LAB2

FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMP 1323 MANUFACTURING PROCESS( PROSES PEMBUATAN)

LAB REPORT1

SAND CASTING PROCESS

INSTRUCTOR’S NAME EN. MOHD RUZI BIN HARUN

STUDENT’S NAME MATRIX NO:

S1. MOHD HAMIZAN BIN MOHD RIDZWAN B092010050
S2. MUHAMMAD ADIB ASYRAF BIN ABD NASER B092010204
S3. MUHAMMAD DANIAL AZIZY BIN AZLAN B092010465
S4. MUHAMMAD DANISH BIN JOHARI B092010403
S5. MUHAMMAD AMINUDDIN BIN DAUD B092010323
S6. MOHD SYAFIQ BIN ALI AHMAD B092010154

ASSESSEMENT RUBRICS
GIVEN MARKS
MARK
ASSESSMENT TASK/ITEMS
ALLOCATION S1 S2
1. Introduction (Ability to explain the purpose of 20
the lab session)
2. Results(Ability to construct machine 40
operation, procedures, and safety regulation)
3. Discussion (Ability to explain the importance 20
of selected operation)
4. Conclusion (Ability to conclude the 20
significance of completing the lab)
TOTAL MARKS 100

Approved By: ………………………………………………..…..

(Instructor’s Signature & Stamp)

Date: …………………………………………….........
INTRODUCTION

Casting is one of the earliest metal shaping methods known to human being. It
generally means pouring molten metal into a refractory mold with a cavity of the
desired shape to be made and allowing it to solidify for some time before taking it out.
When solidified, the desire metal object is taking out from the refractory mold either
by breaking the mold or taking the mold apart. The solidified object is called casting.
This process is called founding. Casting required a lot of processes and that includes
fabrication of pattern, mold construction and pouring of molten metal.

In casting, a pattern is a replica of the object to be casted, used to prepare the

cavity into which molten material will be poured during casting process. It provide the
shape for the object that need to be casted. Typically, patterns used in sand casting
may be wood, metal, plastics or other materials. Patterns are made to exacting
standards of construction, so that they can last for a reasonable length of time,
according to the quality grade of the pattern being built, and so that they will
repeatably provide a dimensionally acceptable casting.

The patternmaker or foundry engineer decides where the sprues, gating systems,

and risers are placed with respect to the pattern. Where a hole is desired in a casting,
a core may be used which defines a volume or location in a casting where metal will
not flow into. Sometimes chills may be placed on a pattern surface prior to molding,
which are then formed into the sand mould. Chills are heat sinks which enable
localized rapid cooling. The rapid cooling may be desired to refine the grain structure
or determine the freezing sequence of the molten metal which is poured into the
mould. Because they are at a much cooler temperature, and often a different metal
than what is being poured, they do not attach to the casting when the casting cools.
The chills can then be reclaimed and reused.

Mold construction required some criteria. The choice of molding materials is based
on their processing properties. Generally, the properties are refractoriness, green
strength, dry strength, hot strength and permeability. Refractoriness is an ability of
molding material to withstand the high temperature of the metal so that it does not
cause fusion.

The molding sand that contains moisture is termed as green sand. The sand
selected should have enough strength so that the constructed mold retains its shape. In
the mean time, when the moisture in the molding sand is completely expelled, it is
called dry sand. While the strength of the sand that is required to hold the shape of the
mold cavity then is called hot strength. Finally, the permeability is a term used to
measure gas evolution capability during solidification of a casting.

Pouring of molten metal (Aluminum alloy ingot A356) required a good

discipline both from gating system design and risering system application. Several
parameters are applied such as pouring time, gating elements, gating ratios, and slag
trap system, methods of solidification behaviour, feeding distances and feeding aids.
PROCEDURE
There are 3 types process that are involved in sand casting
1. Melting metal process

 This process is melting Aluminium alloy A356 into aluminium ingot

 Then, it will be heated for 12 hour
 When the metal is heated, it will become liquid metal
 After that, it will be poured into flask

. Preparing moulding sand

 Sand moulding need to be created to ensure a proper sand casting

 This process need to set up properly to preventing any product defect.
 A riser need to be created to release the heat from sand moulding
 After the metal is poured into sand moulding, it need to cooled at least 24
hour
 After the casting cooled, the visual inspection need to be done in product that
casted
. Pouring molten metal ( aluminium ingot a356 )

 Pouring the metal into moulding sand

 Let the casting to be cooled about 24 hour
 Remove the flask and begin visual inspection on the product
Sand Casting terminology
 Cope: Is the top part of the flask.
 Drag: Is the bottom part of the flask.
 Parting line: Is the line where the drag and cope meet
 Pouring cap/basin: This is the hole on top of the cope part made to pour the
molten aluminum into the flask.
 Gas vent: This is so when pouring the molten metal the gas will escape from the
vent. A gas vent can be easily made using a straight wire.
 Riser: The riser will feed more molten metal into the cavity mould when
shrinking accurse.
 Sprue: This is under the pouring cup connected to the runner channeling the
molten metal into the mould cavity.
 Runner: The horizontal channel feeding the molten metal into the mould cavity.
 Mould Cavity: This is where all the molten metal sets creating a duplicate of the
pattern.
 Pattern: Any objects placed in the casting sand creating an impression of the
pattern to be created. A pattern could be made from steel, wood, plastic and other
materials.
MACHINE OPERATION

I. Melting Metal Process

 The furnaces uses a refractory crucible which contains the metal charge.
 The charge is heated via conduction of heat through the walls of the
crucible.
 The heating fuel is typically coke, oil, gas or electricity.
 Crucible melting is commonly used where small batches of low melting
point alloy are required.
 The capital outlay of these furnaces makes them attractive to small non-
ferrous foundries.
II. Creating sand moulding for pouring process

1. Pattern is selected and the drag part of the pattern is placed on the center of the
flask with gate and runner is positioned properly according to the flow
direction of the molten metal.

2. A fine parting powder is sprinkled over the pattern as to ensure that the pattern
can be removed easily from the sand without sticking of sand to the pattern.

3. The moulding sand is riddled to a depth of about 2cm in the drag. This sand is
packed carefully around the pattern with fingers.

4. More moulding sand in the drag is heaped and rammed with rammer carefully.
The excess sand is stroked off using strike bar.

5. This complete drag is turned and the cope portion (flask) is placed over it.

6. The cope half of the pattern is placed over the drag pattern matching the guide
pins and parting sand is placed over the parting surface. The sprue pin and
riser pin is placed in proper positions.
7. The moulding sand is sieved to depth of about 2cm in the cope. More sand is
added and compacted using rammer.

8. The sprue and riser pins are removed and a pouring basin was made. The cope
and drag is separated halves, and their parting is faced up.

9. The pattern is removed halves carefully using draw spikes. The cavities in the
cut gate and runner in the drag is repaired and cleaned.

10. The core was placed in position. The two mould halves was assembled and
clamped together.
III. Pouring melting metal into sand moulding flask

1. The molten metal is poured into the pouring ladle at a higher temperature than
the pouring temperature.

2. Metal is allowed to have sufficient time for complete solidification. The mould
is broke carefully and casting is removed.

3. The riser and gating system is cut-off from the casting and cleaned from any
sand.

4. The casting is inspected visually. Any surface and dimensional defects is

observed and recorded.

5. Finishing process will be carrying out if necessary.

RESULT

The final casting after been cooled

The final product that has made from sand casting

 SAFETY PRECAUTION WHEN
PERFORMING CASTING PROCESS

1. SAFETY PRECAUTION TO USE – Careful layout of studio and procedure,

fireproof clothing, eye protection, skin protection, if concerned about the
binder used in the sand, eye protection from the radiation-infrared radiation
and ultraviolet radiation from melting-good local ventilation for fumes from
melting and from the binding material in the sand.

2. POURING THE HOT METAL – When molten metal is transferred from

furnace or ladle, clearly it can be very hot. Temperature will be in the region
of 800c. During this activity our foundry teams must display the utmost care.
We ensure that they have received the necessary training and guidance to
achieve this, and all times we make sure they are suitably protected with
modern molten metal splash wear clothing.

3. PHYSICAL – Thing that you must be ready is physical if got any tripping,
fire safety, or materials flying into the eyes by accident, moving about the
room with molten metal in crucibles that can pour on you. Those thing are
types of hazards.

4. EXPOSURE ROUTES – Skin contact, both for any potential chemicals used
as binders in the sand, and for burns and so on. Eyes-it’s a good idea to wear
eye protection, whenever around things that can fly through the air or
accidentally be flung about. Inhalation of chemical fumes and metal fumes.

5. ENVIRONMENT - The environment that our teams cast in is well ventilated

to prevent the build-up of any fumes, additionally aided by local exhaust
ventilation. The areas are also off-limits to unprotested personnel during any
casting process.
DISCUSSION

1. What are the importances of sand casting

Sand casting is a processes for metals with high melting

temperatures such as steels, nickel, and titanium. Here is the importances
of sand casting :

Good design flexibility :- The size and weight of parts can range from
few milimetre and grams to meter and many tons

High complexity shapes :- No other process offers the same range of

possibilities for the shapping of complex features than casting

Wider material choice :- virtually all types of engineering alloys can be

cast

Low cost tooling :- Tooling and equipment costs are low compared to
some other metal manufacturing processes

Short lead time :- short lead time compared to others and hence ideal for
shorts production runs

2. What are the critical parameters involved in the process.

Here is the critical parameters that involved in the process:-

1. Pouring temperature.
2. Pouring speed.
3. Solidification time.
4. Mould hardeness.
5. Sand particle size.
6. Permeability.
CONCLUSION

The product is casted successfully based on the proper techniques

and methods which started from the making of the mould using sand, the
removal of the pattern, melting of the aluminium metals and pouring it to
the mould through the sprue and pouring cup. Visual Inspection should be
done to check the strengthness of the product. The quality of product are
determined based on visual inspection that have been made to the
product. Lastly,The finishing work should be done to remove the gate and
runner.
REFERENCE

1. Beeley, P. (2001). Foundary Technology. Woburn: Butterworth-Heinnemann.

Casting Shrinkage. (2015). Retrieved Mac 13, 2015, from ESP International:

2. http://www.espint.com/engineering/technical-reference-guides/casting-design-guide/casting-
design-guidelines/casting-shrinkage.aspx

3. Different types of Castings defects. (2014). Retrieved from Mechanical Engineering:

http://mechanicalinventions.blogspot.com/2012/11/different-types-of-castings-defects.html

4. Hareesha, N. G. (2013, December 18). Sand Moulding. Retrieved Mac 20, 2015, from Slide Share:
http://www.slideshare.net/hareeshang/unit-2sand-moulding-etc

5. Kumar, A. (2011, April). PRINCIPAL INGREDIENTS OF MOULDING SANDS. Retrieved from

Mechanical Arena: http://mechanicalarena.blogspot.com/2011/04/normal-0-false-false-false-
en-us-x-none.html

6. Mechanical Engineering. (n.d.). Retrieved Mac 22, 2015, from Defects In Casting | Molding
Defects | Casting Defects And Remedies:
http://www.mechanicalengineeringblog.com/tag/casting-defects-and-remedies/