JODHPUR INSTITUTE OF ENGINEERING & TECHNOLOGY

MECHANICAL ENGINEERING DEPARTMENT

Ist YEAR B.TECH (2023-24)
1FY3-27/ 2FY3-27: Manufacturing Practices Workshop
FOUNDARY SHOP

OBJECT: To prepare a mould of a given pattern & cast it in aluminum.

TOOLS REQUIRED: Moulder’s Hand Tool Set, Moulding Box, Hand Rammer, Sprue Pin, Riser Pin,
Bellows, Shovel etc.

MATERIAL REQUIRED: Moulding Sand, Parting Sand.

THEORY:

Foundry: -
A foundry is a place that produces metal castings. Metals are cast into shapes by melting them into a
liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it
cools. The most common metals processed are aluminum and cast iron.
Tools and equipment used in Foundry

MOULDING BOARD RAMMER

RISER

LADDLE

RUNNER BRUSH STRIKE-OFF BAR

RIDDLE SWAB
GATE CUTTER LIFTER

JIET/ME/LM/FY3-27 Page 1
 JODHPUR INSTITUTE OF ENGINEERING & TECHNOLOGY
MECHANICAL ENGINEERING DEPARTMENT
Ist YEAR B.TECH (2023-24)
1FY3-27/ 2FY3-27: Manufacturing Practices Workshop
FOUNDARY SHOP

Dowel pins

MOULDING FLASK

SLICK VENT ROD TROWELS SPIKES OR DRAW PIN

CASTING:-
Casting is the oldest method of manufacturing and invariably the first step in the sequence of
manufacturing a product. In this process the raw material is melted, heated to the desired temperature and
poured into the mould cavity where it takes the desired shape.

Applications of Casting
Typical applications of sand casting process are cylinder blocks, pistons, piston rings, machine tool bed,
water supply pipes and specials, bells, linears, mill rolls, wheels and housing.

Pattern
Pattern is defined as a model of a casting or replica of a desired product. The first step in a casting is to
prepare a model known as Pattern.

Pattern Materials
The following materials are commonly used: -
1. wood
2. Metal
3. Plastic
4. Quick setting compounds

JIET/ME/LM/FY3-27 Page 2
 JODHPUR INSTITUTE OF ENGINEERING & TECHNOLOGY
MECHANICAL ENGINEERING DEPARTMENT
Ist YEAR B.TECH (2023-24)
1FY3-27/ 2FY3-27: Manufacturing Practices Workshop
FOUNDARY SHOP

Types of Patterns:-

SPLIT PATTERN Sweep Pattern

SOLID PATTERN

Skelton Pattern
MATCH PLATE PATTERN
COPE & DRAG PATTERN

Mould:-
It may be defined as the negative print of the part to be cast and is obtained by the Pattern in the moulding
sand container into which molten metals is poured and allowed to solidly.

Moulding:-
It is an art of making sand mould out of sand by means of pattern and cores so that metal can be poured
into the moulds to produce castings.

Properties of Moulding Sand:-

1. Strength
2. Permeability
3. Flow ability
4. Collapsibility
5. Refractoriness
Constituents of Moulding Sand: -
1. Silica Sand 2. Binder 3. Additives 4. Water
Classification of Moulding Sand: -
1. Natural Sand 2. Synthetic Sand 3. Special Sand

JIET/ME/LM/FY3-27 Page 3
 JODHPUR INSTITUTE OF ENGINEERING & TECHNOLOGY
MECHANICAL ENGINEERING DEPARTMENT
Ist YEAR B.TECH (2023-24)
1FY3-27/ 2FY3-27: Manufacturing Practices Workshop
FOUNDARY SHOP

Types of Mould:-
1. Dry Sand Mould: - Prepared from fine grained sand mixed with suitable binder.
2. Green Sand Mould: - Prepared from natural moulding sand in its green state.
3. Skin dried Mould: - Sand Mould with a dry sand facing and a green sand backing.
4. Loam Mould: - The mould made with a loam (mixture of sand and clay).
5. Metal Mould: - The mould made of metal.
6. Shell Mould: - The mould made of two or more thin shell like parts consisting of thermosetting
resin-bonded sand.

EXPERIMENTAL PROCEDURE:
1. Add molasses & water in sand to prepare moulding sand.
2. Select a moulding box which can accommodate a mould cavity.
3. Place the moulding box on the moulding bench, even surface of pattern should be in contact with the
level surface.
4. In case of split pattern place half part of the pattern on the moulding bench.
5. Sprinkle parting sand over & around the pattern.
6. Invert the drag & place it on the bench keeping the pattern in the center.
7. Fill the drag with loose moulding sand.
8. Ram the sand uniformly in moulding box around the pattern.
9. Fill the drag again, if necessary & ram it.
10. Strip off excess sand over the flask height.
11. Sprinkle the facing sand over the top of the drag.
12. Using trowel give finishing moulding near edge of the pattern.
13. Join the other half part of the pattern to the first half.
14. Make guide ways in the four corner of mould with the help of lifter.
15. Place cope over rammed drag.
16. Place the sprue & runner pin at proper place to form suitable cavities for pouring metals.
17. Fill the cope with loose moulding sand & ram it.
18. Withdraw the sprue pin.
19. Strip off excess sand over the flask height.
20. Sprinkle the facing sand over the top of the cope.
21. Remove the pattern & runner pin from drag.
22. Cut gate between runner & mould cavities

EXPERIMENTAL PROCEDURE OF CASTING:

1. Keep the mould assembly ready for pouring the metal on the floor.
2. Molten metal is prepared in the electric furnace.
3. take the molten metal in the crucible & pour the metal through pouring basin until metal just spoil
over the mould from the vent hole.
4. Allow some time for metal to solidify in the mould then open the moulding box & remove cast
piece.
5. Clean the casting & remove the extra metal.

JIET/ME/LM/FY3-27 Page 4
 JODHPUR INSTITUTE OF ENGINEERING & TECHNOLOGY
MECHANICAL ENGINEERING DEPARTMENT
Ist YEAR B.TECH (2023-24)
1FY3-27/ 2FY3-27: Manufacturing Practices Workshop
FOUNDARY SHOP

Viva Questions:
Q1 Describe the main constituent of moulding sand with their percentage.
Q2 Explain the properties of moulding sand.
Q3 Write down the safety precautions of casting process.
Q4 Give the advantages and applications of casting process.
Q5 Explain various types of furnaces used in foundry.
Q6 Describe the common allowances provided on patterns.

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