DEPARTMENT OF TECHNICAL EDUCATION ANDHRA PRADESH

Name Designation Branch Institute Year/semester Subject Subject Code Topic Duration Sub. Topic Teaching Aids : P. Ramulu : Work Shop Supdt., : Mechanical Engineering : Govt. Polytechnic for women, Medak. : I year : Work shop Technology : M-105 : Foundry : 100 Minutes : Moulding sand , their Properties Types, Ingredients : Animation Clips & Images

Recap
In the previous class , you have learnt Hand moulding tools and their uses Moulding flask for making mould using pattern Shovel used to lift and mixing the sand Riddle for screening the sand Rammer for packing the sand Bellow for blowing the loose sand

Objectives
On completion of this period , would be able to know about What is meant by Moulding sand Properties of moulding sands Types of Moulding sand Ingredients in Moulding sand

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What is Moulding sand

Consists of sand with clay or binder Used to make mould Can be re-used

Fig 1. Moulding Sand

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Properties of Moulding Sand

Porosity (permeability) : A porous material. Gap between sand particles provides passage for flue gases. Plasticity: Acquires the shape of pattern . Deforms to required shape. Contd..
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Properties of moulding sand

Flowability: It flows into corners and deeper into moulding box. Collapsibility: Can be broken into particles and can be reused.

Contd..
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Properties Of Moulding Sand

Adhesiveness : Adheres to surface of pattern and moulding box Cohesiveness : Ability of sand particles to stick each other . Refractoriness : Withstands high temperature . Withstands heat of molten metal .
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Types of Moulding sand

Natural sand Synthetic sand Special sand

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Natural sand
Sand collected from river beds. Sand collected from pits Added with (5-20%) of clay. Clay develops strength and plasticity. Used for non-ferrous casting and gray cast iron castings. Also called greensand.

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Fig 2. Natural Sand

Synthetic sand
It is clay free sand. Mixture of sand ,bentonite(3 to 5%)(binder) ,water (3 to4%). Used for ferrous castings.

Fig 3. Synthetic Sand

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Special Sand
It is high refractory sand. Used for accurate castings Examples are Zirconium Olivinite Chromite Magnesite Chamott
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Advantages of synthetic sand over natural sand

More uniform grain size.
High permeability Mould ability Easier control of properties Suitable for variety of castings

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Limitations
High initial cost
Patching is difficult Dries out fastly Skilled labour is required

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Classification according to the initial condition

Green sand Dry sand Loam sand . Facing sand Backing sand . System sand Parting sand Core sand

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Green sand

Foundry sand containing moisture Green refers the moisture content. Silica sand (18-30%) of Clay+(6-8%) of water Can be re-used Used for small and medium castings

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Dry sand

Moisture free sand Mixed with binder (bentonite ,water) Used for medium and heavy castings.

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Loam sand

Mixture of sand and 50% clay. Used for large casting (pipes , rolls used in paper mills)

Facing sand

Applied to surface of the pattern. Used for getting smooth surface Layer thick ness in mould ranges from 20to30 mm

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Backing sand
Used to support facing sand .

To fill rest of flask. It is porous mixture of sand.

System sand

It is prepared from used sand. It is re-conditioned. Used to fill complete flask. It possess high strength , porosity , refracteriness.

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Parting sand
A fine sand dust. Prevents sticking to pattern surface. eg : brick powder

Core sand

Used for making cores Consists of silica sand ,binder (line-seed oil, resins) and water. Possess high refracteriness

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List of ingredients in foundry sand

Sand (natural or synthetic) Binder a) Clay b) Organic binder (bentonite ,lineseed oil,resines) c) Inorganic binders (port land cement sodium silicate) Water
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Sand additives
These are added to moulding sand. They control sand properties. Widely used additives 1) Coal dust (to improve surface finish) 2) Wood flour (to improve collapsibility of core) 3) Silica flour (reduce metal penetration) 4) Iron oxide (increase dry strength)
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Summary
In this class , we have learnt
Porosity, Refractoriness, Collapsibility, plasticity are some of the properties of moulding sand. Natural Sand used for non-ferrous and grey iron Synthetic Sand used for steel casting Loam Sand used for large cylinders Core Sand used for making cores Sand additives Coal dust, wood flour, silica flour,
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Quiz

1. Porosity is of --------------------------------(Gap between sand particles) 2. Cohesiveness means ---------------------------(Attraction between sand particles)

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Quiz
3. Adhesiveness means ----------------------------(Attraction between sand particles and moulding box)

4.

Ingredients in moulding sand -----------------------( Moulding sand, binder and water )

Frequently Asked Questions

1. 2. 3.

Describe the properties of moulding sand . What are the various types of moulding sand What are the ingredients in moulding sand

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