S4 MECHANICAL

STIST

MODULE 1

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Sand Muller

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Sand Mullers
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MOULDING METHODS
Bench moulding Floor moulding Pit moulding Machine moulding

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Types of Moulds
Green Sand Mould Dry Sand Mould Skin-Dried Sand Mould Air-Dried Sand Mould Core Sand Mould Loam Mould Shell Mould Cement Bonded Sand Mould Ceramic Mould Plaster Mould Sodium Silicate- CO2 Mould
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Types of Moulding
Green Sand Moulding Dry Sand Moulding Skin-Dried Sand Moulding Core Sand Moulding Loam Moulding Shell Moulding Cement Bonded Sand Moulding

Ceramic Moulding Plaster Moulding Sodium Silicate- CO2 Moulding

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Sodium Silicate- CO2 Moulding

Na2 SiO3 + CO2 Na2CO3 + SiO2
Sodium Silicate Silica Gel

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SHELL MOULDING

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Plaster Mould Casting

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Ceramic Slurry

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MOLD MAKING

HAND MOLDING EQUIPMENTS

1. 2. 3. 4. 5. 6.

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Bellow Brush Lifter Dust bag Gaggers Peen Rammer

12. 13. 14. 15. 16. 17.

Spray- Gun Spirit Level Sprigs and Nails Swab Trowels Shovel

7.
8. 9. 10. 11.

Hand Ramer
Floor Rammer Hand Riddle Sprue Pin Sprue Cutter

18.
19. 20. 21. 22.

Vent Wire
Strike off bar Draw Spike Gate Cutter Draw Screws

CORE

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Required Casting

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Pattern

CORE

Properties of CORE Sand

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Green Strength
Dry strength Hardness

Permeability
Refractoriness Collapsibility Should generate minimum amount of gases during pouring of molten metal Bench life (should be able to retain its properties during storage.)

Core Sand Ingredients

1.

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ii. iii.

Granular Refractories
1. 2. 3.

Silica floor Iron oxide

Silica Sand (Dry, Clean & Pure) Zircon Carbon Organic

i. ii. iii. iv.

c)

Other binders
a) b)

Portland cement Sodium silicate

2.

Core Binders
a)

3. 4.

Water Special additives

Core oil Water soluble binders

Synthetic resins, thermosetting

Wood floor

b)

Inorganic
i.

Fire clay

Core Box

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CORE BAKING
EQUIPMENTS USED FOR THE BAKING OF CORES
1.

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Core Ovens
a)

Batch type
i. ii.

Drawer type
Rack type

b)

Continuous type

2. 3.

Dielectric Bakers Radiant Bakers

FINISHING OF CORE
1.

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Cleaning
a) b) c) d)

Trimming Brushing

Coating
Mudding

2. 3.

Sizing

Core Assembly

Core Shifting & Chaplets

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Permanent Mold Casting (Gravity Die Casting)

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CASTING DEFECTS
BLOW HOLES

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BLOW HOLES

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MISRUNS

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COLD SHUT

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MISMATCH

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FINS OR FLASH

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SHRINKAGE CAVITY

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METAL PENETRATION & SURFACE ROUGHNESS

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HOT TEAR

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SLAG INCLUSIONS

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SWELL
Swelled section

REQUIRED CASTING

DEFECTED CASTING
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INSPECTION & TESTING OF CASTINGS

VISUAL INSPECTION DIMENSIONAL INSPECTION PRESSURE TESTING
WATER PRESSURE TEST AIR PRESSURE TEST

RADIO-GRAPHICAL TESTING
X-RAY TESTING -RAY TESTING

EDDY CURRENT INSPECTION ULTRASONIC TESTING

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Radio-Graphical Testing

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LIQUID PENETRANT TEST

1. Section of material with a crack that is not visible to the naked eye.
1 2

2. Penetrant is applied to the surface. 3. Excess penetrant is removed. 4. Developer is applied, rendering the crack visible.
3
4
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EDDY CURRENT INSPECTION

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ULTRASONIC TESTING

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Pouring Cup Sprue Sprue Base/Well Runner Gate Riser

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FUNCTIONS OF A GATING SYSTEM

Fill the mould cavity before solidification starts Reduce the turbulence of molten metal Minimize wastage of metal

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ELEMENTS OF GATING SYSTEM

Pouring basin/cup: Funnel shaped cup which forms the top portion of the sprue. Sprue: A vertical passage, usually tapered to minimize turbulence. It connects the poring basin to runner via sprue well Sprue well: Deep and enlarged portion beneath the sprue It absorbs shocks of the molten metal and retains inclusions Runner: Horizontal passage which connects sprue well & Gates Gate: Passage that finally leads molten metal from runner in the mould cavity Riser: A riser is a vertical passage or opening through the cope
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PRINCIPLES OF RISERING
A riser or a feeder head is a passage of sand made in the mould. The molten metal rises in the feeder head after the mould cavity is filled up. FUNCTIONS OF RISER: Act as a vent for gases Helps to confirm that the mould is completely filled Act as a reservoir of molten metal to feed and compensate for shrinkage during solidification of a casting.
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BLIND RISER

OPEN RISER

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BLIND RISER Advantages:

Smaller in size, less wastage of metal Slow solidification of molten metal

Disadvantages:
Difficult to mould Does not indicate the filling of mould cavity

OPEN RISER Advantages:

Easy to mould

Disadvantages:
Larger in size, more wastage of metal Difficult to remove from the casting KSC-STIST
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CHILLS

External Chills Direct chills Indirect chills Internal chills

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GATING RATIO
Sprue Well area : Runner cross sectional area : Gate cross sectional area 1:3:3 1: 0.75 : 0.50

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TYPES OF GATING SYSTEM

Pressurized Gating System
The total cross sectional area decreases towards the mold cavity

Unpressurized Gating System

The total cross sectional area increases towards the mold cavity

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CENTRIFUGAL CASTING

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CENTRIFUGAL CASTING
True Centrifugal casting Semi-Centrifugal Casting Centrifuged Casting
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TRUE CENTRIFUGAL CASTING

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SEMI CENTRIFUGAL CASTING

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CENTRIFUGED CASTING

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CONTINOUS CASTING

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CONTINOUS CASTING

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