Foundry (Manufacturing Process Module 1)
-
Upload
kailas-sree-chandran -
Category
Documents
-
view
97 -
download
1
description
Transcript of Foundry (Manufacturing Process Module 1)
![Page 1: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/1.jpg)
S4 MECHANICALSTIST
1
MODULE 1
KSC-STIST
![Page 2: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/2.jpg)
Sand Muller
KSC-STIST 2
![Page 3: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/3.jpg)
Sand Mullers
KSC-STIST 3
![Page 4: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/4.jpg)
MOULDING METHODS
•Bench moulding
• Floor moulding
•Pit moulding
•Machine moulding
KSC-STIST 4
![Page 5: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/5.jpg)
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
KSC-STIST 5
![Page 6: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/6.jpg)
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
KSC-STIST 6
![Page 7: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/7.jpg)
Sodium Silicate- CO2 Moulding
Na2 SiO3 + CO2 Na2CO3 + SiO2
Sodium Silicate Silica Gel
KSC-STIST 7
![Page 8: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/8.jpg)
SHELL MOULDING
KSC-STIST 8
![Page 9: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/9.jpg)
Plaster Mould Casting
KSC-STIST 9
![Page 10: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/10.jpg)
Ceramic Slurry
KSC-STIST 10
![Page 11: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/11.jpg)
MOLD MAKING
11
![Page 12: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/12.jpg)
HAND MOLDING EQUIPMENTS
1. Bellow
2. Brush
3. Lifter
4. Dust bag
5. Gaggers
6. Peen Rammer
7. Hand Ramer
8. Floor Rammer
9. Hand Riddle
10. Sprue Pin
11. Sprue Cutter
12. Spray- Gun
13. Spirit Level
14. Sprigs and Nails
15. Swab
16. Trowels
17. Shovel
18. Vent Wire
19. Strike off bar
20. Draw Spike
21. Gate Cutter
22. Draw Screws
12
![Page 13: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/13.jpg)
CORE
Required Casting
13
![Page 14: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/14.jpg)
Pattern
CORE
14
![Page 15: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/15.jpg)
Properties of CORE Sand 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.)
15
![Page 16: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/16.jpg)
Core Sand Ingredients1. Granular Refractories
1. Silica Sand (Dry, Clean & Pure)
2. Zircon
3. Carbon
2. Core Binders
a) Organic
i. Core oil
ii. Water soluble binders
iii. Synthetic resins, thermosetting
iv. Wood floor
b) Inorganic
i. Fire clay
ii. Silica floor
iii. Iron oxide
c) Other binders
a) Portland cement
b) Sodium silicate
3. Water
4. Special additives
16
![Page 17: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/17.jpg)
Core Box 17
![Page 18: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/18.jpg)
CORE BAKINGEQUIPMENTS USED FOR THE BAKING OF CORES
1. Core Ovens
a) Batch type
i. Drawer type
ii. Rack type
b) Continuous type
2. Dielectric Bakers
3. Radiant Bakers
18
![Page 19: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/19.jpg)
FINISHING OF CORE
1. Cleaning
a) Trimming
b) Brushing
c) Coating
d) Mudding
2. Sizing
3. Core Assembly
19
![Page 20: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/20.jpg)
Core Shifting & Chaplets20
![Page 21: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/21.jpg)
Permanent Mold Casting
(Gravity Die Casting)21
![Page 22: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/22.jpg)
22KSC-STIST
![Page 23: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/23.jpg)
23KSC-STIST
![Page 24: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/24.jpg)
BLOW HOLES
CASTING DEFECTS
24KSC-STIST
![Page 25: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/25.jpg)
BLOW HOLES
25KSC-STIST
![Page 26: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/26.jpg)
MISRUNS
26KSC-STIST
![Page 27: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/27.jpg)
COLD SHUT
27KSC-STIST
![Page 28: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/28.jpg)
MISMATCH
28KSC-STIST
![Page 29: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/29.jpg)
FINS OR FLASH
29KSC-STIST
![Page 30: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/30.jpg)
SHRINKAGE CAVITY
30KSC-STIST
![Page 31: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/31.jpg)
METAL PENETRATION & SURFACE ROUGHNESS
31KSC-STIST
![Page 32: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/32.jpg)
HOT TEAR
32KSC-STIST
![Page 33: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/33.jpg)
SLAG INCLUSIONS
33KSC-STIST
![Page 34: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/34.jpg)
SWELL
REQUIRED CASTING DEFECTED CASTING
Swelled section
34KSC-STIST
![Page 35: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/35.jpg)
INSPECTION & TESTING OF CASTINGS• VISUAL INSPECTION
• DIMENSIONAL INSPECTION
• PRESSURE TESTING• WATER PRESSURE TEST
• AIR PRESSURE TEST
• RADIO-GRAPHICAL TESTING• X-RAY TESTING
• γ-RAY TESTING
• EDDY CURRENT INSPECTION
• ULTRASONIC TESTING
35KSC-STIST
![Page 36: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/36.jpg)
Radio-Graphical Testing
36KSC-STIST
![Page 37: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/37.jpg)
37KSC-STIST
![Page 38: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/38.jpg)
LIQUID PENETRANT TEST
1 2
3 4
1. Section of material with a crackthat is not visible to the nakedeye.
2. Penetrant is applied to the surface.3. Excess penetrant is removed.4. Developer is applied, rendering the crack visible.
38KSC-STIST
![Page 39: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/39.jpg)
EDDY CURRENT INSPECTION
39KSC-STIST
![Page 40: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/40.jpg)
ULTRASONIC TESTING
40KSC-STIST
![Page 41: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/41.jpg)
41KSC-STIST
![Page 42: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/42.jpg)
42
• Pouring Cup• Sprue• Sprue Base/Well• Runner• Gate• Riser
KSC-STIST
![Page 43: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/43.jpg)
FUNCTIONS OF A GATING SYSTEM
•Fill the mould cavity before solidification starts
•Reduce the turbulence of molten metal
•Minimize wastage of metal
43KSC-STIST
![Page 44: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/44.jpg)
44KSC-STIST
![Page 45: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/45.jpg)
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 retainsinclusions
• Runner: Horizontal passage which connects sprue well & Gates
• Gate: Passage that finally leads molten metal from runner in themould cavity
• Riser: A riser is a vertical passage or opening through the cope
45KSC-STIST
![Page 46: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/46.jpg)
46KSC-STIST
![Page 47: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/47.jpg)
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 mouldcavity 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 compensatefor shrinkage during solidification of a casting.
47KSC-STIST
![Page 48: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/48.jpg)
48
OPEN RISERBLIND RISER
KSC-STIST
![Page 49: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/49.jpg)
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 49KSC-STIST
![Page 50: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/50.jpg)
CHILLS
50
• External Chills• Direct chills• Indirect chills
• Internal chills
KSC-STIST
![Page 51: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/51.jpg)
GATING RATIOSprue Well area : Runner cross sectional area : Gate cross sectional area
1 : 3 : 3
1: 0.75 : 0.50
51KSC-STIST
![Page 52: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/52.jpg)
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
52KSC-STIST
![Page 53: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/53.jpg)
CENTRIFUGAL CASTING
53KSC-STIST
![Page 54: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/54.jpg)
54KSC-STIST
![Page 55: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/55.jpg)
•CENTRIFUGAL CASTING•True Centrifugal casting•Semi-Centrifugal Casting•Centrifuged Casting
55KSC-STIST
![Page 56: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/56.jpg)
TRUE CENTRIFUGAL CASTING
56KSC-STIST
![Page 57: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/57.jpg)
57
SEMI CENTRIFUGAL CASTING
KSC-STIST
![Page 58: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/58.jpg)
58
CENTRIFUGED CASTING
KSC-STIST
![Page 59: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/59.jpg)
59
CONTINOUS CASTING
KSC-STIST
![Page 60: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/60.jpg)
CONTINOUS CASTING
60KSC-STIST
![Page 61: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/61.jpg)
61KSC-STIST
![Page 62: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/62.jpg)
62KSC-STIST
![Page 63: Foundry (Manufacturing Process Module 1)](https://reader034.fdocuments.us/reader034/viewer/2022052322/553e98c7550346a57f8b4583/html5/thumbnails/63.jpg)
KSC-STIST 63