Green Sand, Moulding

Page 1
Technical Presentation
Green sand Molding Management
Page 2
01 Oct 2011, Suranaree University of Technology,
Nakhon Ratchasima
Prepared by U. Ittipon
INTRODUCTION
Green sand Molding process
Green sand molding is more wide develop than any other
process.
Green sand molding is replacing many of the more
expensive molding methods as sand control is being
Page 3
expensive molding methods as sand control is being
applied.
INTRODUCTION
-Green Sand Molding process (bentonite bonded sand)
-Chemical Sand Molding process
CO
2
Mold (Sodium Silicate binder)
Types of Molding process
Page 4
Shell Mold (Phenoric resin binder)
Furan Resin Mold (Furan resin binder)
Cold Box (Polyurethane resin binder)
INTRODUCTION
-Reasonable cost.
-Environmental friendly.
-High productivity (Economical)
Why we use Green sand Molding process
Page 5
-Easily adaptable to manual , semi-auto and automatic
molding Machine.
INTRODUCTION
Green sand Molding process
Jolt Squeeze _Video file
Page 6
Automatic Molding
machine _Video file
PROPERTIES
1- Green sand for moulding must fulfil and pack tightly round the pattern under
pressure. It must be Flowable.
2- Green sand for moulding should be able of being deformed slightly without
cracking, so that the pattern can be withdrawn. In other words, it must exhibit
Plastic behaviour.
3- Green sand must have sufficient strength to strip from the patterns and support its
own weight without deforming, and withstand the pressure of molten metal when the
mould is cast. It must therefore get Green Strength.
Page 7
mould is cast. It must therefore get Green Strength.
4- Green sand should be Permeable, so gases and steam can escape from the mould
at the beginning of pouring.
5- Green sand must get Dry Strength to prevent erosion by liquid metal during
pouring as the mould surface dries out.
6- Green sand must guarantee a good Refractoriness to withstand the high
temperature involved without melting or fusing with the metal.
SAND SYSTEM
Core making
New Sand
Resins
Core wash
Bentonite
Additives Water
New Sand
PREPARATION
Homogenization
Hydration
Mixing
MOLDING
Vertical or Horizontal
Dust
Extraction
CIRCULATION
Aerator
[Increase of
Compactibility]
Page 8
Sand Losses
COOLING
POURING
Sand extracted
Sand adhering to castings
SHAKEOUT
(Drum or Vibratory)
Screening
Magnet.
Separator
CIRCULATION
SYSTEM
Increase of sand
temperature
Burnout of Clay
and Sea Coal
Gas emissions
CASTING DEFECTS
Castings defects relative to Green Sand Moulding could be due to :
- The COMPONENTS of the Green Sand for Moulding
- The PROPERTIES of the Green Sand for Moulding
- The UTILIZATION of the Green Sand for Moulding
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Foundry sand
Bentonite
Additives
GREEN SAND COMPONENTS
Page 10
Water
Additives
Dead Clay
FOUNDRY SAND
SILICA CHROMITE ZIRCON OLIVINE
Formula SiO
2
FeO Cr O
3
Zr Si O
4
2 (MgFe) O
SiO
2
Specific Density 2.65 4.3 4.7 3.5
Bulk density 1.6 2.7 2.8 1.95
Available Materials
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Sinterpoint 1730 2095 >2200 1857
Thermal
conductivity
Low High High Low
Reaction
mold/metal
High Low Low Low
Utilisation All metals
Steel &
Manganese
Steel Steel
Disponibility High Very low Very Low Good
Price Low High High Medium
SILICA SAND
Material used for its Economic advantages and
sufficient thermal resistance
Important characteristics:
The Grain size
The Grains distribution
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The Grains distribution
The Grain surface shape
The thermal resistance
(sinter Point)
Silica content
Main components:
SiO
2
= Min 98 %
Al
2
O
3
= Max 0.13 %
Fe
2
O
3
= Max 0.06 %
Physical properties:
Density = 1.5
Grain size Distribution
10
15
20
25
30
35
40
45
50
I
n
d
i
v
i
d
u
a
l

r
e
s
i
d
u
e

i
n

%
SILICA SAND
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Density = 1.5
Hardness = 7
pH = 7
LOI = Max 0.15%
Moisture = Max 0.1%
Sinter point = Min.1500 C
o
0
5
600 425 300 212 150 106 75 53 Pan
Sieves opening in Microns
AFS No = 55 - 60
3 Screens Distribution with 80 % min on
cumulative ASTM sieves 50, 70, 100
AFS GRAIN FINENESS
SILICA SAND
70 AFS
0
10
20
30
40
50
60
70
80
90
100
R
e
s
i
d
u
e

%
72 AFS
0
10
20
30
40
50
60
70
80
90
100
R
e
s
i
d
u
e

%
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6
2
0
4
0
7
0
1
4
0
2
7
0
6
2
0
4
0
7
0
1
4
0
2
7
0
70 AFS
0
5
10
15
20
25
30
35
40
6
1
2
2
0
3
0
4
0
5
0
7
0
1
0
0
1
4
0
2
0
0
2
7
0
<
5
3
m
R
e
s
i
d
u
e

%
Thermal expansion
Temperature Crystallography
of SiO
2
Density Expansion
rate
SILICA SAND
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Ambient Quarz 2,65 = F (
o
C)
573
o
C Quartz 2,49 1,5%
867
o
C Tridymite
1470
o
C Cristobalite 2,33 3~5%
1730
o
C Amorphous Silica
Thermal expansion
SILICA SAND
SILICA
ZIRCON
OLIVINE
1
2
%

E
x
p
a
n
s
i
o
n
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CHROMITE
-1
0
0
2
0
0
4
0
0
6
0
0
8
0
0
1
0
0
0
1
2
0
0
1
4
0
0
Degrees Celsius
%

E
x
p
a
n
s
i
o
n
Bentonite
Foundry sand
Bentonite
Additives
Page 17
Water
Additives
Dead Clay
RULE OF BENTONITE = THE SAND BINDER
Sand Grains
x 3800
Page 18
(bridge between sand grains)
Sand Grains
Bentonite
WHAT IS BENTONITE?
Bentonite is a type of clay whose main constituent is Montmorillonite
belonging to the smectite group.
CLAYS
(app. 200 types)
1/1 GROUP
Primary layers 7
2/1-1 GROUP
Primary layers 14
2/1 GROUP
Primary layers 10
Sub-groups and families Sub-groups and families Sub-groups and families
Other Clays family
[Tetrahedral - Octahedral Tetrahedral] Layers
Other Clays family Other Clays family
Page 19
SMECTITE FAMILY
Sub-groups and families
MONTMORILLONITE:
Other Clays family Other Clays family
Clays Classification
Division : particles size less than 2 microns
Appearance : no symmetrical particles with lamella tendency.
Dispersion : possibility to make colloidal suspension with more or
less stability in water
Chemical formula : alumina silicates
[Hydrated Alumina and Magnesia silicates]
[Rk: 1 micron = 10,000 Angstrom units ()]
Natural Treasure
WHAT IS BENTONITE?
Montmorillonite has been identified in France by Mr. Damour and Mr. Salvetat
in 1847 on a small mine nearby Montmorillon city (France).
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The first industrial exploitation at the beginning of the 20
th
Century started at a
mine located near Fort Benton in Wyoming province (USA). This explains the
origin of the term Bentonite which was first a trade name.
Bentonite is a relatively soft stone,
formed over geological time by the
natural alteration of volcanic tuffs
due to acid or alkaline rain.
WHAT IS BENTONITE?
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Ca++
Na+ Na+
Aluminium dioctahedral layer
App.
10
LATTICE STRUCTURE
Na+ Na+
Silicon-Oxygen tetrahedral layer
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Na+ Na+
Na+
Aluminium dioctahedral layer
In the nature, existing exchangeable cations are:
calcium => Natural Calcium Bentonite
sodium => Natural Sodium Bentonite
BENTONITE MINES
Most exploitable mines in the world are Natural Calcium Bentonite
Therefore, we are proceeding to a chemical treatment to substitute the Ca
Page 23
Therefore, we are proceeding to a chemical treatment to substitute the Ca
cation by Na cation .
This operation is called ACTIVATION PROCESS that consist in
mixing bentonite with soda ash, combining specific moisture, mechanical
treatment and temperature conditions.
After activation, processed bentonites are called:
Activated Sodium Bentonites.
By pass
process
By pass
process and
characteristics
BENTONITE : LAYERS STRUCTURE
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The space between the layers is maximum with Na-Ions
BENTONITE - MILLING
Granules
Box Feeder
Cyclone
system
[ Material Flow Milling ]
Page 25
Finish Product
Raymond
Mill
Quality
Control
Quality
Control
BENTONITE : FROM MINING TO FOUNDRY
Mining Stocking
Exploitation
Page 26
Activation Drying
Milling
(PM 12)
Packing
BENTONITE : FROM MINING TO FOUNDRY
Raw Material
Drying
Activation / Extrusion
Raw Material Stocking
Mining Exploitation
Mining Exploration
Granules
Page 27
Finish Products Stock
Milling / Drying
Granules Stocking
Finish Product
Packing
Delivery to Foundry Industry
Quality Quality
control control
Foundry
BENTONITE : LABORATORY CONTROL
Swelling Volume Swelling Volume
Water content Water content
Particle size Particle size
Page 28
Wet Tensile Strengths & Green Compression Strengths Wet Tensile Strengths & Green Compression Strengths
Methylen Blue Retention Methylen Blue Retention
VDG P VDG P 69 69 Norm Norm Method Method
swelling volume ml / g
18
17
20
BENTONITE : MAIN CHARACTERISTICS
-Swelling: one of the main characteristics of Montmorrillonite is to fix water molecules between the
layers which causes the inner structural water. Swelling highly depends on the nature and quantity of the
exchanged cations but also on the % of Na
2
CO
3
for Activated Sodium Bentonites.
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5
10
15
18
17
0
5
10
15
0 2 4 6 8
activation rate : % soda ash
-Swelling:
Page 30
% Na
2
CO
3
activation changes according to the origin and content of Montmorrillonite
Control of the Activation = Wet Tensile Strength
Page 31
- Montmorillonite content:
The montmorillonite content is improperly associated to the measurement of the Methylene Blue
Retention. Other methods are difference of density or X-ray diffraction. A calibration is possible to make a
link between the % of Montmorillonite and the MB retention. Professionals agreed to call bentonite, all
clays with Montmorillonite content over 60%.
- Methylene Blue Retention = method based on the retention capacity of Montmorillonite by
the molecules of dyestuff the Methylene Blue. In fact, this test indicates the specific surface of bentonite.
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- Water content:
2 types of water must be considered in case of Montmorillonite:
- Bonding water (existing in the lattice network structure)
[ evaporation from 100
O
C ] = important factors because:
- Exceeding, it can lead to plugging in the pneumatic transport system
- Too low means bentonite will be difficult to re-hydrate
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- Constitution water in the macroscopic primary layers network
[ influence on the durability of bentonite - evaporation around 500
O
C ]
- Particle Size: measure of the sieve residue at 75m with specific equipment.
Page 34
- Too coarse particles can affect the speed of the water absorption.
- Too fine particles can affect the consumption of bentonite (lost in dust collectors)
- Carbonates content:
The purpose is to determine the Total carbonates. (all carbonates existing in the bentonite ie. Na, Ca, Mg,
etc). This process is not to control the activation level but the consistency of the bentonite.
[The volume of CO
2
given off when attacked by hydrochloric acid. Results are expressed in CaCO
3
].
- Cohesion characteristics:
The purpose is to measure the binding capacity of bentonites. These characteristics will be measured by
Page 35
The purpose is to measure the binding capacity of bentonites. These characteristics will be measured by
introducing another component - Silica sand.
Rk = Control receipt on bentonite = VDG P 69 Din Method as mixture of 100 parts silica sand (AFS 55-
60) with 5 parts bentonite and necessary water to get 45% Compactibility.
- Test of Compressive Strengths, Shear Strengths, Wet Tensile strengths.
- Durability:
Capacity of the bentonite to loose its water more or less quickly.
3 methods can be applied:
1- Testing the cohesion characteristics on bentonite heated at 550
O
C (1/2 H in ventilated
furnace) based on the VDP 69 Din Method. Durability is the % of drop between the characteristics
before and after heating.
2- Comparing the MBR on bentonite heated at different temperatures.
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2- Comparing the MBR on bentonite heated at different temperatures.
0
50
100
150
200
250
300
350
400
450
0 100 200 300 400 500 600 700 800
temperature C
M
B
R

m
g
/
g
bentonite 1
bentonite 2
Foundry sand
Bentonite
Additives
Page 37
Water
Additives
Dead Clay
When molten metal is poured, the moulding sand undergoes some
modification that influence casting quality:
Liquid metal could penetrate in the green sand interstice
(Metal penetration defects)
The mould atmosphere is wet and could oxidize the metal.
Oxides could create defects but also react with silica and increase
LUSTROUS CARBON FORMER
Page 38
Oxides could create defects but also react with silica and increase
the casting surface alteration.
Solution :
Addition of Lustrous
Carbon Former
Feature Coals Resins
LOI, %
Sulphur content, %
Nitrogen content, %
92 to 96
0,4 to 0,8
1,2 to 2,6
98 to 100
0,1 to 0,3
0,1 to 3,0
Basic data for Coals and resins (asphalt) suitable for the production of lustrous carbon:
LUSTROUS CARBON FORMER
Page 39
Volatiles, %
Swelling Index
(according to DIN 51741)
Lustrous Carbon, %
Surface quality
34 to 40
2 to 7
9 to 14
Moderate to very good
76 to 98
0
36 to 44
Only in combination with
sea coal, good to
excellent, especially with
thin wall castings.
ECOSIL
Lustrous carbon former, (sea coal) Lustrous carbon former, (sea coal)
is added to green sand in order to : is added to green sand in order to :
prevent metal penetration.
obtain a smooth casting surface.
lessen the incidence of expansion
defects (silica sand dilution).
reduce the mould-wall movement
and formation of shrinkage
Page 40
and formation of shrinkage
cavities.
create excellent breakdown
characteristics of the mould upon
shakeout.
reinforce and to stabilise the
green strength properties of
moulding sand.
To improve moulding sand properties as:
- Elasticity (sand deformation)
- Erosion and abrasion resistance
ADDITIVES
Organic Carbohydrates - Starch
Page 41
- Erosion and abrasion resistance
In specific cases, could compensate the expansion of silica grains (in
fact to reduce expansion defects as scab, rat tail, veining, etc)
Foundry sand
Bentonite
Additives
Page 42
Water
Additives
Dead Clay
WATER
One of the most influent element.
Development of the Moulding Sand Properties
Page 43
Contains impurities that affect the bentonite properties
Na Na
++
Na Na
++
WATER : INFLUENCE OF SALTS
Salt de-actives the
bentonite electrostatic
bonding properties
Normal
Polluted
Page 44
Na Na
++
Na Na
++
Cl Cl
--
bonding properties
Polluted
COMPOSITION : INFLUENCE OF WATER
De-activation phenomenon could be verified by the WTS test.
Page 45
Foundry sand
Bentonite
Additives
COMPOSITION
Page 46
Dead Clay
Additives
Water
DEAD CLAY
The part of bentonite heated above 500
O
C loses its structural water and settles itself on
the sand grain.
This bentonite loses permanently its properties and becomes a dead clay.
At each sand circulation, a part of the sand grains is coated by this dead clay. This is
the Oolitisation process .
Dead clay reduces the expansion of the green sand and permits to fix a part of the free
water in the mold.
Oolitisation process
Page 47
water in the mold.
Dead Clay
High Oolitisation Low Oolitisation
COMPOSITION
100 % = (Silica sand+Dead Clay) + (Active Clay+Combustibles) + Water
Refractory
Absorbents
Catalyst
GREEN SAND MOULDING FORMULA
100 % = SiO
2
+ DC + AC + LOI+ H
2
O
Page 48
The Green Sand Formula depends mainly on:
- the type of sand plant (mixer, cooling system, etc..)
- the type of moulding process
- the type of shake-out process
- the materials used (new sand, bentonite, additives, etc)
- the castings produced (sand/metal ratio, type of metal, etc..)
COMPOSITION
GREEN SAND MOULDING COMPOSITION
Generally, the moulding sand is made up with :
[Iron Castings] [Steel Castings]
Page 49
[Iron Castings] [Steel Castings]
SiO
2
= 75% to 85% SiO
2
= 75% to 85%
DC= 5% to 8% DC= 6% to 9%
AC= 6% to 10% AC= 8% to 12%
LOI= 3% to 5% LOI= 2% to 3%
H
2
O= 2% to 4% H
2
O= 2% to 4%
CONTROL THE COMPOSITION
1- Active Clay (using Methylene-blue method)
The AC determines the quantity (in %) of bentonite that is able to bond the sand
grains. The AC represents the bentonite that could absorb a methylene-blue
solution.
The AC content mainly depends on:
The type and origin of bentonite (MB retention of the bentonite in use in the
Page 50
The type and origin of bentonite (MB retention of the bentonite in use in the
sand system) up-date its value regularly and calibrate each new MB solution
before dosage
The durability of the bentonite (thermal resistance)
The type of metal pouring (grey iron, ductile iron, steel, etc..)
The Foundry equipments (molding process, mixing process, cooling process,
shake-out process)
2- Loss on Ignition (LOI)
The LOI determines any element burnt at 900
o
C that is the combustible materials
in the green sand system. In fact, LOI relates to the carbon former (seacoal), the
structural water of bentonite, the carbonless of core sand, etc.
LOI permits to estimate the exchange of sea coal in the sand system.
The LOI content mainly depends on:
Page 51
The LOI content mainly depends on:
The type and origin of sea coal (composition of the original sea coal added in
the sand system),
The quantity and type of core sand
The Foundry equipments (shake-out process and dust collectors)
3 Water content
The Water Content is one of the most important and easiest test. Water content
affects every properties of green sand, but mainly permits to swell the bentonite.
The test represents the water loss at 105
o
C.
Control sometimes its pH, conductivity (<500 S/cm), hardness and composition if
necessary
Page 52
The Water content depends on:
The type, origin and quantity of bentonite, sea coal and foundry sand in the
system.
The Foundry equipments and its influence on the compactibility required
(molding process, mixing process)
The cooling process (water content in the returned sand system)
4 Silica and Dead clay content
The silica and dead clay represent the refractory part of the green sand.
Dead clay is the bentonite that has lost its structural water.
The Silica content mainly depends on:
The type, origin and quantity of foundry sand and core sand in the system. (Vs
the sintering point of original foundry sand)
Page 53
The Dead clay content mainly depends on:
The type, origin and durability of the original bentonite added in the sand
system,
The quantity of silica sand added in the system.
Inactive fines
Dead- burnt bentonite ( Bentonite which has lost the structural water)
Coal dust particles less than 0.02 mm.
Dead burnt coal dust ( coke, ash).
Natural fines from the base sand.
Crushed and thermally disrupted silica sand grains.
Page 54
Total fines ( Total clay)
Fines are defined as all the particles size that are smaller than 0.02 mm.
Active fines (active bentonite)
Inactive fines
25
50
75
100
Wat er
LOI
Act ive Clay
Dead Clay
Example:
Page 55
No 1 :High silica content (85%), therefore low bentonite , sea coal and dead clay contents.
Main problems are : all defects in relation with the expansion of the silica as veins, scabs but also explosion
- metal penetration, erosion, abrasion defects.
No 2 : Lower silica content (70%) no problem in relation with the expansion of the silica.
Main problems are: all defects as broken mould, formation of lumps, sand-slag defects,
0
25
1 2
Dead Clay
Silica
Page 56
PROPERTIES
Compactibility = Plastic or not?
First Control First Control
Page 57
Compactibility = Plastic or not?
Water content = Dry or wet sand?
Temperature = Hot or cold?
Strengths = Brittle or not?
PROPERTIES : COMPACTIBILITY
The compactibility indicates the water tempering degree of the green sand moulding.
Represented by a percentage number, the compactibility test determines the
decrease in height of a loose mass of sand under the influence of a controlled
compaction.
The compactibility is directly related to the sand quality or the performance of a molding
sand mixture.
The following factors affect the compactibility :
The water content (sand temperature of returned sand)
Page 58
The water content (sand temperature of returned sand)
The mixing time (calibration and mulling energy)
The Active clay and LOI levels
The inert fines (fines from silica absorbing water)
The quality of Bentonite (Swelling capacity, water holding capacity)
The quality of sea coal (type of coal and coke transformation capacity )
The used of starch and Cereals (change the bonding properties)
Video. file
40
42
44
46
Dry sand
OK
Wet sand
50 mm
1
Compactibility %
COMPACTIBILITY
Page 59
32
34
36
38
Sand Specimen Compactibility
Water Content %
40
42
44
46
Compactibility %
7 % 8 % 9 %
Active clay (MBR) %
PROPERTIES : COMPACTIBILITY
Page 60
32
34
36
38
Water content %
PROPERTIES : STRENGTH
The mould sand strength can be expressed by several standard tests :
Green Compression Strength :
Wet Tensile Strength
Dry Compression Strength
Page 61
But also : green shear strength, resistance to fissuring, resistance to abrasion,
etc
They depend on the composition and the preparation of the moulding sand
PROPERTIES
Green compressive strength - GCS: (N/cm
2
)
The working strength of molding sand is a combination of
compressive strength and deformation or mold plasticity ( Keep mold
wall stability).
The most influential factor in controlling GCS is the tempering
moisture , general composition, type and amount of Bentonite binder
Page 62
moisture , general composition, type and amount of Bentonite binder
and degree of mulling ( Active clay and moisture ratio)
Green tensile strength: mostly effect to mold wall stability of
horizontal molding on cope side.
Green Shear strength: mostly effect during remove the pattern or put
core in Mold.
Test Simpson _Video file Test Rid _Video file Test Shear _Video file
PROPERTIES
Wet Tensile Strength WTS : N/cm
2
The working strength for the sand resistance to scabbing and other
sand expansion defect that occur on the iron sand face after pouring.
The water (moisture) from sand layer moves away from casting
surface and creating a water condensation zone between the dry and
wet sand area.
Page 63
Test _Video file
wet sand area.
The strength of the sand in layer of condensation zone is called Wet
tensile Strength
The most influential factor in controlling WTS is type and amount of
bentonite including the content of inactive fines and permeability
Form Compacted moulding sand
Condensation zone
Form - Dried and Burnt moulding sand
Liquid Iron
Strengths profile during the heat penetration into moulds Strengths profile during the heat penetration into moulds
Condensation Condensation
Strengths:
Heat penetration into
Foundry Mold
Problem zones of bentonite bonded sand
Page 64
Form Form-- Dried sand Dried sand
Form Form Tempered Molding Tempered Molding
sand sand
S
t
r
e
n
g
t
h
s

N
/
c
m
2
Form Form-- Dried sand Dried sand
P
e
r
m
e
a
b
i
l
i
t
y
Distance to the liquid metal (mm) Distance to the liquid metal (mm)
M
o
l
t
e
n

M
e
t
a
l
M
o
l
t
e
n

M
e
t
a
l
Dry tensile strengths
Green strengths
zone zone
zone zone
Form Form Tempered Molding Tempered Molding
sand sand
Permeability through different zones of moulding during pouring process Permeability through different zones of moulding during pouring process
WTS Area
- - - - Effect of Starch
PROPERTIES : PERMEABILITY
The permeability indicates the ability of the gas to escape through the mould
The permeability is directly related to the sand composition
The following factors affect the permeability :
The water content
The silica sand AFS index and its repartition
The Active clay, dead clay and LOI levels
Page 65
The Active clay, dead clay and LOI levels
The inert fines (fines from silica absorbing water)
The used of starch and Cereals
The moulding machine
The shake-out
Green Sand Molding test report
Page 66
Green Sand Molding test report
Page 67
Iron Sand ratio
New sand Consumption
Materials Consumption Vs Cast Iron Quality
Heat penetration into mold
Page 68
New sand Consumption
Bentonite Consumption
Coal Dust Consumption
Metal Cast into the mould
Heat Penetration Heat Penetration
__________ __________
Transformations of the molding sand materials Transformations of the molding sand materials
Page 69
FOUNDRY
Page 70
FOUNDRY
MOULD
Pouring
Page 71
Evaporation of the water
at the mould surface
(to external forms of the mould)
Page 72
(to external forms of the mould)
Page 73
Condensation of
the water:
Formation of wet layers
Page 74
Heat Radiation from liquid metal
Reducing Atmosphere
Page 75
Formation of a
Lustrous carbon film
Lustrous Carbon Film Lustrous Carbon Film
Page 76
Gas Cushion
FOUNDRYC
CASTING CASTING
Page 77
FOUNDRYC
ASTING
SAND BURNT
Wet layers
Influences : Iron Sand Ratio
Foundry Example
Iron-Sand ratio = 1:10
Sand Replenishment = 90 kg/t Fe
Bentonite consumption = 45 kg/t Fe
Coal dust consumption = 18 kg/t Fe
Page 78
Influences
Foundry Example
Page 79
Influences
Foundry Example
Page 80
Influences
Foundry Example
Page 81
Bentonite-bonded molding sand Balance
Why a Balance is necessary:
to maintain a constant composition of the green sand molding
to stabilize the properties of the green sand molding to stabilize the properties of the green sand molding
to control the right utilization of the green sand molding
to simulate a specific future condition or future phase of
development
Circulation 1
A
0
[TOTAL AMOUNT = 100]
0,1 A
0
10% Removed
A
B 10% Addition
HOMOGENISATION 90 A
B
Circulation 2
0,1 A
0
10% Removed
B 10% Addition
90 A
10 B
90 A
10 B
A
0
Circulation system General principle
Page 83
Circulation 2
81 A
9 B
B 10% Addition
HOMOGENISATION
B
Circulation 3
10% Removed
10% Addition
81 A
19 B
0,1 A
0
B
A
0
81 A
19 B
72,9 A
17,1 B
HOMOGENISATION
B
Circulation system General principle
Page 84
From this relation, it can be determined how high the percentage of a newly added material is,
at a specific time.
Core making
New Sand
Resins
Core wash
Bentonite
Sea Coal Water
New Sand
PREPARATION
Homogenization
Hydration
Mixing
MOLDING
Vertical or Horizontal
Dust
Extraction
CIRCULATION
Application to the sand circulation system
1. Time needed per sand circulation
2. Number of circulations per working
Page 85
Sand Losses
COOLING
POURING
Sand extracted
Sand adhering to castings
SHAKEOUT
(Drum or Vibratory)
Screening
Magnet.
Separator
Burnout of Clay
and Sea Coal
Increase of sand
temperature
Gas emissions
CIRCULATION
SYSTEM
2. Number of circulations per working
time (hour/day/shift).
3. Exchange rate of materials per
circulation at a specific time
When considering the total moulding sand system,
- A
0
is the total amount of sand in the system as [sum of the sand in the machine bunkers, in the used
sand silos, on the cooling conveyor, etc].
- B
Z
is the sum of all additives as [new sand +recovered core sand + bentonite + sea coal]
- B
n
is the percentage of all new additives in the total sand system after n circulations.
B
n
is the part of the total sand that has been exchanged by the total new additives after n
circulations.
Page 86
Circulation: During a circulation x parts of Material (B) is added to an amount of Material (A) and
the same quantity (x parts) is drawn out of the system. After this both materials are homogenised.
Addition: Material (B) is added, x is the quantity added as a percentage of the amount of material
(A).
Exchange: After n circulations there remains 100% material (B). Material (A) is completely
exchanged.
Page 87
UTILIZATION : green sand circulation report
The green sand circulation system report : essential
driver for technicians
Follow the consumption
of your additives in kg/T
of liquid metal
0
5
10
15
20
25
30
35
40
s
e
a
c
o
a
l

a
n
d

b
e
n
t
o
n
i
t
e

c
o
n
s
u
m
p
t
i
o
n
0
20
40
60
80
100
120
140
160
180
s
a
n
d
s

c
o
n
s
u
m
p
t
i
o
n
New sand 2 2. 0. 0. 7. 20 35 42482416 15112015 4. 1. 5.
New sand 1 65 965026 24 21 15212615 20262213 374863
J
a
n
F
e
b
M
a
r-
A
p
r-
M
a
y
J
u
n
J
ul
-
S
e
p
O
ct
-
N
o
v
D
e
c
J
a
n
F
e
b
M
a
r-
A
p
r-
M
a
y
J
u
n
FOUNDRY XXX - Additives
consumption in kg/ T of liquid metal
Page 88
Be aware of :
-Sand system circulation speed
-Regeneration of additives
-Changes of additives formula
New sand 1 65 965026 24 21 15212615 20262213 374863
Core sand 62 616253 58 61 53637860 68815267 716257
Seacoal 5. 5. 7. 7. 8. 10 7. 7. 6. 9. 5. 6. 6. 5. 5. 5. 6.
bentonite 33 322528 29 25 29282730 24293026 303230
UTILIZATION : Data collection (example)
Total mix Sand Bentonite Sea coal Core Sand Melting Sand Bentonite Sea Coal Core Sand
- Mt - Recovery
08/01/2007 590 5900 6490 1180 13367 140.6 41.97 46.17 8.39 76.1 118.05 46.17 8.39
09/01/2007 587 5870 6457 1174 14631 154.0 38.12 41.94 7.62 76.0 114.14 41.94 7.62
10/01/2007 519 5190 5709 1038 13529 122.4 42.39 46.63 8.48 88.4 130.80 46.63 8.48
11/01/2007 522 5220 5742 1044 9901 118.2 44.18 48.60 8.84 67.0 111.22 48.60 8.84
12/01/2007 579 5790 6369 1158 10890 136.5 42.41 46.65 8.48 63.8 106.23 46.65 8.48
15/01/2007 673 6730 7403 1346 12034 147.7 45.56 50.12 9.11 65.2 110.74 50.12 9.11
16/01/2007 529 5290 5819 1058 8978 127.4 41.53 45.69 8.31 56.4 97.93 45.69 8.31
17/01/2007 599 5990 6589 1198 15304 160.7 37.27 41.00 7.45 76.2 113.45 41.00 7.45
18/01/2007 577 5770 6347 1154 12820 141.4 40.80 44.88 8.16 72.5 113.31 44.88 8.16
19/01/2007 646 6460 7106 1292 12169 144.5 44.72 49.19 8.94 67.4 112.10 49.19 8.94
ADDITIVE RATIO ON JANUARY-FEBRUARY 2007
Consumption Consumption ratio ~ kg per Mt Melting ~
Date Total Sand Total Bentonite Total Seacoal
- kg - Actual
Page 89
19/01/2007 646 6460 7106 1292 12169 144.5 44.72 49.19 8.94 67.4 112.10 49.19 8.94
22/01/2007 635 6350 6985 1270 11017 145.2 43.74 48.11 8.75 60.7 104.44 48.11 8.75
23/01/2007 632 6320 6952 1264 11581 153.1 41.29 45.42 8.26 60.5 101.83 45.42 8.26
24/01/2007 646 6460 7106 1292 10765 151.0 42.77 47.05 8.55 57.0 99.80 47.05 8.55
25/01/2007 621 6210 6831 1242 10633 151.1 41.09 45.19 8.22 56.3 97.36 45.19 8.22
26/01/2007 597 5970 6567 1194 10066 148.7 40.14 44.15 8.03 54.1 94.28 44.15 8.03
28/01/2007 250 2500 2750 500 6411 58.6 42.64 46.90 8.53 87.5 130.11 46.90 8.53
29/01/2007 523 5230 5753 1046 8348 126.2 41.46 45.60 8.29 52.9 94.40 45.60 8.29
30/01/2007 533 5330 5863 1066 8566 120.2 44.34 48.77 8.87 57.0 101.34 48.77 8.87
31/01/2007 570 5700 6270 1140 11241 151.8 37.56 41.31 7.51 59.3 96.81 41.31 7.51
TOTAL 10828 108280 119108 21656 212250 2599
AVG 570 5699 6269 1140 11171 136.8 41.79 45.97 8.36 66.02 107.81 45.97 8.36
SD 90.61 906.10 996.71 181.22 2232.13 22.77 2.33 2.56 0.47 10.76 10.85 2.56 0.47
UTILIZATION : Consumption report (example)
FOLLOW-UP OF THE CONSUMPTION'S RATIO
50.00
60.00
70.00
Bentonite SPEC = 40-60 kg
kg / Mt of liquid Metal pouring
50.00
75.00
100.00
125.00
150.00
175.00
200.00
225.00
250.00
0
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2
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Foundry sand
SPEC = 150-250 kg
Page 90
20.00
30.00
40.00
50.00
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3
1
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0
7
5.00
10.00
15.00
20.00
25.00
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1
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0
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0
9
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1
1
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1
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1
2
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1
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1
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1
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1
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1
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1
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1
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1
9
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1
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0
7
2
0
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1
/
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0
0
7
2
1
/
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1
/
2
0
0
7
2
2
/
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1
/
2
0
0
7
2
3
/
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1
/
2
0
0
7
2
4
/
0
1
/
2
0
0
7
2
5
/
0
1
/
2
0
0
7
2
6
/
0
1
/
2
0
0
7
2
7
/
0
1
/
2
0
0
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2
8
/
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1
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2
0
0
7
2
9
/
0
1
/
2
0
0
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3
0
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1
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2
0
0
7
3
1
/
0
1
/
2
0
0
7
Sea coal
SPEC = 15-20 kg
UTILIZATION : GSB calculation(example)
Page 91
Thank you
Page 92
Thank you

Green Sand, Moulding

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