LAB SESSION NO 4

Experiment # 3:

Objective:
To prepare a sand mold using a split piece pattern.

Apparatus:
Work material required:
 Molding Sand.
 Clay powder.

Tool required:
 Double piece pattern block.
 Cope.
 Drag.
 Rammer.
 Strike off bar.
 Sprue pin.
 Riser cut.
 Vent rod.
 Gate cutter.
 Trowels.
 Lifter.

Fig # 1 material and tool which require

Related theory:

ONE PIECE OR SOLID PATTERN:

It is simplest type of pattern. As the name suggest the pattern is made from one piece
and does not contain loose piece or joints. It is expensive. It is used for making a few
large size simple casting s. One piece pattern is usually made up of wood or metal
depending upon the quantity of casting to be produced. Stuffing box of steam engine
may be cast with the help of one piece pattern.

Fig # 2 single cavity

Double cavity or split pattern:

Patterns of complicated shape cannot be made of one piece because of

inherent difficulties associate with molding operation. Such patterns are
made as split or two piece pattern. The upper and the lower part of the
split pattern are accommodated in the cope and drag portions of the mold
respectively. Dowel pins are used for keeping the alignment between the
two parts of the pattern. Taps and Water stop-cocks are produced with the
help of split pattern.

Fig # 3 Double cavity Fig # 4 double piece pattern block

Advantages:
Design flexibility:
The size and weight of parts can range from a few millimeters & grams to meters &
many tons. The size and weight of the cast are only limited by the restriction imposed by
molten metal handling and supply. Hence large parts can be produced.
High-complexity shapes:
No other process offers the same range of possibilities for shaping complex features as
casting that produces near-net-shape components.
Wider material choice:
Virtually all types of engineering alloys can be cast as long as it can be melted.
Low-cost tooling:
Tooling and equipment costs are low compared to other metal manufacturing
processes. Hence making it one of the cheapest methods to achieve near net shape
components

Disadvantages:
Low material strength:
Low material strength due to high porosity compared to a machined part.
Low dimensional accuracy:
Shrinking and the surface finish dimensional accuracy is very poor.
Poor surface finishes:
Due to internal sand mold wall surface texture.
Defects unavoidable:

Like any other metallurgical process, defects or quality variations such as shrinkage,
porosity, pouring metal defects, surface defects are unavoidable. Porosity is high on
sand casts compared to other casting processes such as Die casting and investment
casting.
Procedure:

 First we prepare molding sand. It is a refractory material used for making mold .it is
a mixture of different material like silica clay and water.

Fig # 5 molding sand

 The mold box, pattern, tools and the table/floor are cleaned.

Fig # 6 cleaned tool

 Enter the half pattern into the drag. Pattern is the replica of the part to be cast
these are are made of wood or metal. The pattern is always made larger than
the final object to be made.

Fig # 7 pattern into drag

 The drag is filled with mold sand after positioning the round on the table.

Fig # 8 mold sand filed into drag.

 The mold sand is rammed carefully and the excess sand is struck off.

Fig # 9 ramming sand Fig # 10 stuck off extra sand

 Tilt the drag upside down and sprinkle clay powder on top of it.

Fig # 11 sprinkle clay powder

 The cope is positioned on top of the drag. And enter second half pattern.

Fig # 12 cope is on the drag

 Position the square pin, then fill the cope with sand and ramming is done and the
excess sand is struck off.

Fig # 13 Cope is ready

 Remove the sprue pin and the riser pin carefully. Sprue is the passage through which
the molten metal from the pouring basin reaches the mold cavity it is a vertical
channel which connect the poaching basin to the runner. And riser is a reservoir of
hot molten metal used to flow of hot metal back into mold cavity when there is a
reduction of volume of metal due to solidification.
 Fig # 14 pins are remove

 Apply water on the edges of the pattern and remove it carefully using the draw spike
and then finish the cavity.

Fig # 15 cavity are make

 Vent holes are made using vent wire.

Fig # 16 vent hole make on cope

 Now pour molten metal into mold cavity and wait for metal cool.

Fig # 17 pouring molten metal into the cavity

 Break open mold to remove the metal casting.

 Result:
Thus the required work piece are made.

Fig # 18 work piece

Conclusion:
 In the split pattern the mold is made up from one part and then the other part is
placed.

 The split pattern is pressed and split the mold to take away the pattern.

 The joining of mold is carefully to make sure there is no parting line.

 After the casting the baked sand is not useable.

 And outside of baked sand is mold sand which is useable.