FOUNDRY

Founding or casting is the process of forming metal objects by melting and

pouring it in to mould cavities. A foundry is an establishment for producing casting.

INTRODUCTION TO METAL CASTING PROCESS

Metal casting process can be broadly classified in to two:
1. Conventional sand casting process
2. Special casting process
Sand casting is the most common of all casting processes. Sand moulds are
used for this purpose. All the casting process, other than the conventional sand
casting, is called special casting process. They include shell mould casting, die
casting, investment casting, centrifugal casting etc.

SAND CASTING PROCESS

Sand casting process consists basically the making of the sand mould having
properly shaped cavity and pouring molten metal into it to produce a casting. The
process of produsing sand casting contains the following sections.
1.
2.
3.
4.

Pattern making
Moulding
Melting and pouring
Fetling and cleaning and inspection

The shape of casting is initially made using wood or plastics, which is called
patterns. Using the pattern a cavity is made inside the sand mould and the process is
called sand moulding. Metal to be cast is melted in a furnace and poured in to a
cavity of the mould. After solidification and cooling the sand mould is broken and the
casting is taken out. Unnecessary projections are removed and the surface is clean to
finish the casting for inspection.

Depending on the condition of the moulding sand such as wet or dried at the
time of pouring molten metal. The casting process is divided in to two,
1. Green (wet) sand moulding casting
2. Dry sand moulding casting
Metal commonly cast in foundry can be grouped as given below:
a) Ferrous metal.
1. Cast iron
2. Steel
b) Nonferrous metal
1. Heavy nonferrous metal like copper, zinc, lead and it alloys
2. Light nonferrous metals like aluminium and its alloys

SAND MOULD
A sand mold can be described as a cavity created in compact sand using a
pattern. When filled with molten metal with produce a casting. The process of
producing the required shape of cavity is called moulding. The fig shows a cross
section of a sand mould ready for casting. It contains three parts
1. The lower half is called drag , resting on a bench or floor
2. The upper half is called cope , assembled over the drag
3. The core is fitted inside the cavity of mould

The outer box used for moulding is called flask. It is in two halves (cope &
drag) and is made of iron or wood. The cavity at the center of the sand mould is
shaped by initially placing the pattern and remaining the moulding sand around it.
Then the pattern is withdrawn. The core is fitted in the position and the two halves
(cope & drag) are assembled together to form the mould. Thus it is ready for
pouring. Various terms related to the parts of a mould are given in the fig. The
molten metal is poured to the pouring basin , so that it flows to the cavity after
passing through the vertical spure. The metal comes out through the flow off. When
the cavity is filled and solidified, casting is taken out by breaking the mould.

PATTERNS
A pattern is made of wood, plastic, metal or any other suitable material.
Around which molding sand is packed to shape the casting cavity of a mould. Teak
wood is most commonly used pattern material. Plastics, aluminum, brass and cast
iron are also used as materials for pattern in special casting processes.

TYPES OF PATTERNS AND CORE BOXES

Pattern and core boxes can be classified depending on the shape and size of the
casting, number of castings taken and the method of moulding employed. The most
commonly used wood patterns for sand casting are given below
1. Solid (single piece) pattern made without joint or parting
2. Split pattern this patterns are along parting surface of mould
3. Loose piece pattern this is a pattern with a loose piece, so that the pattern
can be removed from the mould in pieces after moulding.
4. Match plate pattern- they are split patterns, the halves of which are
separated by a plate of the required thickness and shape. Match plate
patterns are generally made of metal or plastics and used for machine
moulding of small components.
5. Gated pattern the passage for flowing molten metal (gates) are provided
inthis type of patterns
6. Sweep pattern moulds which are symmetrical and regular in shape can
be made with the use of a wooden piece called sweep.
7. Segmental pattern they are section of pattern arranged in such a manner
as to form a complete mould by moving form on segment of the mould to
the next
8. Follow board pattern follow board is a wooden board or seat to support
the pattern during moulding so that the function of a split pattern is
achieved
9. Skelton pattern when the casting size is too big the pattern is made as
wood frame (Skelton)
10. Shell pattern hollow construction of pattern reduces weight. The inside
cavity can be used as a core box in shell pattern.

Core boxes although are not referred to as pattern, are required for producing
cores to make holes or under cuts in castings. Core boxes are constructed in wood or
metal. The most commonly used type of core boxes are,
1.
2.
3.
4.

Half core box

Split core box
Dump core box
Stickle core box

While designing the pattern and cores, forevision should be made to support the
cores rigidly inside the mould cavity. For this, an extension called core print on the
core and a similar cavity in the mould is made to support the core
PATTERN ALLOWANCES
The allowances commonly considered for patterns and core boxes are
given below:
1. Shrinkage allowances: 9 13 mm per meter length (approximately 1%) for
cast iron
2. Machine finish allowances: about 3 mm is given as extra size for machining
rough surfaces
3. Pattern draft or taper allowances: a taper of 10 to 20 mm meter (1 in
50mm) for out side vertical surfaces and 40 to 60 mm per meter (1 in
20mm) for inside vertical surfaces

PATTERN MAKING
Basically pattern making is a wood working process and is taking place in
carpentry section. In pattern finishing, all its angled corners are filled in with fillets.
This gives a stronger and cleaner mould and improves strength of the casting.
Wooden patterns, after making and finishing, are coated with shellac and painted as
per American coding for easy understanding of different parts.
1.
2.
3.
4.

Black as cast surface

Red surface to be machined
Yellow core prints, and seats
Red strips on yellow background surface of loose pieces and their seats.

TOOLS AND EQUIPMENT FOR HAND MOULDING

The tools and equipments used for sand moulding process are grouped as :
a. Sand preparation tools and equipments
b. Moulding flasks
c. Moulders tools
SAND PREPARATION TOOLS AND EQUIPMENTS
To prepare the sand for moulding, the following tools are used
1. Shovel: It is used to mix and condition the foundry sand. It is also used to
transfer sand from one place to another.
2. Hand riddle: This is a circular frame fitted with a net, so that the sand can be
riddled (sieved) to remove lumps and foreign materials.
3. Muller: This is a motor operated machine having two stone wheels revolving
at slow speed inside a cylindrical vessel. This can do thorough mixing of the
moulding sand with clay and moisture.
MOULDING FLASKS
They are moulding boxes or flasks used for sand moulding. Wood steel or cast
iron is the material used for flasks. They can be of closed or opened (snap) type. An
open type will be hinged at corner and this enables to open the box by side ways. In
addition to the drag (bottom part) and the cop (top part) if a third middle box is used
for moulding, that box is called cheek.
MOULDERS TOOLS
In hand moulding a number of tools are used to construct, repair and finish
the mould. The most common tools used are given below
1.
2.
3.
4.
5.
6.
7.

Moulding board: It is a wooden board to support flasks and patterns while

moulding
Rammers: It is the tool used to compact the sand by ramming
Strike off bar: It is a metal bar to remove excess sand over box
Vent wire: It is used for making openings in moulds called air vents
Trowels: It is used to finish the mould surface and corners
Slicks: it is used to repair and finish mould surface and corners.
Lifters or cleaners: It is used to finish vertical surface and to remove loose
sand from mould

8. Runner pin and riser pin: To make the down runner (the inlet hole for molten
metal) and the riser passages ( the outlet of gases and to check the filling of
molten metal)
9. Swab: A brush to water the mould surface during finishing or repairing
10. Bellows: For blowing off loose sand from moulding cavities
11. Draw spike and draw screw: Draw spike is a holding tool which is used to
remove the pattern from the moulding cavity
12. Moulding box: Moulding boxes are used for sand moulding. Wood, steel or cast
iron are the material used for moulding boxes. They can be of closed and
opened (snap) type. In addition to the drag ( bottom part) and the cop (top
part), a third middle box is used and is called cheek
13. Gate cutter: Gate cutter is special purpose tool which is used for gate cutting.

HAND MOULDING
Moulding consists of all operations necessary to prepare a mould for receiving
molten metal. Sand moulding usually involves, packing the mixed moulding sand
around the pattern held with in the supported frame (flask). Drawing the pattern to
leave the mould cavity, setting the cores inside the cavity and closing the mould.
These operations can be done either by hand moulding pr by machine moulding. The
most common hand moulding process is flask moulding done over a work bench (
called bench moulding) or on the foundry floor (called floor moulding)
MOULDING SAND AND ITS PREPARATION
Composition
Moulding sand contains the following ingredients:
Sand: silica sand of average fineness no.70 is the major content of moulding
sand comes about 80 to 85% by weight.
Clay: Bentonite is the common type of clay used as binder. The percentage is
varies from 10 to 15 by weight.
Moisture: water about 3 to 6 % is added to actuate the clay for developing
plasticity and strength
Additives: for controlling the mould properties, materials like coal dust,
cereals, iron oxide, wooden floor etc are added in small percentage as additives.

SAND CONDITIONING
The used moulding sand from the foundry floor is added with sufficient
quantity of moisture. The process of spraying water to make it wet is called sand
tempering. The tempered sand is sieved using hand operated or mechanically
operated sieves to remove iron pieces of any large size particles. New sand and
additives are added in sufficient quantity and moisture is added if required. The
mixture is then rammed and mixed several times ( 2 to 4 times) by shovel to coat
sand particles with clay. The sand mixture is tested for its quality and is used for
moulding if it is ok. In mechanized foundries muller is used for mixing operations.
SAND TESTING
Moulding sand properties like moisture content, permeability, strength etc.
are tested after taking sample form batches of conditioned moulding sand. This is
done in sand testing lab of the foundry. For small foundries,only the physical test is
conducted by an expert moulder to judge the quality. For this kind of testing, a hand
full of prepared sand is taken gripped well with fingers and then released. The sand
mass thus produced is broken in to two pieces by hand and the edges found at the
sections are carefully observed. No deformation of edges shows proper sand
conditioning. Gradual setting down of top edge indicates high moistures. Gradual
separation of sand grains from the edge shows low moisture and weak bond. From
experience, moulder can judge quality of the moulding sand by the physical test.
TYPE OF MOULDING SAND
The moulding sand with perfect composition and through mixing is used as
facing sand (sand near by the pattern) in large size moulds. The rest of space is filled
with lower quality moulding sand and it is called the backing sand. To separate the
cope and drag along the mould surface, dry silica sand is used as parting sand.
Facing sand with additive added in required proportion is used for core and is
known as a core sand.
BENCH MOULDING
Moulds for making small castings are made in flasks placed over a bench and
that is called floor moulding. Moulding process using two boxes (the drag and the
cop) are called two box moulding and this is the most common type of moulding
process. If third box is used in between the cope and the drag that box is called cheek
and the moulding is called three box moulding. The boxes are fitted with locating and

clamping devices in order to keep alignment and to prevent lifting of the cope while
pouring molten metal into box.
MOULDING PROCESS
1. Place the moulding board on the work bench and keep the pattern over it with
its flat surface down.
2. Set the drag (bottom part of the flask) over the board keeping the upside down
so that the pattern is located approximately at the center.
3. Fill about 15 to 20 cm layer of facing sand over the pattern and compact and
it bye around the pattern
4. Then fill the backing sand (green sand) in 2-3 layers followed by a ramming to
fill the drag slightly in excess level
5. Remove the excess sand using the strike off bar to get level surface and finish
it by using trowel
6. Make small pin holes with the help of a vent wire so that permeability is
improved for removal of gases during casting.
7. Turn the drag box out side down, so that the parting line face of the
patterncome to the top
8. Finish the top surface with trowel and sprinkle the parting sand over the
surface to form a very thin layer for separation.
9. Fit the cop over the drag in the alignment and place top part of the pattern in
position.
10. Place the runner pin vertical position on the parting face of mould, near by the
pattern and place the riser pin on the top most point of the pattern. A layer of
facing sand is filled and compacted with hand, over the pattern for holding the
pins in position.
11. Fill the baking sand ( green sand ) in two three layers followed by ramming so
that the cope is filled to a slightly excess level.
12. Remove the excess sand using strike of bar and level the surface with a trowel.
13. Make vent holes using vent wire.
14. Remove the runner and riser pins carefully and cut the runner funnel
(pouring basin).
15. Detach the cop and drag and lift it care fully. Place the cope over the board or
bench keeping the parting plane upwards.
16. Cut the runner gate (opening to moulding cavity) from runner hole to the
pattern, using pointed small trowels, slicks and lifter.
17. Moisture the sand around the pattern with the help of swap and draw out the
pattern using a draw screw or spike.

18. Clean the mould cavity and surface using bellows. Inspect the finish and filling
of corners of the cavity. If it is not satisfactory, repair them using moulding
tools.
19. Dust the two halves of moulding cavity in the graphite or coal powder for
better finish of casting.
20. Assembled the two halves carefully, after keeping the core in position, and bolt
them to keep ready for pouring metal.
If dry sand moulds are required, the mould halves may be dried in sunlight
or in ovens. They are assembled at the time of pouring of metal.

MELTING AND POURING

Metal is melted in furnace and the furnace in foundries can be grouped
as
1. Crucible furnace
2. Cupola furnace
3. Electrical furnace
1. Crucible furnace:
Crucible is pot placed inside the furnace in which metal is melted using the
heat produced by burning coke, oil or gas. Metal weighing up to 150kg can be melted
in large size crucible furnace. Figure shows schematic diagram of an oil fired tilting
type crucible furnace. Usually nonferrous metals are melted using this type of
furnace.
2. Cupola furnace:
This is the most widely used furnace in small and medium size foundries,
suitable for melting cast iron. It is cylindrical type vertical furnace erected on four
legs or columns. The shell of cupola is made 8 to 10 mm thick steel plates and the
interior is lined with fire clay bricks. Coke is the material used to burn for
producing heat. Pig iron (raw materials for cast iron), and pieces for old castings,
cock and lime stone are charged (filled) from the top side of the furnace in layers.
During burning of cock, the metal melts and come outs cast iron through metal
spout. The molten metal is collected in ladles and is poured in moulds.

3. Electrical furnace:
Types of electric furnace used in foundries are
1. Induction furnace suitable for melting all metals, used in large size
foundries.
2. Arc furnace usually used to melt steel in steel foundries
3. Resistance type furnace usually used to melt non ferrous metals.

METAL POURING
The handling of molten metal from melting furnace to the mould for pouring
is done using ladles. Ladles are constructed of steel plates and are coated with
refractory material. Large size ladles are handled by over head traveling cranes. For
small and medium size casting, the metal is poured using hand ladles.
The molten metal after taping from the furnace should be poured in moulds
with in seconds. For better fluidity of metal and to get defect free castings of correct
composition, certain chemicals are added to the ladle top carrying the molten metal.
The process is called inoculation.

Model no: 1
Date:

MOULDING OF CYLINDER
Aim:
To prepare a sand mould of cylinder using the given cylindrical split pattern.
Operation to be carried out:
. Preparation of moulding sand
. Compacting of sand over pattern
. Withdrawal of pattern
. Cutting of gatting system
. Finishing of mould surface and dusting
Tools required:
Moulding board, Moulding box, Runner, Riser, Rammers, Vent wire, draw
spike, Trowel, Lifter, Gate cutter, Shovel, Bellows, Brush, Strike off bar
Materials required:
Green sand, Parting sand, Water, Plumago powder
Procedure:
Place the pattern on the moulding board ( half piece of the split pattern). The
box walls are wetted with clay. After placing the drag box, fill it with green sand.
Then ram it initially with peen rammer and ensure that the pattern is covered with
the sand thoroughly. Then fill the drag box completely with the green sand. After
that, ram and level at the top of the drag box with a strike of bar. Then roll over the
drag box on to the moulding board. Then wetted the cope box wall and assemble the
cope with legs on the drag box. Place the second part of the pattern over the first
pattern. Sprinkle the parting sand in side to separate cope and drag. Spure pin
(runner pin) and riser pin are placed in position. Fill the cope with green sand. Then
ram and level it. Then make vent holes using vent wire. Then remove both the
runner and riser pins slowly, after that cut out the pouring basine. Separate the cope
and drag. Remove the pattern with the help of draw spike. Cut out a gate for
connecting the bottom of spure passage with the mould cavity. Reassemble the cop
and drag. The mould is now ready for casting.

Model no: 2
Date:

MOULDING OF STEPPED PULLEY

Aim:
To prepare a sand mould of stepped pulley using the given stepped pulley split
pattern.
Operation to be carried out:
. Preparation of moulding sand
. Compacting of sand over pattern
. Withdrawal of pattern
. Cutting of gatting system
. Finishing of mould surface and dusting
Tools required:
Moulding board, Moulding box, Runner, Riser, Rammers, Vent wire, draw
spike, Trowel, Lifter, Gate cutter, Shovel, Bellows, Brush, Strike off bar
Materials required:
Green sand, Parting sand, Water, Plumago powder
Procedure:
Place the pattern on the moulding board ( half piece of the split pattern). The
box walls are wetted with clay. After placing the drag box, fill it with green sand.
Then ram it initially with peen rammer and ensure that the pattern is covered with
the sand thoroughly. Then fill the drag box completely with the green sand. After
that, ram and level at the top of the drag box with a strike of bar. Then roll over the
drag box on to the moulding board. Then wetted the cope box wall and assemble the
cope with legs on the drag box. Place the second part of the pattern over the first
pattern. Sprinkle the parting sand in side to separate cope and drag. Spure pin
(runner pin) and riser pin are placed in position. Fill the cope with green sand. Then
ram and level it. Then make vent holes using vent wire. Then remove both the
runner and riser pins slowly, after that cut out the pouring basine. Separate the cope
and drag. Remove the pattern with the help of draw spike. Cut out a gate for
connecting the bottom of spure passage with the mould cavity. Reassemble the cop
and drag. The mould is now ready for casting.

Model no: 3
Date:

MOULDING OF FLANGED PIPE

Aim:
To prepare a sand mould of flanged pipe using the given flanged pipe split
pattern.
Operation to be carried out:
. Preparation of moulding sand
. Compacting of sand over pattern
. Withdrawal of pattern
. Cutting of gatting system
. Finishing of mould surface and dusting
Tools required:
Moulding board, Moulding box, Runner, Riser, Rammers, Vent wire, draw
spike, Trowel, Lifter, Gate cutter, Shovel, Bellows, Brush, Strike off bar
Materials required:
Green sand, Parting sand, Water, Plumago powder
Procedure:
Place the pattern on the moulding board ( half piece of the split pattern). The
box walls are wetted with clay. After placing the drag box, fill it with green sand.
Then ram it initially with peen rammer and ensure that the pattern is covered with
the sand thoroughly. Then fill the drag box completely with the green sand. After
that, ram and level at the top of the drag box with a strike of bar. Then roll over the
drag box on to the moulding board. Then wetted the cope box wall and assemble the
cope with legs on the drag box. Place the second part of the pattern over the first
pattern. Sprinkle the parting sand in side to separate cope and drag. Spure pin
(runner pin) and riser pin are placed in position. Fill the cope with green sand. Then
ram and level it. Then make vent holes using vent wire. Then remove both the
runner and riser pins slowly, after that cut out the pouring basine. Separate the cope
and drag. Remove the pattern with the help of draw spike. Cut out a gate for
connecting the bottom of spure passage with the mould cavity. Reassemble the cop
and drag. The mould is now ready for casting.