FACULTY OF MECHANICAL ENGINEERING,

UNIVERSITI TECHNOLOGI MARA (UITM)

LABORATORY REPORT

Program : Bachelor of Mechanical Engineering (Hons) (EM220)

Course : Manufacturing Processes Laboratory

Course Code : MEM564
Laboratory Name : Foundry
Lecturer Name : En Mohd. Ridhwan Mohammed Redza
Title of Experiment : Molding Preparation and Pouring
Group : EMD5M15

No Student Name Student ID Number Signature

.
1. Abdul Halem hafidz bin Abdul Kadir 2014633272

2. Ahmad Shafiq bin Jamalluddin 2014231274

3. Nik Muhammad Mohsien bin Bachtier Enier 2014290256

4. Kamisah binti Mohd 2014600402

Date of Practical Session Staff Certification (Signature)

13-October-2016

Date of Report Submission Staff Certification (Signature)

20-October-2016

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Molding Preparation and Pouring

1.0 TABLE OF CONTENT

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Molding Preparation and Pouring

2.0 LIST OF FIGURES

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3.0 INTRODUCTION

In metalworking, casting involves pouring molten metals into a refractory mold with a
cavity of the shape to be made and allowing it to solidify. When solidified the desire metal
object is taken out from the refractory mold either by breaking the mold or taking the mold
part. The solidified part is known as casting. Casting is more often used for making the
complex shapes that would be difficult or uneconomical to make by other methods. Casting is
widely used for sculpture, especially in bronze, jewellery in precious metals, and weapons
and tools. Traditional technique include low-wax casting, plaster mold casting and sand
casting.

Sand casting is the one of the most popular and simplest type of casting and has been
used for centuries. Sand casting also known as sand molded casting. Sand casting allows for
smaller batches than permanent mold casting and at a very reasonable cost. Not only does this
method allow manufacturers to create products at a low cost, but there are other benefits to
sand casting, such as very small size operations. Generally, we can distinguish between two
methods of sand casting, the first one using green sand and the second being the air set
(carbon dioxide) method.
Green sand molding is more wide develop than any other process. Green sand molding is
replacing many of the more expensive molding methods as sand control is being applied.
These expendable molds are made of wet sands that are used to make the molds shape. The
names come from the fact that wet sand are used in the molding process. Green sand is not a
type of sand on its own, but is rather a mixture of silica sand, bentonite (clay), coal dust and
water with ratio 4:2:2:1.
There are some basics process of sand casting. A sand casting or a sand moulded
casting is a cast part produced by forming a mould with the help of a model or pattern pressed
into a sand mixture and then removed, after which molten liquid metal is poured into the
cavity in the mould. The mould is then cooled until the metal has solidified. In the last stage,
the casting is separated from the mould.

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Figure 1: Basic process of green sand casting.

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3.1 OBJECTIVES

The objective of this experiment are:

1. To investigate the principles and terminology underlying the sand casting process.

2. To investigate the defects after the metal has solidified and how to overcome it.

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4.0 THEORY

No Major type of Description

defect

1 Pouring Metal
Defects
-Misrun, cold shut
and inclusion

-A misrun is a type of pouring metal defects that occur when the mold
cavity is not fully filled before the molten metal start to solidified

-Cold shut occur when the molten metal meet and not fuse with each
other

-Inclusion is also one of Pouring metal defects that occur in sand casting.
Inclusion is an impurity on surface of the final product. It is caused by
dirt and sand from the pattern that not cleaned properly.

3 Metallurgical
defects
-Hot Tears and Hot
spot

-Hot tears occur when gates and riser are not placed properly. The
incorrect temperature of molten metal also may produce hot tears.

-Hot spot is another type of metallurgical defect in sand casting which it

is occur when some of the molten metal appeared to be cooled quickly
and caused it to be harder than the other molten metal.

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2 Shrinkage faults
defect

-Shrinkage faults are types of defect occur because of improper

directional solidifications, poor gating and riser design and inadequate
feeding.

4 Gas porosity
defect

-Gas porosity defect is caused by formation of bubbles inside the

product before it is cooled. The gases probably are trapped inside the
metal. The formations of bubbles cause the product to have a rough
surface.

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5.0 APPARATUS

MATERIALS:
Aluminum, green sand and parting agent.

EQUIPMENT:
Pattern, pattern, sand separator, induction furnace, crucible and sand muller.

HAND TOOL:
Aluminium plate, parting sand, Rammer, sprue pin, heart trowel, trowel, lifter, and scriber.

Figure 1 : Sand Muller

Figure 2: Crucible

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Molding Preparation and Pouring

Figure 3: Sand separator

Figure 4: Flat wood bar

Parting agent

Bottom Flask
(Cope)
Jolt squeeze
machine

Figure 5: Jolt squeeze machine

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Figure 6: Pattern

Figure 7: Green sand

Sprue Pin

Upper flask
(drag)

Figure 8: Sprue Pin

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Scriber
Heart Trowel

Figure 9: Equipment

Figure 10: Induction furnace

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Figure 11 : Melting Machine

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5.1 INDUSTRIAL APPARATUS

Figure 12 : Sand casting molding machine

Figure 13 : Mixing mill sand casting

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Figure 14 : Sand sieving machine

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6.0 EXPERIMENTAL PROCEDURES

1. Wear glove, mask, safety boot and jacket for safety.

2. Place green sand into sand Muller Machine.

Figure 15: Sand muller

3. Place the mixture into sand separator to produce fine sand.

Figure 16: Sand separator

4. Place the sand at one place to ease for make mould.

5. Put the bottom flask (cope) on the pattern at centre of flask.
6. Pour the parting agent around the pattern.
7. Poured the green sand into the flask

Figure 17: Poured the green sand

8. Rammed the mixture several times by jolt squeeze machine for several times.

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Molding Preparation and Pouring

9. Placed a flat wood bar above the mixture, rammed the mixture until it’s flattened.
10. Make sure it compact with sand.

Figure 18: Rammed the sand

11. Remove the bottom flask from the jolt squeeze machine.
12. Placed the bottom flask on the floor

Figure 19: bottom flask

13. Place another flask (drag) to make the upper flask on the jolt squeeze machine.
14. Placed the sprue pin with correct measurement at the cope to make riser and dawn
sprue.
15. Pour the mixture into the flask.
16. Repeat step 8 to step 10.

Figure 20: Placed the sprue pin and poured green sand

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17. Pull out the sprue pin and make pouring cup at the dawn sprue using heart trowel.
18. Make the vent for air flow using scriber and remove the board.
19. Coupled both of flask.

Figure 21: Mold

20. Aluminum is heated in the furnace to a temperature of 700°C.

21. Poured the molten aluminium into mold.
22. Let the mold cooled by room temperature.

Figure 22: Let the mold cooled by room temperature

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23. Break the mold to take out the product.

Figure 23: Product

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7.0 RESULT
Several defects persist that can be observed are as below.

Gas porosity defects

Cold shut

Hot tear
Pinholes

misrun

Figure 24 The front view of the product.

Hot tear

misrun

swell

Figure 25 The back view of the product.

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8.0 DISCUSSION

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9.0 CONCLUSION

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10.0 RECOMMENDATION

1. The green sand must be processed longer before being used so that it is in the form of
very fine grains. This is vital so that there is no air gaps during compacting the green
sand.
2. The parting powder used must be just good enough so that the green sand does not
stick to the pattern used. This is to ensure the end product follows the shape of the
pattern properly.
3. Besides that, the parting powder is needed to be applied around the runner thoroughly
so that it is easier to remove the end product without damage to the mould.
4. Next, during ramming process, the force to ram the green sand must be controlled. If
it is too much, the mould will possibly break.
5. Lastly, to obtain a good end product, the rate of pouring the aluminium must be steady
which is not to fast nor too slow. This is because taking too much time in pouring
process will cause the molten metal to freeze faster before it can fully occupies the
mould. This is significant in order to obtain a satisfying end product without many
defects.

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11.0 REFERENCES
1. Theory of Calibration & Validation. (2008). Retrieved September 26, 2014, from
http://datainstrumentsindia.tristonsoftware.com/datainstrumentsindia/ui/userpages/th
calibration.aspx
2. Fundamentals of model calibration: theory & practice. (2012). Retrieved September
26, 2014, from http://www.ispor.org/meetings/WashingtonDC0512/
releasedpresentations/W1-All-Slides.pdf
3. Mechanical Engineering.Com. (27 March, 2013). Retrieved 27 September, 2014,
from http://www.mechanicalengineeringblog.com/tag/sand-casting-defects/
4. Schmid, S.R., & Kalpakjian, S. (2010). Engineering metrology and instrumentation.
In Hamidon Musa (Eds.), Manufacturing engineering and technology (pp. 998 –
1012).Jurang, Singapore: Pearson Education, Inc.
5. Manufacturing Technology, Foundry, Forming & Welding. By P N Rao.
6. The Complete Handbook of Sand Casting. By C. W. Ammen
7. http://mechanicalinventions.blogspot.my/2012/11/different-types-of-castings-
defects.html
8. http://www.engineeringtoolbox.com/melting-temperature-metals-
d_860.html
9. http://www.engineering.com/Library/ArticlesPage/tabid/85/ArticleID/113/Com
mon-Material-Properties.aspx
10.

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12.0 APPENDICES AND RAW DATA

Table 1 : Typical Molding Sand Mixtures and Properties.

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Table 2 : Specific Gravity and Melting Point

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