DEPARTMENT OF TECHNICAL EDUCATION ANDHRA PRADESH

Name of the Staff Members Designation Branch Institute Year/semester Subject Subject Code Topic Duration Sub. Topic : : : : : : : : : : P. Ramulu Work Shop Supdt., Mechanical Engineering Govt. Polytechnic for women, Medak. I year Work shop Technology M-105 Foundry(2/2.14) 100 Minutes Cement bonded sand moulding, ceramic moulding ,shell moulding Animation Clips & Images

Teaching Aids

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Recap
In our previous class , we have learnt
Moulding procedure in which arrangement of cope & drag , pattern, ramming, gate cutting ,pouring of molten metal ,finally moulding is presented
Types of Moulding processes like Green sand moulding Dry sand moulding

Skin dried moulding

Loam sand moulding
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Objectives
On completion of this period , you would be able to know about:
Cement bonded sand moulding Advantages and disadvantages Ceramic moulding Advantages and limitations Shell moulding Advantages and Disadvantages

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Cement bonded Sand moulding

The port land cement of 10% and water 5% are added to synthetic sand. Requires less ramming Setting time is about 72 hours Mould as high strength and hardness. separate cope and drag are prepared and assembled. Vents are made for escapement of flue gasses. Employed for small to large castings.

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Advantages

Smooth surface finish is obtained. Machining is not necessary. Most of sand can be reused.

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Disadvantages
Difficult to knock out of the flask.

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Ceramic moulding
It employs metal pattern. Metal pattern is kept in the flask. Thick slurry of refractory material is applied on pattern . Slurry consists of fine grained Zircon and Silica. Course backing slurry is filled in the flask. It sets within 3 to 5 minutes. Contd..
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Ceramic Moulding
The pattern is withdrawn . The ceramic mould is removed from flask. It is treated with chemical catalyst. It is heated at 9800 C. The molten metal is poured in mould. After solidification, casting is removed

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Ceramic Moulding
FIRECLAY BACKUP CERAMIC FACING COPE PARTING LINE

. .. .. . . .. .. . .. . .. . . . . . .. . . .. .. .. .. .. .. .. .... .. .. .... .. .. .... .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. Fig 1. Ceramic moulding

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DRAG

Advantages
High quality , precision castings are produced. No machining required. All types of materials can be casted. Intricate castings with thin sections can be produced.

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Disadvantages
It is expensive process. Defects at parting line may occur.

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Applications
The following castings are produced Extrusion Dies. Die casting Dies.

Impellers for pump.

Parts for automatic reactor.

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Shell Moulding
Mixture of sand and resin is spread around heated metal pattern. Thin shell is formed. This shell is separated form metal pattern. Two half shells are clamped together to form a mould.

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Preparation of thin shell

Fine silica sand is mixed with 5% resin. Resin is thermosetting material. It is poured in dump box.

Metal pattern is heated to 250 0C.

It is clamped to dump box (moulding box).

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Preparation of thin shell

Fig 2 .Preparation of thin shell

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Preparation of thin shell

Metal pattern has ejecting pins.

Dump box is inverted. The sand resin mixture covers the pattern forming thin shell. Within 30 seconds the resin cures and shell is

formed.

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Separating the shell

Dump box is reversed to original position.

The surplus resin mixture falls back into the box. The pattern plate is removed and shell is ejected out.

Fig 3. Separating the shell

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Mould formation
The mould shell is cured at 320 0C for few minutes. The two halves are joined together . Adhesives is used to join them. This mould shell is placed in a suitable box. It is supported by coarse sand in box. Molten metal is poured in shell mould. It is solidified and casting is removed.

Fig 4.Moulding formation

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Advantages
Accurate castings with good surface finish. Machining is not required. Thin wall sections.

Small holes can be created.

Shell can be reused repeatedly.

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Disadvantages
Cost of resin is high. High cost of metal pattern . Casting size is limited.

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Applications
Used for fine castings. Ferrous and nonferrous metals can be casted. Castings of size a few grams to 25Kg can be

produced.

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Summary
In this class , you have learnt

Cement bonded sand moulding where cement is binder and gives smooth finish on casting
Ceramic moulding where metal pattern and ceramic slurry is used as mould material. It gives castings of high precision and good surface Shell Moulding where shell around the pattern is prepared. It gives a good surface and costly

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Quiz
1. Cement bonded moulding is used for _______ , _______ sized castings. (Small to large)

2. In ceramic moulding _______ ________ material is coated on metal pattern. (Thick slurry of refractory material)

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Quiz

3. __________ __________ moulding is used for tiny and accurate castings. Shell

4. Curing of shell mould is done at ____ ___ temperature. 25000C

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Frequently Asked Questions

1. 2. 3. Explain Cement bonded sand moulding. Explain Ceramic moulding. What are the advantages and limitations of ceramic

moulding.
4. Describe Shell moulding with a neat sketch.

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