FOUNDRY TECHNOLOGY

Workshop & Industrial Visit

Date : 11 Sep 2013
Time : 9:30 AM

SUGUNA COLLEGE OF ENGINEERING
FOUNDRY TECHNOLOGY
Welcome address:
Thiru T.S.Praveen

Presidential address:
Thiru P.R.Varadharajan

Certificate distribution:
Thiru ARUN RANGANATHAN

Vote of Thanks:
Thiru G.VAITHEESWARAN

FOUNDRY TECHNOLOGY
Workshop & Industrial Visit

Presented by

Thiru V.Govindarajalu
Principal I/C

Thiru V. Muthuramkumar

Thiru V.Sudharsan



MANUFACTURING ?
Converting Raw Material to Useful Product


Example :
Wood Carpentry Chair, Table
Rice+Vegetables Cooking - Biriyani



Types of Manufacturing Processes
Primary:
Casting
Rolling
Forging
Extrusion / Drawing
Secondary:
Machining
Surface Finishing (Coating, Polishing, Painting)
Heat Treatment
Fabrication (Welding/Joining)
CASTING PROCESS
The process of producing parts of desired shapes by
heating the metal and changing its state from solid
to liquid and then pouring into a prepared mould (of
that shape) and then allowing the metal to cool and
solidify.
The solidified piece of metal is known as Casting.
The above process is called Casting Process and
the industry where it is done is called Foundry
CASTING PROCESS
Advantages :
Can create complex part.
Can create both external and internal shapes.
Can with stand 5g to 200ton of shaped object.
It is one of the cheapest in mass production.
Disadvantages:
Limitation on Mechanical properties.
Poor dimensional accuracy and surface finish for
some processes.
Safety hazards to workers due to hot molten metals.
CASTING PROCESS - FLOW CHART
VARIOUS PROCESSES INVOLVED IN CASTING

Designing Methoding
Pattern Making
Molding & Core Shop
Melting
Fettling
Heat Treatment
Inspection
Casting Defects

DESIGNING / METHODING
What to look for?
Material
Quantity
Size and Shape
Application

DESIGNING / METHODING
What to design?
Gating and Risering

DESIGNING / METHODING
What to design?
Directional Solidification
Chilling
Manufacturing Process

PATTERN MAKING
Pattern is a model constructed such that it may be used to form an
impression called mould in sand or other suitable material with
necessary pattern allowances.
The quality of the casting mainly depends on the material of the pattern,
dimensional allowances given and technology used for pattern making.
MATERIAL
TYPES
ALLOWANCES
PATTERN MAKING - CONDITIONS
PATTERN MATERIALS
Materials used to make Pat
WOOD (Cheap, low cost)
METAL (long life, mass production)
PLASTICS (good surface finish, complicate shapes)
RUBBER (water resistance, durability)
PLASTER OF PARIS (accuracy, withstand high temperature)
WAX (fine surface finish, expensive)



TYPES of PATTERNS
Types of patterns are

Single piece
Split piece
Gatted pattern
Match plate patter
Loose piece pattern
Sweep pattern
Shell pattern
Skeleton pattern

PATTERN ALLOWANCES

Major allowances of Patterns are

Shrinkage allowance
Distortion allowance
Machining allowance
Shake allowance
Draft allowance

PATTERN ALLOWANCES
Shrinkage allowance

R = Required Dimension
T = Dimension to keep in Pattern
= R*%Shrinkage
=R*(1+0.0104) - For Cast Iron

PATTERN ALLOWANCES
Draft allowance.

Draft is a slight
slope given to all
vertical faces of the
pattern.
This slope permits
the pattern to be
removed from the
moulding medium
without braking the
mould walls.

PATTERN ALLOWANCES
Distortion allowance.
Castings of irregular shape distort during
solidification because of the metal shrinkage.


MOULDING & CORE SHOP
MOULD & CORE
Mould
A mould is a hollowed-out block that is filled with a liquid
metal. The liquid hardens or sets inside the mold, adopting
its shape
Core
Core is a device used in casting and moulding processes
to produce internal cavities.
MOULDING
TOOLS
MOULDING
SAND
MOULDING
MACHINES
MOULDING TOOLS
Tools used
Moulding board
Moulding box
Rapping plate
Shovel
Riddle
Rammer
Lifter
Sprue pin
Trowel
Bellows
Vent wire
Draw spike
Mallet
Gate cutter
Slick
Sand muller
pan


MOULDING SAND
Molding sand is the raw material used in moulding.The
principle ingredient of moulding sand mix are
Sand grain
Clay
Moisture
SAND PROPERTIES
The molding sand should possess the following properties

Permeability
Flowability
Cohesiveness
Collapsibility
Adhesiveness
Refractoriness
Chemical resistivity
MOULDING MACHINES
Due to some economical and time consuming
moulding machines are used over hand moulding
process.
The machines are
Jolt squeeze moulding machine
Vibratory squeeze moulding machine
Blow squeeze moulding machine
Impact moulding machine
Vacuum squeeze machine
Sand slinger
CORE MAKING
Many cast parts have hollow parts, or other cavities in
their shape that are not directly accessible from
either piece of the mould. Such interior holes are
generated by inserts called cores.
SAND MOULDING METHODS
Moulds may be green sand of metal, ceramica or other
refactive substance.This section is concerned with
preparation of sand moulds.
The principles used in sand casting of metals are important
because of their economic advantage over other
manufacturing methods.
TYPES OF MOULDING
Green sand moulding
Shell moulding
Investment moulding
Die Casting

MELTING
Melting is the process of heating the metal ( till to its melting
point ) and change its state from solid to liquid by using the
principle of furnace.
Commonly used furnace are,
Cupola furnace,
Induction furnace,
Electric arc furnace,
Crucible furnace,etc.,

CUPOLA FURNACE
Working principle:

-oldest primary method of melting in
iron foundry.
-Melts the metal by the application
of heat produced by coke.
-alternate layers of metal to be
melted, coke and lime stone flux are
arranged inside the refractories
which can withstand high
temperature .
-The lime stone flux is used to react
with impurities and floats to the top
metal as it melts.
-used to melt cast iron, ni-resist iron,
some Bronzes.

CUPOLA FURNACE
Advantages:
Advantage is it can carry 5g
to 200 ton of shaped objects.
Continuous in operation
High melt rates.
Relatively low operating
costs.
Ease of operation
Minimum maintenance is
required.

CUPOLA FURNACE
Disadvantage:

Close temperature regulation
is difficult to achieve.
Poor cleanliness
Preparation required during
every start.
INDUCTION FURNACAE

Working principle;
-The principle of Induction motor is to
heat the metal by using high voltage
electric source.
-Most common types used by both
ferrous and non-ferrous foundries.
-Copper coils heat the metal using
alternating currents.
-The flux reacts with impurities and
make them to flat on the top of furnace
and removed.
-used to molten iron and non ferrous
metals

INDUCTION FURNACAE

ADVANTAGE:
-It is very fast process
and it can be handle
safely.
-It heats the impurities at
high temperature and
make them evaporate.
-It withstand 1kg to 100
ton of shaped particles.

INDUCTION FURNACAE

Disadvantage:
-It need more frequency
to operate 50hz,60hz to
400hz and power of
10kW to 15 MW
Only for 20 kg to 30 ton
it major disadvantage.
-Due to high power
more safety precautions
should take over to the
furnace.

ELECTRIC ARC FURCANCE
Working principle:
-From carbon electrodes electric
arc form and melt the scrap
metal.
-Induction furnaces are ideal for
melting and alloying a wide
variety of metals with minimum
melt losses
-The flux react with the
impurities and float on the top of
molten metal and removed as a
slag.
-used to metal iron and steel
Properties of flux ;
-Readily react wit impurities .
-withstand more temperature.

ELECTRIC ARC FURCANCE


ADVANTAGES:
It is a clean operation
Energy-efficient is more
Controlled welding process

LIMITATIONS
The drawback in induction furnace
usage in a foundry is the lack of
refining capacity
Material used should be clean of
oxidation.
Some alloying elements may be lost
due to oxidation.
CLEANING

In cleaning the basic process for removing
runners, rasiers and excess metal.
It is also called fettling.




VARIOUS PROCESS OF CLEANING

Shot blasting,
Hydraulic cleaning,
Sawing,
Machining,
Flame cutting, etc..
INSPECTION
The Product Must Need Proper Inspection To
Find Its Defects.

Types of inspections are
DESTRUCTIVE TEST
NON-DESTRUCTIVE TEST.

INSPECTION
DESTRUCTIVE TEST.


VISUAL TEST
TENSILE TEST
COMPRESSION TEST
BEND TEST
NICK BREAK TEST
IMPACT TEST
HARDNESS TEST


INSPECTION
NON DESTRUCTIVE TEST.
MAGNETIC PARTICLE TEST

Magnetic particle test
Magnetic test may have advantages over RT and UT
But it is only for cracks and discontinous in surface
area
INSPECTION
NON DESTRUCTIVE TEST.
RADIOGRAPHY TESTING

RADIOGRAPHIC TEST
Radiography is one of the most widely accepted NDT
method.
Rays used is
gamma ray, x- ray.

INSPECTION
NON DESTRUCTIVE TEST.
ULTRASONIC TESTING

ULTRASONIC TEST
It a method inspections of detecting dis-continuities by
directing a high frequency sound beam through a
base plate.
INSPECTION
NON DESTRUCTIVE TEST.
DYE PENETRANT TESTING

LIQUID PENETRANT TEST
Surface cracks and pin holes are not visible to nacked
eye. So liquid penetrant is used to find these types
of defects.
Liquid used fluorescent ,visible dye ,white developer.
CASTING DEFECTS

Shrinkage
Cold Shut
Mismatch
Crack/Hot tear