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  • *CHAPTER 2 FOUNDARY PROCESSES*CHAPTER 2FOUNDRY PROCESSES 2.1 INTRODUCTIONME 333 PRODUCTION PROCESSES IIFoundry processes consist of making molds, preparing and melting the metal into the molds, cleaning the castings, and reclaiming the sand for reuse.

    Founding, or casting, is the process of forming objects by putting liquid or viscous material into a prepared mold or form. Generally solidification takes place by cooling (metallic materials) but cooling may not be necessary (some plastics).

    A casting (dkm) is an object formed by allowing the material to solidify. So, the casting is the product of the foundry. It may vary from a fraction of a gram to several tons. All metals and alloys can be cast.A foundry (dkmhane) is a collection of the necessary material and equipment to produce a casting.

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*ME 333 PRODUCTION PROCESSES IISelection of castings of various materials, shapes, and sizes

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*ME 333 PRODUCTION PROCESSES IICasting technology involves the next steps:Casting nomenclatureThe figure in the right shows the nomenclature of mold and castings in sand casting.

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*ME 333 PRODUCTION PROCESSES IIThe pouring cup, downsprue, runners, etc., are known as the mold gating system, which serves to deliver the molten metal to all sections of the mold cavity.Gating system in sand casting

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*ME 333 PRODUCTION PROCESSES IITo understand the foundry process, it is necessary to know how a mold is made and what factors are important to produce a good casting.

    The elements necessary for the production of sound casting will be considered throughout this chapter.

    These include:

    Mold Pattern Core Molding Procedure Sand Properties of Cast liquid Behavior of Cast Material

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*A mold (kalp) is the container that has the cavity of the shape to be cast. It may be made of metal, plaster, ceramics, or other refractory substances. Good castings can not be produced without good moldsThere are two types of molds:

    1. Permanent mold: A mold used more than once. They are generally produced from metallic materials such as; heat resisting (Ni-Cr) steels.

    2. Expendable mold: A mold used only once and then destroyed to separate the component. They are generally produced from sand. (for casting of ferrous materials we have to use this type of mold, because melting points of ferrous materials are very high).ME 333 PRODUCTION PROCESSES II2.2 MOLDS

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*There are plenty types of expendable molds, but we will deal with sand molds only;a) Green Sand Molds: The most common type consisting of forming the mold from damp molding sand (silica, clay and moisture)

    b) Skin-dried Molds: It is done in two ways; (1) The sand around the pattern to a depth of about 1/2 in(10 mm). is mixed with a binder so that when it is dried it will leave a hard surface on the mold. (2) Entire mold is made from green sand, but a spray or wash, which hardens when heat is applied, is used.

    c) Dry Sand Molds: These molds are made entirely from fairly coarse molding sand mixed with binders (linseed oil: bezir ya or gelatinised starch: niasta). They baked before being used. A dry sand mold holds its shape when poured and is free from gas troubles due to moisture.ME 333 PRODUCTION PROCESSES II

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*A mold should have the following characteristics:

    i) The mold must be strong enough to hold the weight of the metal,ii) The mold must resist the erosive action of the rapidly flowing metal during pouring,iii) The mold must generate minimum amount of gas when filled with molten metal.iv) The mold must be constructed in such a way that any gasses formed can pass through the body of the mold itself (permeability).v) The mold must be refractory enough to withstand the high temperature of the metal.vi) The mold must collapse easily after the casting solidifies. ME 333 PRODUCTION PROCESSES II

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*2.3 . PATTERNS A pattern (model) is a form used to prepare and produce a mold cavity. It is generally made from wood but it can be produced from materials like aluminium alloys (low in density). (Disadvantage of wood is humidity absorption.)

    The designer of a casting must look forward to the pattern to assure economical production. The design should be as simple as possible to make the pattern easy to draw from the sand and avoid more cores than necessary.

    The pattern may be permanent, so that it may be reused repeatedly. Alternatively, the pattern may be expendable (disposable), made up of a material that is melted out before or burnt up during casting.

    Pattern has some dimensional variations from that of the real component (i.e. casting). These variations from the real component are called Pattern Allowances. ME 333 PRODUCTION PROCESSES II

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*Patterns in sand casting are used to form the mold cavity. One major requirement is that patterns (and therefore the mold cavity) must be oversized:to account for shrinkage in cooling and solidification, andto provide enough metal for the subsequence machining operation(s).ME 333 PRODUCTION PROCESSES IITypes of patterns used in sand casting:(a) solid pattern, (b) split pattern, (c) match-plate pattern, and (d) cope-and-drag pattern

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*ME 333 PRODUCTION PROCESSES IISolid pattern for a pinion gearSplit pattern showing the two sections together and separated. Light-colored portions are core prints.

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*1. Shrinkage Allowance: Shrinkage takes place in a volumetric way, but it is given linearly. Each dimension is measured with a shrinkage rule, which automatically gives shrinkage allowance. It is expressed as in/ft. When metal patterns are to be cast from an original master pattern, double shrinkage must be given.ME 333 PRODUCTION PROCESSES II2.3.1 Pattern Allowances Fig. 2.1. Pattern Allowances for a Cast Connecting Rod.

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*ME 333 PRODUCTION PROCESSES IITypical shrinkage allowances:

    Cast IronSteelAlBrassBronzeIn/ft1/81/45/323/361/8-1/4%1.042.081.302.01.04-2.08

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*ME 333 PRODUCTION PROCESSES II2. Draft: It is the taper placed on the sides of the pattern on the parting line. This allows the pattern to be removed from the mold without damaging the sand surface. Draft is added to the dimensions on the parting line

    Exterior dimensions: 1/8 - 1/4 (in/ft), 1.04 %- 2.08 %Interior dimensions: As large as 3/4 (in/ft), 6.25 %

    3. Machining Allowance: It is given on the working areas of the part where further machining will be performed. In value, it is equal to shrinkage allowance.

    4. Shake: Negative allowance is given by making the pattern slightly smaller to compensate for the rapping of the mold.

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*2.4 CORESA core (maa) is a body of material, usually sand, used to produce a cavity in or on a casting. A core must have sufficient strength to support itself and should not fracture when liquid metal is approaching to it.

    Cores may be classified as Green-Sand and Dry-Sand Cores. Green-sand cores are formed by the pattern and made from the same sand as rest of the mold. Dry-sand cores are made separately to be inserted after the pattern is drawn but before the mold is closed. They are usually made of clean river sand (40 parts) which is mixed with a binder (1 part) and then baked to give the desired shape. The box in which cores are formed to proper shape is called a CORE BOX. Generally, perforated pipe or wire frames are added to give sufficient strength. ME 333 PRODUCTION PROCESSES II

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*ME 333 PRODUCTION PROCESSES IIMost commonly used binder is Linseed oil. The oil forms a film around the sand grain and hardens when baked at 180-2200C for 2 hours. Other binders are wheat flour, dextrin, starch and several types of thermosetting plastics.Fig. 2.2. Types of Cores.

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*Cores serve to produce internal surfaces in castings In some cases, they have to be supported by chaplets for more stable positioning:Core held in place in the mold cavity by chaplets,chaplet design,casting with internal cavity

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*Cores are made of foundry sand with addition of some resin for strength by means of core boxes:Core box, two core halves ready for baking, and the complete core made by gluing the two halves together

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*Production sequence in sand casting

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*2.5 MOLDING PROCEDURE Procedure for making green sand molds; ME 333 PRODUCTION PROCESSES IIA. Pattern on molding board ready to ram up drag

    CHAPTER 2 FOUNDARY PROCESSES

  • *CHAPTER 2 FOUNDARY PROCESSES*B. Drag rolled over and pattern assembled ready to ram cope ME 333 PRODUCTION PROCESSES II

    CHAPTER 2 FOUNDARY PROCESSES