JADAVPUR UNIVRSITY

Department of Mechanical Engineering

A Report On Moulding Sand Testing

And Machine

 NAME: MD FIRDOSH ANSARI  ROLL NO.: 302011201011

 DEPARTMENT: BACHELOR OF M.E.  SECTION: B2
 SUBJECT : WORKSHOP  SEMESTER: 4th Semester
 YEAR : 2nd Year (2020-21)
 GOOD PROPERTIRS OF MOULDING SAND

PERMIA COHESI ADHESI PLAST

BILITY VENESS VENESS ICITY
REFRAC GREEN BINDING
Allow
Allow gases
●
●
gases to
to escape
escape from
from mold
mold Ability
Ability of
●
●
of sand
sand particles
particles to
to stick
stick together
together Ability
Ability to
●
●
to stick
stick with
with other
other particles
particles i.e.
i.e. Molding
Molding box
box
●

●
Ability of getting predetermined shape under pressure and retain it when the pressure is removed
Ability of getting predetermined shape under pressure and retain it when the pressure is removed

CHEMICAL
TORINE STRENG PROPER RESISTIVI
SS TH TIES TY
Ability of sand to withstand high heat without breaking down it or fusing Strength of sand with moisture content should be very Ability of sand to flow to flow to take up the pattern shape Should not chemically react or combine with molten metal

FLOWA
● ● ● ●
●
Ability of sand to withstand high heat without breaking down it or fusing Strength of sand with moisture content should be very
● ●
Ability of sand to flow to flow to take up the pattern shape Should not chemically react or combine with molten metal
●

BINDING PROPERTIES

●
BILITY
Ability of sand to take up the desired the shape during ramming
 TYPES OF MOLDING SAND
Mixture of silica sand, clay (18-30%) and water (6-8%) Green sand when dried & backed in oven to remove moistures Mixture of silica and clay (30-50%) with water (18%) to a thin state
Mixture of silica sand, clay (18-30%) and water (6-8%) Green sand when dried & backed in oven to remove moistures Mixture of silica and clay (30-50%) with water (18%) to a thin state

GREE
DRY LOAM
N
SAND SAND
Sand which is black in color due to addition of coal dust & burning in
Sand which is black in color due to addition of coal dust & burning in
SAND Sand which is used to fill the whole flask. Its strength, reactiveness
Sand which is used to fill the whole flask. Its strength, reactiveness
Sand without binder and moisture which is used to keep the green
Sand without binder and moisture which is used to keep the green
contact with the Molten metal and permeability is high sand not to stick to the pattern
contact with the Molten metal and permeability is high sand not to stick to the pattern

BACKI SYSTE PARTI

NG M NG
SAND SAND SAND

CORE
SAND Highly riched silica FACING Sand which is first
sand mixed with oil SAND applied on the
binders which is pattern so that it
used to make cores comes in contact
i.e. holes in cast with molten metal
MOLDING SAND TESTING AND ITS MACHINE

SAND TESTINGS are necessary to determine the essential qualities of the

molding sand. The properties of molding sand depends upon shapes, size,
composition and distribution of sand grain. The sand can be tested either
chemical or mechanical methods but we generally use mechanical methods
due to its simple and do not require elaborate equipment. These are the most
important tests to be conducted for any molding sand

●
Moisture Content Test
●
Clay Content Test
●
Grain Fitness Test
●
Air Permeability Test
●
Refractoriness Test
●
Strength Test
●
Mould Hardness Test (i.e. Brinell Hardness, Rockwell Hardness)
●
Flowability Test
 MOISTURE CONTENT TEST

Moisture is the property of the moulding sand it is defined as the amount of water
present in the moulding sand. Low moisture content in the moulding sand does not
develop strength properties. High moisture content decreases permeability. Moisture
content may be determined by the loss of weight after evaporation.

STEPS
   INVOLVES ARE:
 20 to 50 gm of sample sand placed in the span and
heated by an infrared heater bulb
 The moisture in the moulding sand is thus evaporate
 The percentage of moisture can be calculated from
the difference in the weights, of the original moist
and the consequently dried sand samples
 Percentage of moisture content =
 CLAY CONTENT TEST

Clay influences strength, permeability and other molding properties. It is

responsible for bonding sand particles together. Clay content is determined by
finding the loss of weight after washing of sample obtained after Moisture
Content Test i.e. Dry Sand

STEP INVOLVES ARE:

 Small quantity of prepared molding sand dried
 Separate 50 gm of dry molding sand and transfer wash bottle
 Add 475cc of distilled water + 25cc of a 3% NaOH
 Rotate this mixture at 60 rpm by electric motor for about 1 hour
 Fill the wash bottle with water up to the marker for washing
 Sand, etc are left to settled downed into the jar
 The material, which is not able to settled through 125 mm in 5
minutes is clay and should be removed
 Dry the settled down sand
 The clay content determined from the difference in weights of the
initial and final sand samples.
 GRAIN FITNESS TEST
Fine grains have higher strength but lower permeability whereas coarse grains has lower strength
but higher permeability. The grain size, distribution, grain fitness are determined with the help
of the fitness testing of molding sands. The apparatus consists of a number of standard sieves
mounted one above the other, on a power driven shaker. The shaker vibrates the sieves and the
sand placed on the top sieve gets screened and collects on different sieves depending upon the
various sizes of grains present in the moulding sand. The top sieve is coarsest and the bottom-
most sieve is the finest of all the sieves. In between sieve placed in order of fineness from top to
bottom.

STEPS
   INVOLVES ARE:
 A set of Standard sieves having meshes 6, 12, 20, 30,
40, 50, 70, 100, 140, 200 and 270 are mounted on a
mechanical shaker
 Sample of dry sand weighted 50 gm (clay removed sand)
placed in the upper sieve
 The above sample is shake about 15 minutes
 The amount of sand retained on each sieve weighted
 Percentage distribution of grain is computed
 The A.F.S grain fineness number will be,
=
 REFRACTORINESS TEST
The refractoriness used to measure the ability of the sand to withstand the
higher temperature.

STEPS INVOLVES ARE:

 Prepare a cylindrical specimen of sand
 Heating the specimen at 1500 C for 2
hours
 Observe the changes in dimension and
appearance
 If the sand is good, it retains specimen
share and shows very little expansion. If
the sand is poor, specimen will shrink and
distort.
 MOLD HARDNESS TEST
Hardness of the mold surface tested with the help of an “indentation hardness
tester”. It consists of indicator, spring loaded spherical indenter. The spherical
indenter is penetrates into the mold surface at the time of testing. The depth of
penetration w.r.t. the flat reference surface of the tester.

MOLD
   HARDNESS NUMBER CAN BE CALCULATED
FROM THE FOLLOWING FORMULA:
 Mold hardness number =
Where, P- Applied Force (N)
D- Diameter of the indenter (mm)
d- Diameter of the indentation (mm)
 PERMEABILITY TEST
The quantity of air that will pass per minute through a standard specimen of
the sand at a particular pressure condition is called the permeability of the
sand. There are four conditions of permeability test: (a) Base Permeability
Test, (b) Green Permeability Test, (c) Dry Permeability Test and (d) Back
Permeability Test

PERMEABILITY TEST IS CARRIED OUT BY USING A

PERMEABILITY METER: It has the following parts:
 (a) Water Tank,
 (b) Balanced Air Tank (i.e. Jar) which is floats
over the Water Tank,
 (c) Specimen Tube and
 (d) Pressure Manometer
 PERMEABILITY TEST (Contd)
Steps involved are:
 1. The air (2000cc volume) held in the bell
jar forced to pass through the sand
specimen.
 2. At this time air entering the specimen
equal to the air escaped through the
specimen
 3. Take the pressure reading in the
manometer.
 4. Note the time required for 2000cc of air
to pass the sand
 5. Calculate the permeability number
PERMEABILITY
   NUMBER (N) CAN BE CALCULATED
FROM THE FOLLOWING FORMULA:
Permeability number (N) =
Where,
V-Volume of air passing through the specimen
()
H-Height of the specimen (mm)
A-Cross sectional area of the specimen (mm 2)
P-Air pressure (gm / cm2)
T-Time taken by the air to pass through the
sand (seconds)
 STRENGTH TEST
Strength of mold sand depends on the size and shape of sand grains, quantity of moisture
content and also degree of hardness. Measurements of strength of molding sands carried out on
the universal sand strength testing machine. The strength measured such as compression, shear
and tension. The sands that could be tested are green sand, dry sand or core sand. The
compression and shear test involve the standard cylindrical specimen that was used for the
permeability test.

STEPS INVOLVES ARE:

 Prepare a cylindrical specimen of sand
whose strength is to be measured
 Place the specimen between the grip of
test equipment
 Pressure is applied by hand wheel until
the specimen breaks
 Reading the high pressure and low
pressure manometers whose scales are
graduated in four different scales each
for compressive, tensile, shear and
bending strength
THANKING YOU