SAND Casting Report - Bengkel Foundary - Muhammad Lukman BIN Romzi (04DKM20F1056) PDF

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DEPARTMENT OF MECHANICAL ENGINEERING SESSION : 1 2021/2022 CODE : DJJ20042 - MECHANICAL WORKSHOP PRACTICE 2 REPORT BENGKEL SAND CASTING PROCESS

NAME : MUHAMMAD LUKMAN BIN ROMZI NO.MATRIX : 04DKM20F1056 CLASS: DKM3B LECTURER’S NAME : PUAN ROHANA BINTI SEMAAIL@ISMAIL

TITLE - SAND CASTING PROCESS

OBJECTIVE 1. To get a hands-on experience on metal casting through the process of sand casting. 2. To deploy the knowledge of metal casting into making useful products through the process of sand casting. 3. To use a new, indirect composite tooling technique to produce molds for the lost-foam pattern making process. 4. Identify the capabilities of the lost foam casting process. 5. To fabricate a mould for casting cavity based on given pattern assembly. 6. To melt a given metal and adjusting any relevant chemical alteration. 7. To pour the molten metal, let it solidified inside cavity and observation on product quality

EQUIPMENTS :I. II. III. IV. V. VI. VII. VIII. IX. X. XI. XII. XIII. XIV. XV. XVI. XVII. XVIII.

Wood block Hand saw Chisels File Hammer Sand + Clay + Water Cope and Drag Plywood Parting powder Spru Wood hammer Pattern Puller Screw Furnace Shovels Trowels Rammers Hand Grinder Sand paper

INTRODUCTION OF PATTERN : This process is the oldest one used since ancient times up until today. A mold is produced by compacting molding sand (silica sand mixed with a proportion of clay that acts as glue), around pattern components that is usually made of wood. These molds are dividedinto two or more parts. The top of the mold is called "COPE" and the bottom is called the "DRAG". This arrangement allows the form / pattern of the wood produced and thereby leaving an empty mold form in which it will be filled with liquid metal

PROCEDURE OF MAKING PATTERN DESIGN A) PROCEDURE CASTING 1) 2) 3) 4) 5) 6)

Imagine and sketch the design in the paper Cut the wood block to maximum 10 inch with Hand Saw Draw the design again at the wood block and leave ONE (1) flat surface Use hand tools such as chisels, hammer, file and hacksaw to create the pattern After finished the main design, use the hand grinder to finish the design Use the sand paper to make the pattern smoother

B) PROCEDURE (MELTING METALS AND POURING TO THE SAND CASTING):

1) The mold box is placed on the board flat and clean. Make sure the floor the floor boardswhere the mold is placed is flat. Mold box below must be reversed.

Mold Box or Drag and Flat

2) The pattern of the mold is placed into the box below. Separator powder sprinkled into themold and the pattern of board level.

3) Mixture of fine sand is placed around the pattern until the sand under the cover thicknessof 3 cm all around the pattern. Mixed sand so pressed by the fingertips around the patternto make it compact. Make sure the pattern does not move when a mixture of compacted sand.

Fine sand is placed around the

4) Available mixture of sand into the mold box below to ¾ of the container. After the ram is used to compress the sand with a slow shock. Add sand mixture until it isfull of mold box below and compact with a stronger impact . This process is repeated until the compacted mixture of sand above the mold box below.

Fill the box with one third of sand and Compacting

5) A bar Smoothing is used to smooth the surface above the sand that hasbeen compressed. Leveler bar is pulled from one end of the mold box as he moved left and right

Steel bar used to flatten sand and smooth the

6) Mold box is flip over below to pattern is at the top, then the mold box is placed in the correct position on the mold box like below. Both the mold box is locked withcare so that its position is consistent.

Drag and Cope locked together for consistent

7) The pattern on the right is placed in position on the pattern, then spru placed in a suitableposition. After the powder is sprinkled into the bag separator on the surface of the mold box below.

8) Fine sand is placed around the pattern on the pattern of cover up about 3 cm. Fingers areused to compact the soft sand around the pattern. A mixture of sand added to the box up and pack the mold in the same manner as the fourth step.

9) Leveler bar used to smooth the surface of the mold box. Spatula is usedto smooth the sand surface around spru.

10) Loose up the spru and lift it. Use the vent wire to make the poresof the mold of ventilation in the box.

11) Overturning on a separate box and mold to produce the pattern. Before the adoption pattern tap gently to the surface pattern and sand distant. Use screws to remove the pattern drawing on the pattern and the pattern of the mold. Permanent mold cavity will beproduced after the pattern produced.

12) Metal flow at the end of the grooves made by using the square shape casting spoons. Groove metal flow must connect the cavity and the cavity spru. The groove metal function is to flow of molten metal into the mold cavity from the holespru.

13) Core is placed in position in the cavity of the mold box and then reversed over the moldbox below.

14. Casting spoon with rounded ends used for flushing the basin of the mold box. Mold that has been provided earlier to be near the furnace of molten metal is poured. Flowof molten metal is poured to meet spru and cavity.

15. Give aproper time for the molten metal to solidify inside the cavity. The solidified cavity from themould is removed after the temperature dropped to a proper handling condition (the melted aluminium will turn into solidified metal with 10 – 15 minutes).

16. Finally, this process is mainly to detach the sand from the solidified metal (carefully remove the remaining sand).

RESULT 1. Sketch The Mould

2. The Mould

DISCUSSION 1. Explain on how the water content can be effected the quality of the sand castings •

When mould is applied under drycondition, high moisture content could be an advantage andwhen the strength is the major factor under consideration. These important properties, such as permeability, green compression strength, and dry compression strength attain their highest valuewith moisture of 2% and 4% water addition. This makes 2% and 4% water addition more suitable for optimum moulding properties requirement. Water and clay are the major property variables that influence the strength of the moulding.

2. Explain the problems and difficulties during the practice a) Lower Dimensional Accuracy:No-bake molding can deliver better dimensional accuracy and repeatability than green sand molding, but this process will, on average, provide less precision than other common castingprocesses. b) Pattern Maintenance:While of lower cost than tooling for other casting processes, there is still an art to pattern creation. Patterns can be bulky so the storage must be managed; this is especially significant if the casting is produced infrequently. Patternless molding can relieve some challenges of patternstorage and maintenance. c) Surface Finish:Sand castings tend to deliver a rougher surface finish than other casting processes. That point may be moot if certain surfaces are machined anyway, or if surfaces in the as-cast condition are acceptable.

3) Show some examples of the products made from sand castings

CONCLUSION The sand casting process is a versatile and well understood process. Process refinements over time have helped make sand casting the process of choice for applications in many, many industrial markets. As with most materials and design decisions, a discussion with a metals expert can help drive the best metals decision. For new designs, that is a conversation that best happens as earlyas possible to optimize manufacturability. But even applications that have used metal components the same way for a long time can be evaluated to provide higher performance or a more cost effective conversion to a different process like sand casting. Sand casting is one of the more efficient and environmentally friendly manufacturing processes and at Haworth Castings we are conscious of the impact that sand casting can have on the planet. This process is widely used to manufacture complex parts. All major parts like milling machine bed, the bed of lathe machine, IC engine components, etc. are made by this casting process.

REFERRENCE •

https://www.studocu.com/row/document/university-of-engineering-andtechnology-lahore/manufacturing-process/sand-casting-labreport/1124166

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https://mechanicalenotes.com/casting-process/

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