FACULTY OF MECHANICAL ENGINEERING

BMM 3611
MANUFACTURING PROCESSES LABORATORY

SOLIDIFICATION PROCESSING LAB

(Casting)
Laboratory Date
Submission Date
Lecturer
1)
JP/PJP

2)
3)

Learning objectives
By the end of semester, students should be able to:
1. Know safe practices in manufacturing processing area.
2. Know tools, equipment and raw material for the respective lab.
3. Know standard operating procedure for the demonstrated machine.
4. Analyzed specific case study related to manufacturing process.

Members

ID

Section

Signature

1. Introduction
The objective of this laboratory is to provide hands on experience of sand casting
process. Casting generally means pouring molten metal into a refractory mold with a cavity of
the shape to be made, and allowing it to solidify. When solidified, the desired metal object is
taken out from the refractory mold either by breaking the mold or taking the mold apart. The
solidified object is called casting. This process is also called founding. Casting required
fabrication of pattern, mold constructions and pouring of molten metal
2. Lab activities
Safety in lab

Know tools and processes materials

Brief on all machines

Case study

Activity
Safety

Know tools,
equipment and
materials
Intro to SPL
Case study

Task

Form

Each student gather in group

In sequence, each student read the saftety clause. If not
understand, put a note and JP/PJP will explain later.
Sign the acknowledgement forms
JP/PJP will give 10 questions about raw material, tool and
equipment application in this lab.
Student must find out the answer. (Eg. tool name & their
purpose, raw material description and the final product, etc..)
JP/PJP give brief explainaton on all machines in SPL ( their
function advantages & limitation)
Student must give attention. Prefer to take a note.
A case study requires student to find out an answer on the
specific problem in production.
Based on the chosen case study, JP/PJP will explain and
demonstrate process sequence (SOP) for the selected process.
In certain cases, student will be asked to do spesific task.
Student must explain thoroughly on outcome of their
investigation

Acknowledgement
of safety
requirement form
Give your answer
in lab report

JP/PJP brief

Describe in details
in lab report

BMM3611(1112)_SPL ( Casting Lab )

Prepared by:
MZS@FKM,UMP(2012)

3. Case study : Sand casting

Process sequence
o Based on the completed sand casting mould, investigate;
Quality of the mould and pattern such as radiused corners, drafted sides (tapered),
shrinkage allowance and good surface finish.
o Get full specification of the furnace used in this lab.
Check how temperature of molten metal is controlled prior to pouring process
1) Discussion
o Sketch internal sand castings mould configuration.
o What is green sand mold? State the physical and mixture composition of green sand.
o State the essential ingredient of molding sands.
o Discuss the effect of molding parameters. What are the desirable properties of molding
sand required from stand point of view of sound casting?

4. Lab report
For your project report, provide the following:
1. Use a cover page similar to the labsheet format.
2. Contents for the report are;
Introduction, Raw materials, Process tools, Machines and their applications, Case study
Process setting / Design consideration/ Product defect & countermeasure,
Conclusion/Lesson learned, References
3. Discuss the strengths and weaknesses of this laboratory. Did the laboratory help you to learn
the material better? Explain why or why not.
4. The report should be done in MS Word and an equation editor should be used for all
equations.
5. Equations should be numbered and plots should be numbered and referenced with a
descriptive caption.

BMM3611(1112)_SPL ( Casting Lab )

Prepared by:
MZS@FKM,UMP(2012)

BMM 3611
Process Sheet
(Casting)
Sand casting mould details
Type:________________

Number of cavity :_______________________

Mould cheklists
#
1
2
3

5
6
7
8
9

Cheklists
The sand needs to be damp enough to hold its own shape when clenched in the hand. If it is too wet it can
be dangerous when casting and dry sand should be added and mixed. It should be sieved thoroughly and
all lumps removed.
The drag (the bottom half of the casting flask) should be placed upside down on a moulding board and
one half of the pattern should be placed flat side down on it.
The sand should be sieved over the pattern to a depth of at least 30 mm and it should then be rammed
down firmly. Once compact the drag should be filled and rammed once again before finally being leveled
off.
The drag should be turned over and the cope fixed in place and the pattern should be assembled and
lightly dusted once again. Sprue pins should now be inserted and these will ultimately create a cavity for
the metal to run into. The sieving process is repeated and once again the sand should be compacted.
Finally, a small well should be created around the top of one of the sprue pins.
The sprue pins should be removed and the cope and drag separated. Gates and basins should be cut into
the sand in both the cope and the drag before the pattern is removed.
The mould box should now be reassembled and placed on the floor ready for pouring.
With the metal in a molten state, it should be fluxed and degassed to remove any impurities. These will
form on the surface and should be removed before pouring commences.
The melt should be poured slowly and with an even flow into the small well. Once the metal has
solidified, the sand can be broken but great care should be taken because the components and sand may
still be hot.
Finally the casting will need to be fettled which involves cutting off the runners and risers and any
flashes.

List of Tools Used

1. _________________________
2. _________________________
3. _________________________
4. _________________________
5. _________________________
6. _________________________
7. _________________________
8. _________________________
9. _________________________
10. _________________________
BMM3611(1112)_SPL ( Casting Lab )
Prepared by:
MZS@FKM,UMP(2012)

Casting product
1) Draw the designed casting product

2) Casted part inspection

Type of
defects

Inspection
(Visual/NDT Test)

Sketch of the part defects

Countermeasure

BMM3611(1112)_SPL ( Casting Lab )

Prepared by:
MZS@FKM,UMP(2012)