 213.19cm 3

Area = A = 2πR(R+h)

A = 2x3.14x2.58(2.58+10.2)
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 A = 207.066cm2

Modulus of Casting :

𝑉
MC = 𝐴

As, we deduced values of V and A above putting them in equation of Mc , we get the
modulus of the casting , which is

213.19
MC = 207.066

Mc = 1.029m

Cooling Characteristics of casting:

𝐴
Cc = 𝑉

207.066
Cc = 213.19

Cc = 0.97

Modulus of Riser :

Mr = 1.2 Mc

Mr = 1.2(1.029)

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 Mr = 1.235 cm

For h/d = 1.5

So ,
𝒅 𝑴r
=
𝟖 1.5

Re-arranging equation above & putting values , we get

d = 1.235x 8
1.5
d = 6.586cm

h = 1.5 x d

h=1.5x6.586

h= 9.586cm

Figure : Riser dimenstions

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Cooling Characteristics of riser :

𝐴
Cr = 𝑉

2
266.036cm
Cr =
325.80cm3

Cr = 0.81

As Cr < Cc, so it indicates that casting solidifies first than riser.

Riser design:

As the side riser is attached to the casting so effective height of riser is added to the
riser dimensions and 8-degree taper is included to avoid turbulence.

Pipe Height:

𝟔𝐕𝐂 𝐒
𝒉 =
𝝅𝒓𝟐

(𝟔)(𝟐𝟏𝟑.𝟏𝟗)(𝟔)
h = (𝟑.𝟏𝟒)(𝟑.𝟐𝟗𝟑)𝟐

h = 0.02254cm
hence,

hp < hr

height of the pipe being smaller than the height of the riser.

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Riser Neck:

For side riser

𝑑
LN = 2

6.856
LN =
2

LN = 3.293cm

D = 1.2LN + 0.1d
N

D N = 1.2(23) + 0.1(46)

DN = 32.2mm

Yield of casting:

Weight of casting
Yield=
Weight of (Casting+runner+gates+risers) x 100

575.61 X 100
Yield =
575.61+336.3

Yield = 63%

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EXPERIMENTATION:
First Attempt:
Pattern Making:
Firstly, pattern was made from plastic according to the design mentioned.

Figure: Plastic Pattern for solid casting

Sand and Mold Preparation:

After the design was finalized and pattern was made then mold was preparedwith
molasses sand. Molasses sand was prepared by adding 5-8% molasses in the river
sand and mixed it properly and then heated to make proper bond between sand and
molasses and remove moisture from it.
Facing sand was also prepared for better finishing of the casting. Facing sand was
prepared by sieving the river sand from mesh 40/60 and then mixed it with
molasses.[6]

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 Figure : Mold and Sand Making

Failure:

In our first attempt we use hollow plastic pipe to make a pattern but while ramming
the mold became distorted because when we apply pressure on cope and drag so that
plastic pattern got break . The reason behind is the smallest thickness of plastic
pattern which did not bear the load during ramming.

Second Attempt:

Keeping in mind all the defects and their remedies we decided to change some
processes which is explained below:

• We use wooden pattern instead of plastic to give strength during ramming.

• We added calculated flux (Coverall flux) and degasser (Hexachloroethane)in
the melt.
• We properly heated the mold to remove all the moisture from the mold toavoid
the porosity defect

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 Figure : Wooden pattern being rammed and sprinkled with graphite powder

Sand and Mold Preparation:

Molasses sand was prepared by adding 5-8% molasses in the river sand and mixed
it properly and then heated to make proper bond between sand and molasses and
remove moisture from it.
Facing sand was also prepared for better finishing of the casting. Facing sand was

prepared by sieving the river sand from mesh 40/60 and then mixed it with molasses.

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Considering our calculated riser and assumed gating channel we prepared a complete
mould to cast our four piece solid cylinder casting as shown in figure (A). After this
Drag part,was rammed puring basin was created and at the end again cope and drag
part was separated to remove our pattern,riser,neck and gating channel equipments.
It is shown in figure (B).

After removal of all the things we get a complete mould with riser and gating
equipments , now the phase of pouring gets started . material known as aluminium
whose melting point is close to 660.3 C is poured at a temperature close to 950 celcius
after melting usin pit furnace . After pouring, our product was achieved by frettling
action as shown in figure (C)

After mold preparation, the melt was prepared by adding 3.5kg aluminum scrap in
the pit furnace and heat it up to 7500C for 15-20 minutes. Proper fluxing and degassing
were done to avoid porosity defect. After melt was readythe ladle was brought out
from furnace and metal was poured into the mold.

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After solidification of the sample. The gating system was removed and then machining
of each sample is performed by grinding of sample in order to remove the extra material
from the sample.
Grinding was performed on the grinder and then polishing is performed to beautify the
surface of the sample.

Final Product:
After pouring the melt in the mold, the casting was allowed to solidify. After solidification the
casting was extracted out. Cylinders were cut with the help of hacksaw and then machined on
lath machine.

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 Figure-Casting after machining

CONCLUSION:

At the end of our report, we conclude proper fluxing and degassing is required to
avoid the porosity defect. As in our first attempt we did not make the mold due to
plastic pattern But in our second attempt we properly made mold by using wooden
mold and performed casting.

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 REFERENCES:

1. Principles of metal casting chapter no. 09

2. Neuser, M., Grydin, O., Andreiev, A. and Schaper, M., 2021. Effect of Solidification
Rates at Sand Casting on the Mechanical Joinability of a Cast Aluminum
Alloy. Metals, 11(8), p.1304
3. Dr. N. K. Srinivasan (2012). Foundry Engineering (4th edition). (Chap 7-8)
4. Principles of metal casting chapter no. 09
5. Metal casting by ProfKarl B Rundman page no. 56 to 58
6. Kiran R. Jathar, Anant V. Hankare, Amol A. Sapkal (2017). Gating System and
Feeder Design of Aluminium Alloy (AA6063) Casting for Rectangular Component
(Vol. 13).
7. Foundry Engineering Casting Defects, hand notes by Engr. Fahad Ri

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