Banchhor, et al.

, International Journal of Advanced Engineering Research and Studies E-ISSN22498974

Proceedings of BITCON-2015 Innovations For National Development
National Conference on : Innovations In Mechanical Engineering For Sustainable Development
Research Paper
PREDICTION OF OPTIMUM POURING POSITION IN THE
VERTICALLY PARTED AUTOMATIC FLASKLESS GREEN
SAND CASTING PROCESS
Raghwendra Banchhor1, S.K.Ganguly2
Address for Correspondence
1
Associate Professor, 2 Professor and Head, Department of Mechanical Engineering,
Bhilai Institute of Technology, Durg, CG India
ABSTRACT
Casting defects causes losses for a foundry, loss of time for reworked item and loss of material for scrapped unusable
products. Investigating the reason followed by eliminating the causes will reduce defect percentage and positively contribute
to productivity.
In the vertically parted automatic flaskless green sand casting process the pouring position of mould string is an important
parameter to be decided before pouring the mould string to avoid casting defects like fins and metal run out. Fins and run-out
are the casting defects which may occur due to mould separation caused by unbalanced metallostatic force of liquid metal.
This study proposes a mathematical relationship to predict the optimum pouring position of the mould string with varying
pattern plate utilization, sand metal ratio and metallostatic head in Disamatic moulding line. A table is presented to guide the
operation team to predict the optimum pouring position
KEYWORDS: Flaskless green sand moulding, Sand-metal ratio, Pattern plate utilization, Optimum pouring position.
1. INTRODUCTION established on the conveyor. The molds can now be
Vertically Parted Automatic Flaskless Green Sand filled with molten metal and the poured molds will be
Casting Process consists of a molding machine and moved forward on the cooling conveyor in the same
mold transporting conveyor. It applies clay green pace as the fabrication of new moulds takes place. At
molding sands mixtures consist of silica sand, clay the end of the conveyor the solidified castings are
called bentonite and few other additives. Their main separated from the molds and processed further,
component is relatively cheap silica (SiO2) sand, one while the sand is directed to the sand preparation
the most common compounds on the Earth. The plant for reconditioning and reuse in the next cycles
molding sand mixture is blown by means of of the molding process.[1-5].
compressed air into a rectangular steel chamber, 2. LITERATURE REVIEW
squeezed to a mold by two patterns fasted to the two In the vertically parted automatic flaskless green sand
opposed side plates of the chamber. After squeezing casting process the pouring position of mould string
one of the chamber plates retracts and swings is an important parameter to be decided before
upwards and the opposite plates pushes the ready pouring the mould string to avoid casting defects like
mold out of the chamber on a mold transporting fins and metal run out. Fins and run-out are the
conveyor. Here cores can be set automatically into casting defects which may occur due to mould
the mold cavity while the next mould is about to be separation caused by unbalanced metallostatic force
prepared. The above cycle repeats until a chain of of liquid metal.
such molds closed-up to each other has been

Figure1: Optimum Pouring Position in Disamatic moulding line [7]

Fins mould. This occurs during the pouring or just after
A thin projection of metal, not intended as part of the the pouring of mould.
casting is called fin. In usually occurs at the parting 3. METHODOLOGY
line of the mould or care sections. Mould and core The objective of this study is to establish a
incorrectly assembled cause fins. Insufficient mathematical relationship to predict optimum
weighing of the mould or improper clamping of the pouring position when pouring the mould string of
mould again causes fins. various casting in Disamatic moulding line. The
Run-out methodology used to develop the mathematical
Run-out is a condition in metal casting in which model for optimum pouring position is shown in
liquid metal escape out through the parting line of Figure 2.
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 Banchhor, et al., International Journal of Advanced Engineering Research and Studies
Figure 2. Flow chart for formulating a relationship for predicting optimum pouring length
4. DERIVATION OF MATHEMATICAL
EQUATION FOR OPTIMUM POURING
POSITION
4.1. Expression for Horizontal Force on Mould
due to Metallostatic Pressure:
FH = Horizontal metallostatic force
Wm = Width of the mould (meter)
Hm = Height of the mould (meter)
PPU = Pattern plate utilization factor
g = Acceleration due to gravity (m/sec2)
HA = Average metallostatic height (meter)
M = Density of the metal (kg/m3)
FH = M g (projected area of mould cavity occupied
by liquid metal) HA
FH = M g (Wm x Hm x PPU) HA
4.2. Expression for Resistive Frictional Force
between mould string and AMC:
FR = Friction force between mould string and AMC
= Coefficient of Friction between mould string and
AMC
Wm = Width of the mould (metre)
Hm = Height of the mould (meter)
L = Length of mould string between moulding
machine and pouring position (meter)
VU = Volume Utilization factor of moulds
S = Density of Squeezed moulding sand (kg/m3)
FR = Coefficient of Friction x Normal Reaction
= x Weight of all empty moulds between
pouring position and moulding machine
FR = (Wm x Hm x L x VU ) S g
The Volume utilization factor of moulds is defined as
the ratio of volume occupied by the compacted
moulding sand to the total volume of the mould
4.3. Expression for Optimum Poring Position
To avoid separation of moulds in the mould string the
resistive frictional force between the mould and
Int. J. Adv. Engg. Res. Studies/IV/II/Jan.-March,2015/223-226
E-ISSN22498974
automatic mould conveyor should be greater than or
equal to horizontal pushing force due to metallostatic
pressure of liquid metal in the poured mould
FR S x FH
Where S is a factor of safety which is taking into
account the internal mould gas pressure, pouring
choke pressure into account.
PPU x H A M 1
L Sx
S SM
M = Density of the metal = 7000 kg/m3
S = Density of Squeezed moulding sand = 1500
kg/m 3
= Coefficient of Friction between mould string and
AMC (in worst case) = 0.25
S = Factor of safety (Assuming extra pressure in
excess of metallostatic pressure will normally not
exceed 20%) = 1.2
L 1.2 x PPU x H A 7000 1
0.25 1500 SM
L PPU x H A 22.4 SM 4.8
SM
4.4. Range of Independent Variables
Range of average metallostatic height considering the
safety margin of mould cavity from the edges of the
= 0.1 to 0.4 meter
Range of Sand Metal Ratio (SM) = 3 to 20
Range of Pattern Plate Utilization Factor (PPU)
= 0.2 to 0.7
Considering above ranges of matallostatic height,
sand metal ratio and pattern plate utilization factor
Tables are prepared to find optimum pouring position
i.e. the distance of pouring ladle from the chamber
front of moulding machine.
 Banchhor, et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974

Table1 : Optimum Pouring Length

Length of Mould String Between Moulding Machine and Pouring Position "L" (meter)

Pattern Plate Utilization Factor (PPU)

HA = 0.2 meter
0.2 0.3 0.4 0.5 0.6 0.7
3 0.96 1.44 1.92 2.40 2.88 3.36
4 0.94 1.42 1.89 2.36 2.83 3.30
5 0.93 1.40 1.87 2.34 2.80 3.27
6 0.93 1.39 1.86 2.32 2.78 3.25
7 0.92 1.39 1.85 2.31 2.77 3.23
8 0.92 1.38 1.84 2.30 2.76 3.22
Sand Metal Ratio (SM)

9 0.92 1.38 1.83 2.29 2.75 3.21

10 0.92 1.37 1.83 2.29 2.75 3.20
11 0.91 1.37 1.83 2.28 2.74 3.20
12 0.91 1.37 1.82 2.28 2.74 3.19
13 0.91 1.37 1.82 2.28 2.73 3.19
14 0.91 1.36 1.82 2.27 2.73 3.18
15 0.91 1.36 1.82 2.27 2.73 3.18
16 0.91 1.36 1.82 2.27 2.72 3.18
17 0.91 1.36 1.81 2.27 2.72 3.18
18 0.91 1.36 1.81 2.27 2.72 3.17
19 0.91 1.36 1.81 2.27 2.72 3.17
20 0.91 1.36 1.81 2.26 2.72 3.17

HA = 0.3 Pattern Plate Utilization Factor (PPU)

meter 0.2 0.3 0.4 0.5 0.6 0.7
3 1.44 2.16 2.88 3.60 4.32 5.04
4 1.42 2.12 2.83 3.54 4.25 4.96
5 1.40 2.10 2.80 3.50 4.20 4.91
6 1.39 2.09 2.78 3.48 4.18 4.87
7 1.39 2.08 2.77 3.46 4.16 4.85
Sand Metal Ratio (SM)

8 1.38 2.07 2.76 3.45 4.14 4.83

9 1.38 2.06 2.75 3.44 4.13 4.82
10 1.37 2.06 2.75 3.43 4.12 4.80
11 1.37 2.06 2.74 3.43 4.11 4.80
12 1.37 2.05 2.74 3.42 4.10 4.79
13 1.37 2.05 2.73 3.42 4.10 4.78
14 1.36 2.05 2.73 3.41 4.09 4.78
15 1.36 2.04 2.73 3.41 4.09 4.77
16 1.36 2.04 2.72 3.41 4.09 4.77
17 1.36 2.04 2.72 3.40 4.08 4.76
18 1.36 2.04 2.72 3.40 4.08 4.76
19 1.36 2.04 2.72 3.40 4.08 4.76
20 1.36 2.04 2.72 3.40 4.08 4.75

5. RESULT AND DISCUSSION: REFERENCES

Expression for pouring position : 1. Moulding solutions, www.disagroup.com
2. Disamatic moulding explained,
L PPU x H A 22.4 SM 4.8 www.metaltechnology.com
SM 3. Variation of green sand molding, Flaskless
Expression for pouring position clearly molding, www.engineershandbook.com
indicates that optimum pouring position 4. Vertical and Flaskless moulding,
depends on metallostatic height, sand metal www.industrialmetalcasting.com
ratio and pattern plate utilization. 5. DISA MATCH article by Michael Colditz, State
To avoid mould opening by pouring operation of the art in the manufacture of flaskless,
horizontally parted moulds18/06/2012
optimum pouring position should be taken into
6. Per Larson, Iron melt flow in thin walled section
consideration. cast in vertically parted green sand mould,
Following the proposed guideline during metal Industrial research project at DISA Industries,
pouring surely prevents occurrence of casting Technical University of Denmark
defects due mould separation caused by 7. Application Manual (2011), Sand Moulding
metallostatic force of liquid metal. System, DISA 230-A, Reg. No. 9155 H 6910,
Edition 11-04.

Int. J. Adv. Engg. Res. Studies/IV/II/Jan.-March,2015/223-226

 Banchhor, et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974

8. Serope Kalpakjian and Steven R. Schmid , "

Manufacturing Engineering and Technology ",
4th edition , Pearson,New Delhi,2013
9. Raghwendra Banchhor,S.K.Ganguly, Critical
Assessment of Green Sand Moulding Processes,
International Journal of Recent Development in
Engineering and Technology Website:
www.ijrdet.com (ISSN 2347 - 6435 (Online)
Volume 2, Issue 4, April 2014) 90
10. Raghwendra Banchhor, S.K. Ganguly,
Optimization in Green Sand Casting Process for
Efficient, Economical and Quality Casting, Int J
Adv Engg Tech/Vol. V/Issue I/Jan.-
March,2014/25-29.
Note: This Paper/Article is scrutinised and reviewed by
Scientific Committee, BITCON-2015, BIT, Durg, CG, India

Int. J. Adv. Engg. Res. Studies/IV/II/Jan.-March,2015/223-226