Foundry Workshop:

A foundry is workshop in which casting of metal is done. 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. In this process, parts of desired shapes and sizes can be formed. Some of the commonly used tools
in foundry shop for molding process are shovel, trowel, riddle, rammer, draw spike, swab, vent wire and
slick tool.
Foundry processes can be divided into two types:-
➢ Ferrous foundries
➢ Non-ferrous foundries
Foundry processes involve making the mold and the core, melting and pouring the metal into the mold,
and finally removing the mold and core and finishing the product.

Accessories:
❖ Molding Box: Molding or molding (see spelling differences) is the process of manufacturing by
shaping liquid or pliable raw material using a rigid frame called a mold or matrix. This it may have
been made using a pattern or model of the final object. A mold is the counterpart to a cast. Sand is
filling in the mold and pattern is put into it.

Figure 1: Molding Box

Molding box consists of following parts:

➢ Upper part (cope)

➢ Lower part drag)
➢ Molding board
➢ Sprue
➢ Runner (thinner)
➢ Riser (thicker)
➢ Gate
❖ Pattern: In casting, a pattern is a replica of the object to be cast, used to prepare the cavity into
which molten material will be poured during the casting process. Patterns used in sand casting may be
made of wood, metal, plastics or other materials.
 Figure 2: Pattern

Pattern is of two types:

➢ Single Pattern
➢ Split Pattern
❖ Ladle: In metallurgy, a ladle is a vessel used to transport and pour out molten metals. Ladles are
often used in foundries and range in size from small hand carried vessels. Ladle is made of ceramics
material.

Figure 3: Ladle

❖ Chalk Powder or Clay: To avoid stickiness.

Figure 4: Chalk Powder

❖ Molasses: The application of molasses as a binder in sand mold operation.
❖ Roller: To smoother the surface

Figure 5: Roller

❖ Rammer: A rammer is a wood or metal tool used for ramming or packing the sand in
the molding box. It has two parts peen and butt. Rammers are available in different designs and
constructions.

Figure 6: Rammer

❖ Vent Wire: Vent wire is a thin rod or wire carrying a pointed edge at one end and a wooden handle
at the other end. Vent wire is used to make small holes called vents in the sand mold.

Figure 7: Vent Wire

❖ Cutting Scale: To remove extra sand.

Figure 8: Cutting scale

❖ Lifter: Lifter is used to remove sand from edges.

Figure 9: Lifter

❖ Slick: A slick is used for repair and finishing the mold surface after the removal of pattern. It is a
double ended tool having a spoon on one end and a flat on the other end Fig.

Figure 10: Slick

❖ Sand Mixer Machine: 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.

Figure 11: Sand Mixer Machine

❖ Pneumatic Press: A forming press, commonly shortened to press, is a machine tool that changes
the shape of a work piece by the application of pressure. The operator of a forming press is known as
a press-tool setter, often shortened to tool setter.

Figure 12: Pneumatic Press and Compressor

❖ Sand Separator: Sand separator is used to remove grit or other rock particles from sand.

Figure 13: Sand Separator

❖ Gas Furnace: Gas furnace is used to convert solid metal into liquidify form at high temperature.

Figure 14: Gas Furnace