NIT JAMSHEDPUR

LAB MANUAL

FOUNDRY SHOP
Objective:

• To comprehend the elementary fundamentals of Casting process.

• To provide an acquaintance platform to exercise basic engineering
confined to Foundry shop.
• To address the use and importance of numerous tools.

Outcome:

• Able to address casting process with clarity.

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Introduction INTRODUCTION
A foundry is a metal casting manufacturing facility. Or the place where jobs are prepared by
melting and pouring the molten metal into the moulds is known as foundry. In simple words,
It is the workspace where all the facilities are facilitated to manufacture product by casting
process. The casting process is one of the simple and oldest traditional method to make
complicated product economically.

Figure 1 Basic elements of Casting process.

Casting is one of oldest and one of the most popular processes of converting materials into final
useful shapes. Casting process is primarily used for shaping metallic materials; although it can
be adopted for shaping other materials such as ceramic, polymeric and glassy materials. In
casting, a solid is melted, treated to proper temperature and then poured into a cavity called
mould, which contains it in proper shape during solidification. Simple or complex shapes can
be made from any metal that can be melted. The resulting product can have virtually any
configuration the designer desires. Casting product range in size from a fraction of centimeter
and fraction of kilogram to over 10 meters and many tons. Moreover, casting has marked
advantages in production of complex shapes, of parts having hollow sections or internal
cavities, of parts that contain irregular curved surfaces and of parts made from metals which
are difficult to machine. Several casting processes have been developed to suit economic
production of cast products with desired mechanical properties, dimensional accuracy, surface
finish etc. The various processes differ primarily in mould material (whether sand, metal or
other material) and pouring method (gravity, pressure or vacuum). All the processes share the
requirement that the material solidify in a manner that would avoid potential defects such as

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shrinkage voids, gas porosity and trapped inclusions. Any casting process involves three basic
steps, i.e. mould making, melting and pouring of metals into the mould cavity, and removal
and finishing of casting after complete solidification. The elements of casting process
illustrated in Figure 1.

A suitable and workable material possessing high refractoriness in nature can be used for mould
making. Thus, the mold making material can be metallic or non-metallic. For metallic category,
the common materials are cast iron, mild steel and alloy steels. In the non-metallic group
molding sands, plaster of paris, graphite, silicon carbide and ceramics are included. But, out of
all, the molding sand is the most common utilized non-metallic molding material because of
its certain inherent properties namely refractoriness, chemical and thermal stability at higher
temperature, high permeability and workability along with good strength. Moreover, it is also
highly cheap and easily available.

BASIC INGREDIENTS TO PREPARE MOULD

The general sources of receiving molding sands are the beds of sea, rivers, lakes, granular
elements of rocks, and deserts. The common sources of molding sands available in India are as
follows:

• Batala sand ( Punjab)

• Ganges sand (Uttar Pradesh)
• Oyaria sand (Bihar)
• Damodar and Barakar sands (Bengal- Bihar Border)
• Londha sand (Bombay)
• Gigatamannu sand (Andhra Pradesh)
• Avadi and Veeriyambakam sand (Madras)

Molding sands may be of two types namely natural or synthetic. Natural molding sands contain
sufficient binder. Whereas synthetic molding sands are prepared artificially using basic sand
molding constituents (silica sand in 88-92%, binder 6-12%, water or moisture content 3-6%)
and other additives in proper proportion by weight with perfect mixing and mulling in suitable
equipments. The main constituents of molding sand involve silica sand, binder, moisture
content and additives.

SILICA SAND: Silica sand in form of granular quarts is the main constituent of molding sand
having enough refractoriness which can impart strength, stability and permeability to molding

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and core sand. But along with silica small amounts of iron oxide, alumina, lime stone,
magnesia, soda and potash are present as impurities. The chemical composition of silica sand
gives an idea of the impurities like lime, magnesia, alkalis etc. present. The presence of
excessive amounts of iron oxide, alkali oxides and lime can lower the fusion point to a
considerable extent which is undesirable. The silica sand can be specified according to the size
(small, medium and large silica sand grain) and the shape (angular, sub-angular and rounded).

BINDER: In general, the binders can be either inorganic or organic substance. The inorganic
group includes clay sodium silicate and port land cement etc. In foundry shop, the clay acts as
binder which may be Kaolonite, Ball Clay, Fire Clay, Limonite, Fuller’s earth and Bentonite.
Binders included in the organic group are dextrin, molasses, cereal binders, linseed oil and
resins like phenol formaldehyde, urea formaldehyde etc. Organic binders are mostly used for
core making. Among all the above binders, the bentonite variety of clay is the most common.
However, this clay alone cannot develop bonds among sand grins without the presence of
moisture in molding sand and core sand.

MOISTURE: The amount of moisture content in the molding sand varies generally between
2 to 8 percent. This amount is added to the mixture of clay and silica sand for developing bonds.
This is the amount of water required to fill the pores between the particles of clay without
separating them. This amount of water is held rigidly by the clay and is mainly responsible for
developing the strength in the sand. The effect of clay and water decreases permeability with
increasing clay and moisture content. The green compressive strength first increases with the
increase in clay content, but after a certain value, it starts decreasing. For increasing the
molding sand characteristics some other additional materials besides basic constituents are
added which are known as additives.

KINDS OF MOULDING SAND

GREEN SAND: Green sand is also known as tempered or natural sand which is a just prepared
mixture of silica sand with 18 to 30 percent clay, having moisture content from 6 to 8%. The
clay and water furnish the bond for green sand. It is fine, soft, light, and porous. Green sand is
damp, when squeezed in the hand and it retains the shape and the impression to give to it under
pressure. Molds prepared by this sand are not requiring backing and hence are known as green
sand molds. This sand is easily available and it possesses low cost. It is commonly employed
for production of ferrous and non-ferrous castings.

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DRY SAND: Green sand that has been dried or baked in suitable oven after the making mold
and cores, is called dry sand. It possesses more strength, rigidity and thermal stability. It is
mainly suitable for larger castings. Mold prepared in this sand are known as dry sand molds.

LOAM SAND: Loam is mixture of sand and clay with water to a thin plastic paste. Loam sand
possesses high clay as much as 30-50% and 18% water. Patterns are not used for loam molding
and shape is given to mold by sweeps. This is particularly employed for loam molding used for
large grey iron castings.

FACING SAND: Facing sand is just prepared and forms the face of the mould. It is directly
next to the surface of the pattern and it comes into contact molten metal when the mould is
poured. Initial coating around the pattern and hence for mold surface is given by this sand. This
sand is subjected severest conditions and must possess, therefore, high strength refractoriness.
It is made of silica sand and clay, without the use of used sand. Different forms of carbon are
used to prevent the metal burning into the sand. A facing sand mixture for green sand of cast
iron may consist of 25% fresh and specially prepared and 5% sea coal. They are sometimes
mixed with 6-15 times as much fine molding sand to make facings. The layer of facing sand in
a mold usually ranges from 22-28 mm. From 10 to 15% of the whole amount of molding sand
is the facing sand.

BACKING SAND: Backing sand or floor sand is used to back up the facing sand and is used
to fill the whole volume of the molding flask. Used molding sand is mainly employed for this
purpose. The backing sand is sometimes called black sand because that old, repeatedly used
molding sand is black in color due to addition of coal dust and burning on coming in contact
with the molten metal.

PARTING SAND: Parting sand without binder and moisture is used to keep the green sand
not to stick to the pattern and also to allow the sand on the parting surface the cope and drag to
separate without clinging. This is clean clay-free silica sand which serves the same purpose as
parting dust.

CORE SAND: Core sand is used for making cores and it is sometimes also known as oil sand.
This is highly rich silica sand mixed with oil binders such as core oil which composed of linseed
oil, resin, light mineral oil and other bind materials. Pitch or flours and water may also be used
in large cores for the sake of economy.

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 BASIC ELEMENTS OF GATING SYSTEM
POURING BASIN: It is the conical hollow element or tapered hollow vertical portion of the
gating system which helps to feed the molten metal initially through the path of gating system
to mold cavity. It may be made out of core sand or it may be cut in cope portion of the sand
mold. It makes easier for the ladle operator to direct the flow of molten metal from crucible to
pouring basin and sprue. It helps in maintaining the required rate of liquid metal flow. It reduces
turbulence and vertexing at the sprue entrance. It also helps in separating dross, slag and foreign
element etc. from molten metal before it enters the sprue. Figure 2 for better visualisation.

Figure 2 Basic elements of Gating system

SPRUE: It is a vertical passage made generally in the cope using tapered sprue pin. It is
connected at bottom of pouring basin. It is tapered with its bigger end at to receive the molten
metal the smaller end is connected to the runner. It helps to feed molten metal without
turbulence to the runner which in turn reaches the mold cavity through gate. It sometimes
possesses skim bob at its lower end. The main purpose of skim bob is to collect impurities from
molten metal and it does not allow them to reach the mold cavity through runner and gate.

GATE: It is a small passage or channel being cut by gate cutter which connect runner with the
mould cavity and through which molten metal flows to fill the mould cavity. It feeds the liquid
metal to the casting at the rate consistent with the rate of solidification.

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CHOKE: It is that part of the gating system which possesses smallest cross-section area. In
choked system, gate serves as a choke, but in free gating system sprue serves as a choke.

RUNNER: It is a channel which connects the sprue to the gate for avoiding turbulence and gas
entrapment.

RISER: It is a passage in molding sand made in the cope portion of the mold. Molten metal
rises in it after filling the mould cavity completely. The molten metal in the riser compensates
the shrinkage during solidification of the casting thus avoiding the shrinkage defect in the
casting. It also permits the escape of air and mould gases. It promotes directional solidification
too and helps in bringing the soundness in the casting.

PATTERN
A pattern is a model or the replica of the object (to be casted). It is embedded in molding sand
and suitable ramming of molding sand around the pattern is made. The pattern is then
withdrawn for generating cavity (known as mold) in molding sand. Thus, it is a mould forming
tool. Pattern can be said as a model or the replica of the object to be cast except for the various
al1owances a pattern exactly resembles the casting to be made. A pattern prepares a mold cavity
for the purpose of making a casting. The common materials used for making patterns are wood,
metal, plastic, plaster, wax or mercury.

ADVANTAGES OF WOODEN PATTERNS

• Wood can be easily worked.

• It is light in weight.
• It is easily available.
• It is very cheap.
• It is easy to join.
• It is easy to obtain good surface finish.
• Wooden laminated patterns are strong.
• It can be easily repaired.

DISADVANTAGES

• It is susceptible to moisture.
• It tends to warp.
• It wears out quickly due to sand abrasion.

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 • It is weaker than metallic patterns.

TYPES OF PATTERNS: The types of the pattern and the description of each are given as
under.

• One piece or solid pattern

• Two piece or split pattern
• Cope and drag pattern
• Three-piece or multi- piece pattern
• Loose piece pattern
• Match plate pattern
• Follow board pattern
• Gated pattern
• Sweep pattern
• Skeleton pattern
• Segmental or part pattern

SINGLE-PIECE OR SOLID PATTERN: Solid pattern is made of single piece without

joints, parting lines or loose pieces. It is the simplest form of the pattern. Typical single piece
pattern is shown in Fig. 10.1.

TWO-PIECE OR SPLIT PATTERN: When solid pattern is difficult for withdrawal from
the mold cavity, then solid pattern is splited in two parts. Split pattern is made in two pieces
which are joined at the parting line by means of dowel pins. The splitting at the parting line is
done to facilitate the withdrawal of the pattern.

TOOLS
HAND RIDDLE: Hand riddle is shown in Figure 3 (a). It consists of a screen of standard
circular wire mesh equipped with circular wooden frame. It is generally used for cleaning the
sand for removing foreign material such as nails, shot metal, splinters of wood etc. from it.
Even power operated riddles are available for riddling large volume of sand.

SHOVEL: Shovel is shown in Figure 3 (b). It 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.

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RAMMERS: Rammers are shown in Figure 3 (c). These are required for striking the molding
sand mass in the molding box to pack or compact it uniformly all around the pattern. The
common forms of rammers used in ramming are hand rammer, peen rammer, floor rammer and
pneumatic rammer which are briefly described as

SPRUE PIN: Sprue pin is shown in Figure 3 (d). It is a tapered rod of wood or iron which is
placed or pushed in cope to join mold cavity while the molding sand in the cope is being
rammed. Later its withdrawal from cope produce a vertical hole in molding sand, called sprue
through which the molten metal is poured into the mould using gating system. It helps to make
a passage for pouring molten metal in mold through gating system.

STRIKE OFF BAR: Strike off bar (Figure 3 (e)) is a flat bar having straight edge and is made
of wood or iron. It is used to strike off or remove the excess sand from the top of a molding
box after completion of ramming thereby making its surface plane and smooth. Its one edge is
made beveled and the other end is kept perfectly smooth and plane.

MALLET: Mallet is similar to a wooden hammer and is generally as used in carpentry or sheet
metal shops. In molding shop, it is used for driving the draw spike into the pattern and then
rapping it for separation from the mould surfaces so that pattern can be easily withdrawn
leaving the mold cavity without damaging the mold surfaces. Figure 3 (f) for reference.

DRAW SPIKE: Draw spike is shown Figure 3 (g). It is a tapered steel rod having a loop or
ring at its one end and a sharp point at the other. It may have screw threads on the end to engage
metal pattern for it withdrawal from the mold. It is used for driven into pattern which is
embedded in the molding sand and raps the pattern to get separated from the pattern and finally
draws out it from the mold cavity.

VENT ROD: Vent rod is shown in Figure 3 (h). It is a thin spiked steel rod or wire carrying
a pointed edge at one end and a wooden handle or a bent loop at the other. After ramming and
striking off the excess sand it is utilized to pierce series of small holes in the molding sand in
the cope portion. The series of pierced small holes are called vents holes which allow the exit
or escape of steam and gases during pouring mold and solidifying of the molten metal for
getting a sound casting.

LIFTER: Lifters are shown in Figure 3 (i). They are also known as cleaners or finishing tool
which are made of thin sections of steel of various length and width with one end bent at right
angle. They are used for cleaning, repairing and finishing the bottom and sides of deep and

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narrow openings in mold cavity after withdrawal of pattern. They are also used for removing
loose sand from mold cavity.

TROWELS: Trowels are shown in Figure 3 (j). They are utilized for finishing flat surfaces
and joints and partings lines of the mold. They consist of metal blade made of iron and are
equipped with a wooden handle. The common metal blade shapes of trowels may be pointed
or contoured or rectangular oriented. The trowels are basically employed for smoothing or
slicking the surfaces of molds. They may also be used to cut in-gates and repair the mold
surfaces.

SLICKS: Slicks are shown in Figure 3 (k). They are also recognized as small double ended
mold finishing tool which are generally used for repairing and finishing the mold surfaces and
their edges after withdrawal of the pattern. The commonly used slicks are of the types of heart
and leaf, square and heart, spoon and bead and heart and spoon. The nomenclatures of the slicks
are largely due to their shapes.

SWAB: Swab is shown in Figure 3 (l). It is a small hemp fiber brush used for moistening the
edges of sand mould, which are in contact with the pattern surface before withdrawing the
pattern. It is used for sweeping away the molding sand from the mold surface and pattern. It is
also used for coating the liquid blacking on the mold faces in dry sand molds.

BELLOWS: Bellows gun is shown in Figure 3 (m). It is hand operated leather made device
equipped with compressed air jet to blow or pump air when operated. It is used to blow away
the loose or unwanted sand from the surfaces of mold cavities.

GATE CUTTER: Gate cutter (Figure 3 (n)) is a small shaped piece of sheet metal commonly
used to cut runners and feeding gates for connecting sprue hole with the mold cavity.

MOLDING BOXES: Molding boxes are shown in Figure 3 (o) which may be made of wood,
cast-iron or steel and consist of two or more parts. The lower part is called the drag, the upper
part the cope and all the intermediate parts, if used, cheeks. All the parts are individually
equipped with suitable means for clamping arrangements during pouring.

LADLE: It is commonly used to receive molten metal from the melting furnace and pour the
same into the mold cavity. Its size is designated by its capacity. Small hand shank ladles are
used by a single foundry personal and are provided with only one handle. It may be available
in different capacities up to 20 kg. Medium and large size ladles are provided with handles on
both sides to be handled by two foundry personals. They are available in various sizes with

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their capacity varying from 30 kg to 150 kg. Extremely large sizes, with capacities ranging
from 250 kg to 1000 kg, are found in crane ladles. Figure 3 (p) for reference.

Figure 3 Foundry tools (a) Riddle, (b) Shovel, (c) Hand rammer, (d) Sprue pin, (e) Strike off
bar, (f) Mallet, (g) Draw spike, (h) Vent rod, (i) Lifter, (j) Trowels, (k) Slicks, (l) Swab, (m)
Bellows, (n) Gate cutter, (o) moulding flask, and (p) Ladle.

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 SAFETY PRACTICE

1. Always wear apron in the shop.

2. Don’t throw sand on each other during working.
3. Don’t waste the moulding sand.
4. Prepare sand properly before start working.
5. Select cope and drag part of proper fitting.
6. Place the pattern properly and carefully in the moulding box.
7. Draw the pattern carefully from the moulding box.
8. Never put water on molten metal, this can cause a huge explosion.
9. Never pour molten metal over wet floor.
10. Foundry shop should be properly ventilated as fumes and other chemicals may be toxic.
11. Always use glasses during casting.
12. Never use damaged or dropped crucible.

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 EXPERIMENT
Aim: To prepare a green sand mould by using single piece wooden pattern cube.

Material Required: Green Sand

Tools and Equipment required: Showel, Trowel, Rammers, Sprue Pins, Draw Spike,
Strike off bar, Slick, Lift, Ventwire, Hand bellow, Sprit Level, Moulding Box and given
pattern.

Procedure
1. First of all prepare the sand properly before start working.
2. Select cope and drag part of proper fitting.
3. Place the drag part on moulding board.
4. After filling the drag part with sand start ramming.
5. Now place the pattern in the sand so that the parting line remains on the upper plane of
the drag.
6. Ram the sand properly from all sides around the pattern.
7. Then by ramming and putting sand make surface plane around the pattern with the help
of strike off bar and rammer.
8. Sprinkle a fine layer of parting sand over the drag surface.
9. Place the cope part of the moulding box over the drag portion.
10. Place two sprue pins in the vertical positions.
11. Fill the moulding box with sand.
12. Ramming is done to compact the sand.
13. After ramming excessive sand is removed with the help of strike off bar.
14. Take out the sprue pins.
15. Check the level with the help of sprit level.
16. Small holes are pierced into the level surface of the cope with vent wire.
17. Then cope part is lifted up very carefully.
18. Then pattern is taken out with the help of draw spike.
19. Pouring basin, gates and runners are made.
20. Loose sand is taken out with lifter and hand bellow, then cope is place over the drag
portion.

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Precautions:
1. Prepare sand properly.
2. Ramming should be done properly.
3. Pattern should be drawn carefully from the mould.
4. Repair of moulding cavity should be done carefully.

JOB Figure:

Result:

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