15.

1 INTRODUCTION

A foundry is a place castings are produced. For performing different operations like
where
hand tools and
battern making, machining, lifting, shifting, inspecting, testing etc., a variety of
quipments are needed.

15.2 FOUNDRY TOOLS AND EQUIPMENTS

and equipments are divided into the following groups

Foundry tools tools etc.
Harnd tools like moulding tools, core making tools, pattern making
Moulding boxes (Flasks).
Moulding machines.
Melting equipments.
Pouring equipments.
 WORKSHOP
262 CHNOLOGYN
HAND TOOLS
15.3 FOUNDRY
below
various hand tools
is given
A brief description of

15.3.1 Shovel
fitted with a wooden
handle. it is used for transferrin
It consists of a square pan flask.
sand in the moulding
the sand mixer and pouring

15.3.2 Strike Off Bar

bar having a true edge. It is used for removing the surnkus
It is a wooden or metallic sand
after the ramming has been completed.

15.3.3 Hand Riddle

It is also known as sieve. It is used to remOve the lumps and foreign particles from the nd.

15.3.4 Vent Wire

It is similar to a needle. After ramming and strike off the excess sand, it is used to make sma
holes in the sand mould to allow the exit of gases and steam during casting.

Fig. 15.1. Shove Fig. 15.2. Strike off Bar. Fig. 15.3. Hand Ridde

Fig. 15.5. Trowel

Flg. 15.6. Slick

Fig. 15.4. Vent Wire.

15.3.5 Trowels
These are used for inishing Tiat surfaces and joints in the mould after wing the pattern
withdrawing
 TOOLS AND EQUIPMENTS
FOUNDAY
FOUN

15.3.6 Slicks 263

e are used for repairing and provide finishing
pattern has been withdrawn. to mould surface and
edges after the
15.3.7 Lifters
ifters are used for
removing loose sand from
for patching deep section of a mould. (inside) the mould cavity. They are also used

Peen
End

Butt End

Fig. 15.7. Lifter Fig. 15.8. Ramme Fig. 15.9. Swab.

15.3.8 Rammers
These are used for
ramming sand in the moulding box to pack it uniformly around the
pattern. Depending upon the nature of
working, there are many types of rammers.
15.3.9 Swab
t is a small brush having long hemp fibres. It is used to
provide a small amount of water
around the edge of the pattern in the sand before the pattern is rapped for removing it from the
mould.

Fig. 15.10. Sprue Pin. Flg. 15.11. Draw Spike and Draw Screw.
 WORKSHOP
264 CHNOLOGY
15.3.10 Spure Pin
sand mould
wooden or iron rod. It
is embedded in the and la.
er withdrawn
It is a
tapered al is poured into thehdra
which the molten metal poured the
to produce a hole called runner, through mould
15.3.11 Draw Spike
from the mould. It
consists of a tapered steal
It is used to withdraw the pattern rod having
at the other.
a ring at one end and a sharp point

15.3.12 Draw Screw and Rapping Plate

rod carrying a ring at one end and a machine
The draw screw is a straight mild steel
with the rapping plate. Rapping plate ieey
at the other. It is always used in conjunction
The pattern can be withdrawn ft
threaded holes in which draw screws are accommodating. om the
mould by liting the draw screw because rapping plate is clamped to the pattern.

15.3.13 Smoothers and Corner Slicks

These are used to repair and finish the round and square corners, round and flat surfaro
and edges etc.
According to their use and shape, they are given different names as shown in Fig. 1512

(a)Pipe Smoother (b) Button Smoother (c)Inside Square (d) Half Round Corner
Fig. 15.12. Smoothers.

15.3.14 Clamps
Clamps are made of steel and are used for holding and clamping the moulding box in proper
position.

Fig. 15.13. Clamps.

15.4 MOULDING BOXES OR FLASKS

The boxes used in sand moulding may be made of contair
wood, cast iron steel. It is aa coetal
or
in which sand is packed an0 rammed. In
moulding sand, there is a cavity metal

is noured. Moulding boxes consist or two or more parts. The upper part in which
is called 'cope.motenIne
 AND EQUIPMENTS
TOOLS
DAY
FOUM
A
led 'drag' and
intermediate parts are called 'cheeks', 265
ating
a ts c a l l e d

the right posifion These are

during casting as shown in
provided with suitable
Fig. 15.14.
Cope
Lug
-Drag
Dowel Pin
(For Alignment)

Fig. 15.14. Moulding Box

(Flask).

15.5 LADLES

1 2dles are used to transport molten metal from the

melting furnace to the mould and vice
versa. These ladles consist of a steel shell lined with a suitable refractory material like fire clay.
To crane hook

Spout
Lining M$ ladle

(a) Small Ladle Inner

hole

Tilting
handle

Handle for pouring Linning

Pipe (c)Tea Pot Ladle
To crane hook Hand Shake Ladle To crane hook
(6)
Stopper rod

Stopper
Lining rod system

Shell
Tilting gear
Lining

Tilting wheel
(d) Large Dip Pouring Ladle Bottom Pouring Ladle
(e)
Fig. 15.15. Ladles.
266 WORKSHO
TECHNOLO
15.6 CRUCIBLES

Crucible is used to melt the metal in a furnace. It is packed inside tho t..
e
crucible.
furna and
material (metal scrap) is put in this

Fig. 15.16. Crucible.

15.7 MOULDING MACHINES

Moulding machines are used to perform the following basic
*Ramming of sand in the mould. operationsS
Lifting or drawing of pattern from the mould.
Rolling over the mould section.
For performing above said operations, following moulding machines are used
15.7.1 Jot Machine
This machine is
used for ramming of sand in the mould. In this
and mould box are
clamped to the table. The table is machine; the pate plate
mechanism. In this machine, the jolted with the help of piston and y
maximum
plate. Moulding sand at the top does not hardness is being achieved nearest atterm

help of compressed air and after get fully compacted. Jolt machine table to e re

down. This causes the raising table, the air is released and the table
the rased droos

sand to pack properly. suaae

15.7.2 Squeezing Machine
in this
machine, the table is lifted
head. Moulding sand gets compacted by the compressed air against the stationary ezing

progressively softer towards the pattern.maximum at the top nearest to the squeeze beiny
 EQUIPMENTS
T O O L S AND

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267
Flask
Squeeze
head

Platen

. '

TRbIe
' '

' .. Sand frame

Flask
Plunger
XX Hole Pattern

X KX Guiding
cylinder

77777 TT Hydraulic or
pneumatic
piston/cylinder
Fig. 15.17. Jolt Machine. Fig. 15.18. Squeeze Machine.

w.wwww Low hardness High

Medium
Medium
hardnessS
Low
-High hardness
-Pattern Pattern
(a) Jolt only (b) Squeeze only
- - High
High
Medium
- Meum
Low

Medium
-High - Pa.
-Pattern
c Jolt and (d) Simultaneous jolt and squeeze
squeezee
Mould.
Fig. 15.19. Hardness Distribution Across
15.7.3 Jolt-Squeeze Machine
This is a to achieve uniformly
high hardness ad
combination of above two operations simultaneously, which helps
S across the entire section of mouid.
15.7.4 Sand Slinger*
moulds, sand
Compact
inigers
a rare used very
e used
large
foarge moulds (exceeding
3000 x 3000 mm size) and in deep
the sand to the
impeller
dst operation. In this, conveyor belt is used to supply
 WORKSHOP TECHNOL
268 OLOGY
ne ram
force into the mould. The
head. The impeller head throws
the sand with high ramming of sand is
the speed of the impeller.
controlled by
Opening
Blade Sand hopper Diaphragm
pressure head Diaphragm
-Housing Pressure head
Air cylinder
Flask
Pattern
Outlet
Trolley
Flask Trolley Machinell Board
bed

777 7777777
Fig. 15.20 Sand Slinger Fig. 15.21. Diaphragm Moulding Machine.

15.7.5 Diaphragm Moulding Machine

Diaphragm moulding machines are used to achieve the uniform hardness of the moulding
sand.In this machine, the match plate and the flask are mounted on a trolley which can be moed
along the machine bed ways by means of an operated piston. In this, first the flask is flled with
sand and then the trolley and the flask is moved to the right side so that the flask comes under
the diaphragm head. The air pressure is now used to force the rubber diaphragm over the entire
surface of the pattern.

15.7.6 Stripping Plate Machine

This machine is used for drawing the pattern from the mould. The pattern is attached to he
stripping plate. When the mould is ready, the pattern is withdrawn by moving the stripping plaie
downward.
.
Flask

Machine Pattern
table

Stripping
plate Pattern
plate

Ram

Fig. 15.22. Stripping Plate Machine.

 EQUIPMENTS
TOOLS AND

UNDRY 269
FOUN

Flask

Pattern
ITT7
/ AxvAxxkkkktttktxzrctkatra

Lifting pin Lifting pin

Fig. 15.23. Pin Lift-Push Off Machine.

15.7.7 Pin Lift or Push Off Machine

upward diretions. This machine
The machine draws the mould away from the pattern in the
is having four pins which lift the four corners
of the flask.

15.7.8 Roll Over Machine

and filled with sand.
In this machine, the pattern and the flask is placed on the pattern plate
rotated by hand through 180° (roll over) and
Aiter ramming, the flask and the pattern plate are The flask is unclamped from the pattern
0OKEd. ThE moving table is raised to butt against the flask.
plate and the moving table with the mould is now lowered.
Trunnion Pattern
Flask

Clamps *********.

***********
"**********
**************

**************
Pattern
Moving plate
table
* ***********

Ram
table and mould
Mould rolled over and (c) Moving
(a) Hand ramming. (b) lowered away
from patern.
plate locked.

Flg. 15.24. Aoll Over Machine

15.8 MELTING EQUIPMENTS

metal used
of the
In order to temperature
should be profDer pouring and melting
good castings, the used
furnaces are
For meltinq the metals, the following
270 WORKSHOP TECHNOLG
1. For ferrous metals
Cupola furnaces
Open hearth furnaces

Electric furnaces
metals
2. For non-ferrous
furnaces are used
Foilowing crucible
Pit type
Stationary type
Tiiing fypo

15.9 CUPOLA
Using of Cupola to melt Cast Iron possesses the following advantages

Advantages:
The cost of melting is low.
The control of chemical composition is better.
Temperature control is easier.
Molten metals can be tapped from the cupola at regular intervals.
t consumes the easily available and less expensive fuels.
Cupola furnace has low initial cost as compared to other furnace of same
Continuous production can be obtained from the
capacity
cupola furnace once started.
Less fioor space requirements as
compared to other furnaces of same capacity
t has high degree of efficiency.
Dissdvantages.
The main
disadvantages of Cupola is that it is not possible to produce iron below 28
carbon in this furnace. So
the duplex process is
for producing white cast iron (containing below 2.7% cat
employed.
Moreover, molte:n iron and coke comes in
as Si, Mn are iost contact with each other, certain elemenis
while others are included in the
SUCT

metal.
25.9.1 Description of
1.
a
Cupola
Sheil: Shell is a vertical and
thick and ined inside cylindrical in shape. It is made with
with refractory bricks
with steel sheet 6 to 12 m
steel sheer o sedbr
cupola lining consist of silica and clay. Refractory bricks and e
to 2 metres and the (Sio,) and Alumina (AI,O,). Cupola diamerEr
2. Foundation: The height 4 to 6 times the diameter.
is
shell is
The bottom of the shel! mounted either on a brick works undation or on steel cou
foundation
of coke, slag etc. can beconsists of a drop bottom door, through wnicd
o nsistng

3. Tuyers:
Air for
discharged at the end of a melting.
combustion
the height of between 0.6 toof fuel is delivered through the tuyers
providedat
1.2 wni
Wind Be!t The air is delivered metres above the working bottom. auct

nounted on the outer shell of the to the tuyers from a wind belt which Isa steelplate
cupola.
 OOLS AND EQUIPMEN
NORYTOOLS AND

271
fan or blower
5 . Blower: A
high pressure
suppiies the air to the
wind belt
blastpipe.
through a

It is located at a level about 250 mm below the centres of

6 Slag Holee
the slag. the tuyers. It is
U S e at o r e m o v e

Door:ItIt is situated 3 to 4 metres above

the tuyers.
1. coke and flux are fed into theturnace.
7 .C h a r g i n g
Through this hole, metal
&Chimney o rCak Stack The shell is usually continued for
4 metres to 5
to form a chimney.
metres above the
charging hole
Spark arrester

1:Coke
2 : Flux Stack
Zone
3: Metal

Charging door

Stage Preheating
zone
Steel shell
3 Metal charge
Refractory
lining ake bed

Melting zone
Wind box
Reducing zone
-Combustion zone
Air blast
inlet Slag hole

Tuyers Tapping hole

Well
Fettling hole w
Sand bottom
Drop bottom- Prop

Fig. 15.25. Cupola.

15.9.2 Zones in
The entire section Cupola
a
of the cupola is divided into the following zones The moten
Cruc ble Zone : t is ween of the sand bed and
bottom of the tuyers.
melal accumulate here. betwe top
It is also called the well"'. the top or
CombustHeationis or
uyers. XIdizing
VOved in this
Zone:
zone
It is situated
because of
normally 150 to
the following oxidation
300 mm above

reactions

CO,+Heat
C+O SiO,+Heat
Si +O
272 WORK
SHOP TECHNO
2 MnO + Heat
2Mn+O2
Fe +O FeO+ Heat
Reducing Zone This zone starts from the top of the combustion zone.
the top of the coke bed. In this zone, the reduction of CO, to CO occurs and t nd etends
to about 1200°C.
2CO- Heat
mperature d
CO +C(coke)
Melting Zone: The zone starts from the top of the coke bed and extends uto
900 mm. The temperature in this zone is highest approx. equal to 1600°C. hei
3 Fe+2Co » FeC+CO2
Preheating Zone or Charging Zone : It starts from the top of the melting zone and
upto the charging door. Charging materials are fed in this zone and get preheated
and enterg
Stack Zone It starts from the charging zone and extends upto the top of the.
the cupola.
gases generated within the furnace are carried to the atmosphere by this zone.

15.9.3 Cupola Operation

1. Preparation of Cupola Clean out the slag and repair the
damaged lining with tt
mixture of fire clay and silica sand. After this bottom doors are raised and
botom s
is introduced. The surface of the sand bottom is
sloped from all directions towards t
tap hole. Slag hole is also formed to remove the slag.
2. Firing the Cupola : A fire of kindling wood is ignited on the sand bottom. After proE
burning of wood, coke is added to a level slightly above the tuyers. Air blast at a slove
rate is turned on. After having red
spots over the fuel bed, extra coke is added tot
predetermined height.
3. Charging the Cupola : After proper burning alternate layers of pig iron, coke and fu
(limestone) E.re charged.from the charging door until the cupola is full. Steel scrap s as
added to control the chemical
well as to emove the
composition. Flux will be added to prevent the oxidaton ä
impurities. (Flux is 2 to 3% of the metal charge by weight) Mes
(pig iron, steel scrap) flux and coke are added in alternate layers until the cupola sU
to the charging door.
4. Soaking of iron : After the furnace is
charged fully, the charge gets slowly d
since the air blast is
kept shut for about 45 minutes, this causes the iron to getheateaket
5. Opening of Air Blast:
At the end of the
suashoe
is closed to accumulate soaking period, the air blast is opened. a
the sufficient amount of
metal. The rate of charging shou
equal to the rate of melting so that the
furnace remains ful.
6. Pouring
the Molten Iron: When sufficient metal collects in the
opened, and the slag is removed. well, the sag metal
After this tap hole is
7. Closing the opened to collect the mo
Cupola : At the end of the pped, a

supply is cut off and the prop is removed operation, the charge feeding is sh
door is supported by a (when the cupola is in operation, the
prop so that it may not
charge, coke etc., it carries). As soon as collapse due to the large weight d o w

the is removed the door s ng

providing a clear space for the coke fire, residueprop of the molten metal with sidy
the

sand bed to fall down and, thus, the fire

inside ceases gradually
 DAY TOOLSAND EQJIPMENTS

FOUNDAY
273
Efficiency
of Cupola
5.9.4

Heat utilized
eat utilized in
Melting efficiency
=
preheating, melting and superheating
Thermalor
rmal or Potential heat in coke + heat from oxidation ofng 100
Si, Mn + Heat in air blast Fe,

10
15.10
DIRECT AR ELECTRIC FURNACE

ac urne consists
of a cylindrical shell with
hemispherical bottom made of thick mild steel
This is a dished ome
dor having three openings for three graphite electrodes. A door is
plate The roof is a
plate. the front
the front side for observation, minor charging, slagging etc. while a tap spout is
rovided in
provvided on the opposite side. The furnace shell is lined in the sides, bottom and roof with
providea bricks to protect it from internal heat. A toothed rack, controlled through hydraulic piston
ractory
cylinder and motor can tilt the shell. The furnace roof which sits on the shell during melting can
t e r and swung aside by the hydraulic ram to facilitate open charging. The electrode's vertical
wement for control of arc length and temperature is done by thyristor and motor drive.
As melting proceeds, the graphite electrodes strike the arc at bottom, gets consumed. Fresh
with threads.
lengths are added from the top by joining nipples provided
To crane
Graphite electrodes
3 power
Roof swinging mechanism extendahle
for charging
Electrodes
holders
o f and lining
mL JILI

Side lining -Shell

Door-
Arc Spout
Pouring ladle
Charge
Bottom lining
Floor
7

Rack

Hydraulic tilting system Pit

a7777777
Electric Furnace
Fig. 15.26. Direct Arc
 WORKSHOP TECH
274
Advantages of arc furnace melting:
HNOLOGY
and fast melting rate.
High melting temperature for economy
can be used in charge,
Cheap, low quality scrap
Good control temperature
over and furnace atmosphere for high quality neltin
Iting for carton
and low alloy steels.
Suitable for melting large quantities (5
to 50 tons).

Disadvantages of arc furnace melting

:

in initial stages of melting.

High fluctuation in the line voltage
Need of comparatively high or maximum demand of electric power.
N o t recommended alloy steels.
for high
Cost of graphite electrodes is high which gets consumed during operation.

More maintenance cost compared to induction furnaces.

Pollution due to fumes, smokes and noise.

15.11 ELECTRIC INDUCTION FURNACE

This furnace has a crucible. Electric power to this furnace is supplied by an induction CGl
placed around the crucible concentrically. The coil is made of thick copper tube, inside which
cooling water is circulated. The crucible and coil are packed in a rectangular box/shell.The bo
is placed at a raised level in a platform and has tilting mechanism for collecting the liquid metal

.. '. '.*
2

77777
-11

Detail coil 9 -12

1. Working rammed lining

7777777TI777T7777
2.
Castable refractory ring 3. M.S. lining former
4. Furnace lid with lining Coil Grout refractory
5.
6. Coil current carrying portion
7. Cooling water opening 8. Insulation between
tuns 9. Castatble refractory botom
10. Inlet for cooling
water 11. Trunnion for
tilting of furnace 12. Outer M.S. shel/box
Fig. 15.27. Electric Induction
Furnace.
 S AND
AND Ec
EQUIPMENTS
TOOLS

wORY

normal upply frequency of 50 to60 Hz A.C. 275

5000 Hz is can be used
The
quencyi e 2 0 0 more
popular as the furnace for
melting
evice is
used to convert the main
frequency
can be
into desired
started cold.irons. Medium
A solid
obchoni
state
finduction
AdVantages o f i n d u c t i o
furnace over arc
furnace: frequency.
For the
same

to arc furnace.
Malume
volun
(capacity) induction furnace has a much faster
melting rate compared
Energy
ary Consumption per ton melte metal is much lower.
Metal losses during elting are much lower.
No requirement of cOstily consumable graphite electrodes.
Simple mechanism and lower maintenance cost.
Lower pollution and befter working conditions.

nsadvantages of induction melting furnace

Refining of metal in the furnace is difficult.
Needs higher quality scrap.
Need of specially treated water, for coil
cooling which is critical.
Needs a costly capacitor bank.

15.12 COKE FIRED-PIT TYPE CRUCIBLE FURNACE

The crucible is kept in a pit surrounded
bottom. Space is provided for
by coke, supported on grate bars. Air is b'own from
and the fiux is
cleaning the ash from the bottom. Metal is
charged into the crucible
or
given as cover. After
melting, crucible is lifted to pour the liquid metal in the ladles
directly into the molds.

Lid
Grating cover Crucible
Floor leval
ZZke Coke

Pit

Grate
Door for ash supply
Refractory collection pipe
brick lining

Type Crucible Furnac.

Flg. 15.28. Coke Fired-Pit
 WORKSHOP
276 TECHN
Advantages
cast iron or on terrous melting upto 100 .
Used for small quantities of g batch
as investment is the lowest.
Very cheap
Disadvantages:
and long cycle time.
Low thermal efficiency
Not used for high quality alloys.
Creates pollution due to dust and fumes.

TILTING TYPE FURNACE

15.13 OIL/GAS FIRED
Crucible is inbuilt in this furnace, which is heated by the flame from furnace oil or a
like producer gas or natural gas. The crucible is kept elevatedwith titing trunnions. Ater fuel
met
the crucible is tilted, emptying liquid metal into carrying ladles for transfer to moulds for n
pouring
Over-head oil tank
Lid
Crucible
Tilting system /Burner
Oil line
Gears
Air blower

Handle-

Outer shell
Refractory lining-
Furnace supports-

Floor

Fig. 15.29. Oil/ Gas Fired

Tilting Type Furnace.
Advantages
This is used for medium
Fast melting rate.
capacity 50 to 500 kg batch.
High thermal efficiency than coke.
Possible to achieve good
Investment lower compared
quality.
to electric melting furnace.
Disadvantages
Investment higher than coke fired.
 ND EQUIPMEN
NOAY TOOLS AND

NNOAY
277
1 5 . 1 4O I L GAS FIRED ROTARY FURNACE
y eiats of
furnace consisi
cylindrical
from oil or
a steel vessel, lined
with
R o t a r y

n2ontalyo n r o l
rollers. Flame
from refractory bricks, supported
gas burner is
gven
The entire Culinder
cylinder is slowly rotated one end and hot
her.
The
doothrough a
system
asystem of
of o not gas exha
exhaust
from charging gears
o t h e r .

the dumped a charging door at and pinions.

natal gets melted. InIs is used tor centre and suitable tapping system Metal
fux
a g e and fux
am are
VdedonCe t h e
special cast iron as well as is
l cCastings. It is not
steel very popular due to the cost of commercial
ofcarbon
aes
JRIES. installation and maintenance.
Chimney
Refractory lining

Door Hood

Shell
Flame
Oil
Svout

Air
Burner

Drive rollers
Motor Sheft

Exhaust

Fig. 15.30. Oil/ Gas Fired Rotary Furnace.