LAB SESSION # 2

Experiment # 1

Objective:
Practice for preparation of molding sand mixtures.

Apparatus:
Equipment:
Sand Muller.
Hot Tray Shovel.

Chemicals / Materials:
Sand.
Molasses Water.

Figure # 1 Sand muller.

Related theory:
Silica sand (SiO2) is used more frequently for making castings than any other
moulding materials. It is relatively cheap, and has sufficiently refractoriness even for
steel foundry use. A suitable bonding agent (clay or molasses) is mixed with the
sand; mixture is moistened with water to develop strength and plasticity and to make
the aggregate suitable for molding. A definite mulling action is always required for
thorough mixing, in which sand grains, bonding agent, and water are rubbed
intimately together. Different types of sand mullers are used to serve this purpose.
Sand muller:
A machine for mixing sand and binders by a kneading and squeezing action for use
in sand molds. The mixture is usually sand, clay, and water, but synthetic chemical
binders may be used. Muller wheels are mounted on independent, spring-loaded
suspensions. As the mixture increases in volume and strength, the mullers react by
raising and increasing the mulling pressure. This is a versatile and inexpensive
source of mixing energy which provides the kneading and compression action of
mulling. Muller cells are living optical fibres that guide light through the inner retinal
tissue. Thereby they enhance the signal/noise ratio by minimizing intraretinal light
scattering and conserve the spatial distribution of light patterns in the propagating
image.

Hot Tray Shovel:

Shovel consists of a steel pan fitted with a long wooden handle. It is used in
mixing, tempering and conditioning the foundry sand by hand. It is also used
for moving and transforming the molding sand to the container and molding box
or flask. It should always be kept clean.

Figure # 2 shovel.

Molasses:
Molasses is used in a diverse range of industries due its excellent non-pollutant
binding properties. It can be used as effective sand binder for the
manufacturing of casting moulds. It has an advantage over binding materials as
it does not produce a toxic emission on combustion. The application of
molasses as a binder in sand mold operation was investigated. Standard Sand
Mold mixture (5 cm diameter x 5 cm height) were made with 1-5% molasses
sand the balance.

Figure # 3 Molasses.
Molding sand:
Molding sand, also known as foundry sand, is a sand that when moistened and
compressed or oiled or heated tends to pack well and hold its shape. Molding
sand has three important advantages over other mold materials: it is
inexpensive, it is easily recycled, and. it can withstand extremely high
temperatures. Green sand is an aggregate of sand, bentonite clay, pulverized
coal and water. Its principal use is in making molds for metal casting.

Properties of molding sand:

Strength:
Green strength:
Adequate strength and toughness for making and handling the mold.
Dry strength:
Dry sand must have strength to resist erosion and also the mettalo static pressure of
the molten metal or else the mold may enlarge.
Hot strength:
Hot molten metal Metalloid static pressure of the liquid metal bearing against the
mold walls may cause mold enlargement, or if the metal is still flowing, erosion,
cracks, or breakages may occur unless the sand possess adequate hot strength.
Permeability:
Steam and other gases. The mold must be permeable, i.e., porous to permit the
gases to escape.
Thermal stability:
Heat from the casting causes rapid expansion of the sand surface at the mold-metal
interface. The mold surface may crack, buckle, or flake off (scab) unless the molding
sand is relatively stable dimensionally under rapid heating.
Refractoriness:
The absence of melting, softening, or adherence of the sand to the casting makes for
better casting surface and easier cleaning of the casting.
Flowability:
The sand should pack well/flow under load. Sands of low flowability may result in
non-uniform hardness. Soft molds --- enlargement of the casting or roughness of the
casting surfaces.
Collapsibility:
The molding sand should also have collapsibility so that during the contraction of the
solidified casting it does not provide any resistance, which may result in cracks in the
castings. Besides these specific properties the molding material should be cheap,
reusable and should have good thermal conductivity
Adhesiveness:
The molding sand should collapse during the contraction of the solidified casting it
does not provide any resistance, which may result in cracks in the castings. Besides
these specific properties the molding material should be cheap, reusable and should
have good thermal conductivity.
Cohesiveness:
It is the property of sand due to which the sand grains stick together during ramming.
It is defined as the strength of the molding sand
Reusability:
Since large quantities of sand are used in a foundry it is very important that the sand
be reusable otherwise apart from cost it will create disposal problems.
Easy of preparation and control:
Sand should lend itself to easy preparation and control by mechanical equipment.
Conductivity:
Sand should have enough conductivity to permit removal of heat from the castings.

Experimental procedure:
1. Take silica sand and stack it over hot tray with the help of a shovel.
2. Put on the fire and heat the sand for some time.

3. When it is sufficiently hot, throw it into the pan of muller with a shovel.
4. Then add some amount of molasses in the sand and switch on the muller.
The wheel’s rotation inside the muller will thoroughly mix up sand and
molasses.
5. Continue adding and mixing molasses in the sand until sufficient strength
and plasticity is developed in the sand-molasses mixture.
Conclusion:

 Molding sand, also known as foundry sand, is a sand that when

moistened and compressed or oiled or heated tends to pack well and
hold its shape.
 Using sand molds has several benefits. Sand is inexpensive and can
withstand high temperatures, thus allowing many metals with high melting
temperatures to be cast using the sand-casting process. Sand casting also
accommodates a large size range of parts.