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I. Objectives
To understand the properties of sand moulding and
the relationship between properties of the prepared
sand and sand moulds that includes:
1. Size and distribution of sand grain.
2. Water content or additives contents inside
sand mould.
3. The relationship between permeability, shear
strength, compressive strength in correlation
with water, clay, and additives contents.
4. Sand moulding flowability.
5. Characteristic differences of green sand (wet
sand), dry sand, and dry sand without heated
(holding sand).
II. Theory
The main function of mould in metal casting process
is to provide a shape, dimension, and also surface
characteristic on the cast product. Sand mould is still
used by foundry industry due to the advantages of
using sand mould, as follows:
1.
2.
3.
4.
PRELIMINARY REPORT
SAND MOULDING PRACTICE
From the figure it is known that sand mould has the
advantage in the cooling rate control compared with
conventional metal mould. The cooling rate of metal
mould is faster and it cause some losses to the cast
product.
Physical Properties of Sand Mould
The physical properties of sand mould would greatly
affect to the quality of resulted cast product. Sand
mould to be made are expected to have following
properties:
1. Strength = mould able to withstand the
weight and pressure of molten metal to be
poured into the mould and they do not
collapse when it is moved.
2. Permeability = mould should be easily to
passing the gas away from inside the mould
and the gas which is dissolved in the molten
metal, thus casting defects due to gases can
be reduced or avoided.
3. Flowability = sand able to occupy spaces
inside the mould well.
4. Suitable sand distribution = related to size
and distribution of sand grain in forming
moulds in order to get desired permeability
and good surface properties (smooth surface
and high dimensional accuracy).
5. Adhesive = sand properties that attached to
the mould, thus the mould is not easily
collapsed or detached from the cope and
drag wall before pouring process.
6. Cohesive = it is expected the mechanical
strength of the sand mould becomes better.
Mechanical strength associated with these
properties are as follows:
o Wet strength due to water content.
o Dry strength due to strength without
water content.
o Thermal strength that means a
strength ability to withstand with
molten metal thermal expansion.
o Chemical strength that means not
easily reacted with molten metal.
o High thermal strength.
7. Collapsibility = sand is capable of collapsing
or may be easily destroyed from the mould
(especially for core sand), it is needed in
order to easily reclaimed and reusable.
8. Low expansion coefficient = in order to avoid
excessive expansion during pouring molten
metal.
Type of Sand Mould
ANDARADHI NARARYA
NPM: 1206291992
2. Synthetic sand, e.g. silica sand contain 95%
SiO2.
3. Other type of sand, e.g. zircon sand, olivine
sand, chromite sand.
Moreover, a sand mould also can be divided based
on the sand quality, such as:
1. Low-grade sand which is contains a lot of
impurities. Usually a natural sand.
2. High-grade sand which is contains low
impurities. This sand type is widely used for
mould in metal casting process, such as:
Silica Sand (SiO2)
o It is a synthetic sand contain 95%
SiO2.
o It is widely used due to
availability and low cost.
Zircon Sand (ZrO2.SiO2)
o There are colored and colorless.
o Usually red-yellowish or brown
color.
o Source from pure Zirconium.
o It has high strength at high
temperature.
o It has corrosion resistance.
Olivine Sand (2MgO2.SiO2)
o Low thermal expansion.
Chromite Sand (Fe2O4.Cr2O4)
o Low thermal expansion.
o High thermal conductivity.
o It has good refractory.
Shape and Distribution of Sand
The shape of sand grains would be affect against the
flowability, permeability, and mechanical properties of
sand and its mould. Based on the shape, sand is
divided into four types:
DATE
CHECKED BY
NOTE
Sand Mould Materials
To make a sand mould, it is required several materials
as follows: sand as the main raw material, binder,
water, and additives.
1. Sand as the main raw materials.
2. Binder bentonite is usually used as binder.
Bentonite plasticity would be increase if
contact with water thus it capable to bonding
sand grains.
3. Water it needs to activate the function of
bentonite to bonding sand grains.
4. Additives a chemical compound which is
added in order to improve properties of
mould. Selection of additives must be
considered carefully to obtain effective
functions. Additives materials are as follows:
Reducing agents it is added to
improve the surface of cast part. e.g.
coal dust; coal dust will fulfill the
cavities of the mould thus makes the
permeability reduced. Coal dust will
prevent the formation of silicate or
ferrous oxide as result of molten
metal with sand reaction.
Fibrous agents it reduces the
roughness in cast part and
increasing collapsibility of mould. e.g.
sawdust or asbestos.
Coating agents it coats the mould
surface cavity to make the surface
smooth thus the defect would be
reduced.
Figure below is shown the effect of bentonite and
water composition against sand mould properties.
PRELIMINARY REPORT
SAND MOULDING PRACTICE
Moisture Content Testing
Materials
1.
2.
3.
4.
5.
Silica sand
Water
Bentonite
Molasses
Coal dust
Equipment
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Scale
Oven
Desiccator
Universal sand testing machine
Permeability tester
Flowability tester
Sand rammer
Sand tube
Sand stripping bar
Sieve shaker
Sieve set
Infrared dryer
Brushes
Stopwatch
Start
Permeability Testing
Start
Wet admixture
Ramming
Calculate permeability
Finish
Finish
Flowability Testing
Sieve sand
Ramming
Finish
Compressive Strength Testing
Calculate sample height after ramming + 0.3 mm
Start
Measure mesh and make a note
Calculate weight difference and GFN
Finish
Group samples according to the type
Start
DATE
CHECKED BY
NOTE
Start
ANDARADHI NARARYA
NPM: 1206291992
V. References
1. Metal Forming Laboratory Practice Module.
2015. Processing Metallurgy Laboratory.
Department of Metallurgy and Materials,
Universitas Indonesia: Depok.
2. Priyono, Bambang. 2015. Metal Forming
Lecture Notes. Department of Metallurgy and
Materials, Universitas Indonesia: Depok.