Foundry Tools and Equipment's
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Foundry Tools and Equipment's
There are large number of tools and equipment's
used in foundry shop for carrying out different
operations such as sand preparation, molding,
melting, pouring and casting.
Hand Tools Used In Foundry Shop:
Hand riddle: Hand riddle is shown in Fig. 3.1(a). It
consists of a screen of standard circular wire mesh
equipped with circular wooden frame. It is
generally used for cleaning the sand for removing
foreign material such as nails, shot metal, splinters
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Cont.
Shovel: Shovel is shown in Fig. 3.1(b). It consists of an steel
pan fitted with a long wooden handle. It is used in mixing,
tempering and conditioning the foundry sand by hand. It is
also used for moving and transforming the molding sand to
Rammers: Rammers are shown in Fig. 3.1(c).
the container and molding box or flask.
These are required for striking the molding sand
mass in the molding box to pack or compact it
uniformly all around the pattern.
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Fig 3.1 a, b, c
Cont.
Strike off bar: Strike off bar Fig. 3.1(e)) is a flat bar having
straight edge and is made of wood or iron.
It is used to strike off or remove the excess sand from the
top of a molding box after completion of ramming thereby
making its surface plane and smooth.
Draw spike: Draw spike is shown Fig. 3.1(f). It is a tapered
steel rod having a loop or ring at its one end and a sharp
point at the other. It may have screw threads on the end to
engage metal pattern for it withdrawal from the mold.
Vent rod: Vent rod is shown in Fig. 3.1(g). It is a thin spiked
steel rod or wire carrying a pointed edge at one end and a
wooden handle or a bent loop at the other. After ramming
and striking off the excess sand it is utilized to pierce series
of small holes in the molding sand in the cope portion.
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Cont.
Fig 3.1 (e)
Fig 3.1 (h)
Fig 3.1 (g)
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Cont.
Trowels: Trowels are shown in Fig. 3.1(l, m and n). They are
utilized for finishing flat surfaces and joints and partings
lines of the mold.
Fig. 3.1(l, m and n).
Bellows: Bellows gun is shown in Fig. 3.1(w). It is
hand operated leather made device equipped with
compressed air jet to blow or pump air when
operated. It is used to blow away the loose or
unwanted sand from the surfaces of mold cavities.
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Fig. 3.1(w).
Cont.
Slicks: Slicks are shown in Fig. 3.1(o, p, q, and r). They are
also recognized as small double ended mold finishing tool
which are generally used for repairing and finishing the
mold surfaces and their edges after withdrawal of the
pattern.
Fig. 3.1(o, p, q, and r)
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Cont.
Smoothers: Smothers are shown in Fig. 3.1(s and t).
According to their use and shape they are given different
names. They are also known as finishing tools which are
commonly used for repairing and finishing flat and round
surfaces, round or square corners and edges of molds.
Fig. 3.1(s and t).
Gate cutter: Gate cutter (Fig. 11.1(v)) is a small
shaped piece of sheet metal commonly used to cut
runners and feeding gates for connecting sprue
hole with the mold cavity.
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Moulding Boxes Cont.
Mold boxes are also known as molding flasks. Boxes used in
sand molding are of two types:
Fig.3.2 Open molding box Fig.3.2 Closed molding box
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Cont.
MOLD MAKING
Sand Conditioning/Preparation: before mold making
conditioning/preparation is carried out.
Steps in Sand Preparation
1. foreign materials removal: The foreign materials, like nails,
hard sand lumps and metals from the used sand are removed.
2. Sand Mixing: The sand constituents are then brought at
required proper proportion and mixed thoroughly. It is done
using Sand mixing muller machine.
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Cont.
Steps Involved In Making A Sand Mold
1. Initially a suitable size of molding box for creating suitable
wall thickness is selected for a two piece pattern.
2. Next, place the drag portion of the pattern with the parting
surface down on the bottom (ram-up) board as shown in Fig.
2.21 (a).
3. The facing sand is then sprinkled carefully all around the
pattern so that the pattern does not stick with molding sand
during withdrawn of the pattern.
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Cont.
4. The drag is then filled with loose prepared molding sand and
ramming of the molding sand is done uniformly in the
molding box around the pattern. Fill the molding sand once
again and then perform ramming. Repeat the process three
four times,
5. The excess amount of sand is then removed using strike off
bar to bring molding sand at the same level of the molding
flask height to completes the drag.
6. The drag is then rolled over and the parting sand is sprinkled
over on the top of the drag [Fig. 2.21(b)].
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Cont.
7. Now the cope pattern is placed on the drag pattern and
alignment is done using dowel pins.
8. Then cope (flask) is placed over the rammed drag and the
parting sand is sprinkled all around the cope pattern.
9. Sprue and riser pins are placed in vertically position at
suitable locations using support of molding sand. It will help
to form suitable sized cavities for pouring molten metal etc.
[Fig. 2.21 (c)].
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Cont.
10. Strike off the excess sand from the top of the cope.
11. Remove sprue and riser pins and create vent holes in the cope
with a vent wire. Sprinkle parting sand over the top of the
cope surface and roll over the cope on the bottom board.
12. Rap and remove both the cope and drag patterns and repair
the mold suitably if needed and dressing is applied.
13. The gate is then cut connecting the lower base of sprue basin
with runner and then the mold cavity.
14. Set the cores in the mold, if needed and close the mold by
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inverting cope over drag.
Cont.
18. The cope is then clamped with drag and the mold is ready for
pouring, [Fig. 2.1 (d)]
Fig. 2.21 Mold making 15
Cont.
Gating System In Mold
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Cont.
2.2.5 Casting Quality
Fig 2.32 Common defects in sand castings: (a) sand blow, (b) pin holes,
(c) sand wash, (d) scabs, (e) penetration, (f) mold shift, (g) core shift,
and (h) mold crack.
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Cont.
Inspection Methods
Foundry Inspection procedures include (Cast)
Visual Inspection
Dimensional measurements
Metallurgical, chemical, physical, and other tests
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