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LABORATORY REPORT
Program
Course
Course Code
Laboratory Name
Lecturer Name
Title of Experiment
Group
:
:
:
:
:
:
No
Student Name
.
1. USMAN BIN TAIB
Student ID Number
2013233774
2.
2013677274
3.
2013633416
4.
2014256308
5.
2013652164
Signature
KUMPUL
AN
30
Contents
Objectives...................................................................................................................................3
Introduction................................................................................................................................3
Apparatus...................................................................................................................................6
Industrial Apparatus...................................................................................................................9
Procedure....................................................................................................................................9
Results and Data Analysis........................................................................................................10
Discussion................................................................................................................................12
Conclusion................................................................................................................................13
Recommendations....................................................................................................................14
References................................................................................................................................15
Objectives
1. To measure the properties of molding sand, green compression strength and permeability
of green sand.
2. To study about molding process.
Introduction
A basic understanding of the materials that constitute a green sand system
and the required equipment to prepare the material are extremely important to
assure castings quality. Green compression strength and permeability are important
mechanical properties to be considered in moulding preparation. Green sand is
made up from silica sand, bentonite, coal dust and water with ratio of 4 : 2 : 2 : 1.
There are four types of test for sand strength which is compression, shear,
tensile, and over-hang bar test. Based on these four test, compression test is most
widely used and very convenient for routine testing of all types of national bonded
and synthetic moulding sand. Green compression strength is define as stress
required to rupture the sand specimen under compressive loading. The sand
specimen is then taken out of the specimen tube and immediately put on the
strength testing machine to determine the force required to cause the compression
failure. The green sand is generally range of 0.03 to 0.16 MPa.
Permeability is defined as property of sand which permits the steam and other
gases to pass through the sand mould. Permeability of moulding sand is controlled
by several factors such as sand particle size and shape, water content of the
moulding mixture and clay content of the moulding mixture. Coarse grained sands
are more permeable than finer ones. Figure 1 and 2 shows the effect on permeability
based on grain size and water content.
2000 cm
the standard specimen while it is confined in the specimen tube with three blows of
standard rammer and under a pressure of 10
V .H
. A.T
where,
V : volume of air =
2000 cm3
gm/cm
2000 cm
1 2
3000.7
T ( sec)
30557
30557
=
air pressurecm of water time( sec) p t
Apparatus
Materials:
1) Green sand : Made of silica sand, bentonite, coal dust and water.
Equipment:
2) Permeability Machine
sand in
through the
permeability or
pass
cc/min.
: To ram and compress the sand to reproduce
conditions.
4) Universal Strength
Testing Machine
Hand Tools:
5) Vernier Caliper
6) Specimen Tube
shape, its
standard test sample shape and before ramming under the sand
rammer.
Industrial Apparatus
In the industry, the apparatus used varies than what is used in the faculty
laboratory.
1)
2) The universal sand strength testing machine is the faculty laboratory are
not electronic, therefore zero and parallax error can occur if the values are
not read properly. In industrial applications, the universal sand strength
testing machines are electronic, such as supplied by Simpson Analytics
Electronic Universal Sand Strength Model 42104. This eliminates zero and
parallax error and a more precise reading of results.
3) As for the permeability machine in the faculty laboratory, it is also not
electronic, and errors can occur when taking the readings. In industries, it
is much more advanced as it is electronic like the Simpson Analytics
Absolute Permeability Tester Model 42501. This way, the results obtained
are much more accurate.
Procedure
1. The green sand was prepared by mixing it again with water to increase its water
quantity in the sand and placed it into a container.
2. The green sand was scooped onto electronic scale and the weight of the sand was
recorded.
3. The casing was cleaned thoroughly to ensure there was no unwanted sand in it.
4. It was transferred into the casing with its bottom covered using a funnel.
5. The casing and the green sand was placed onto ramming device and rammed for 3
times to compact the sand.
6. The cover was removed and the casing was placed into permeability machine and
tested for its permeability and the reading were recorded
7. The green sand was removed from its casing and the length of the specimen is
measured using Vernier calliper.
8. If the length was higher or lower than the limit which is 50.675 to 50.925 mm, steps 2
to 6 were repeated.
9. If the length is acceptable, the specimen was transferred into sand universal sand
strength testing machine. The strength of the specimen was recorded.
64
62
65
68
65
70
Height of sand
(mm)
48.86
50.3
50.9
51.34
51
53.6
50.3
50.9
51.34
51
53.6
Calculation:
P= (V. H)/ (p. A. T)
The theoretical properties of permeability for green sand are;
V: volume of air = 2000 cm
H: height of sand specimen = 2 inches = 5.08cm
P: pressure = 10 gm/cm
A: cross sectional area of the sand specimen =1in = 6.4516 cm
T: time, min, for 2000 cm air to pass through specimen = 1min
P=
VxH
PxAxT
P=
2000 x 5.08
10 x 6.4516 x 1
P=157.48 cc /min
Theoretical Value,
Percentage
Pexp (cc/min)
65
Ptheory (cc/min)
157.48
Error (%)
58.72
Percentage of error =
Experimentalvalue Theoreticalvalue
x 100
Theoreticalvalue
65 157.48
x 100
157.48
= 58.72 %
Discussion
The experiment was executed to analyze the green compression strength and the
permeability of molding sand. Both of these properties are very important to determine the
optimum moisture content to produce a good green sand casting mold. Permeability is the
rate of air flow through the specimen. By getting the permeability value, we can determine
the type of molten metal that is most suitable to be used for the green cast molding. If the
permeability number between 0-50 cc/min, it is considered too low and the range between
150-300 cc/min considered too high. Permeability within the ranges of too low and too high
can lead to defects in the cast when poured into the mold later on. The optimum range for
the permeability for the green sand is 80-150 cc/min. The green compression strength on the
other hand, is referring to the stress required to rupture green sand specimen under
compression loading. The strength is obtained by using universal sand strength testing
machine. The ideal strength of green sand is generally in the range between 0.03 to 0.16
MPa.
Conclusion
It is clearly proven in this experiment that the green compression strength and
permeability test is crucial in obtaining the most optimum sand mold before proceeding for
mold preparation and pouring of molten metal. If the sand specimen is not within the
optimum permeability range value of 80-150 cc/min, the cast will exhibit defects, like gas
defects as the air and steam are not able escape when the molten is poured into the mold.
As for the green compression strength, it is too crucial for the value to be in the optimum
range of 0.03-0.16 MPa as for it to be able to withstand compression loading and will not
rupture upon the pouring of molten metal. By knowing the strength of the green sand mold,
we can determine suitable melting point that the green sand mold can withstand and
subsequently what molten metal can be used for the cast. It is essential to prepare the most
suitable mold before proceeding to pour the molten metal suitable based on its strength and
permeability. Errors that have occurred in this experiment must be avoided in the future to
produce and obtain the most accurate results. Parallax error which is the most recurring
error in the experiment must be eliminated by making sure the readings are taken parallel to
eye level and in bright light. The preparation of the specimen also must be done properly
and with care to ensure it does not contaminated by environmental factors.
Recommendations
During conducting this experiment, there are few recommendations to improve
the accuracy of this experiment :
a) Green sand produced must have right composition of silicon sand, bentonite,
coal dust and water for sand casting quality.
b) The sand specimen can be placed in closed area to prevent the loss of
moisture that will cause drying of the sand specimen.
c) The rammed sand specimen must be handled carefully and avoid too much
force during handling in order to get accurate height of the sample.
d) Carefully remove or take out the sand specimen from specimen tube to
prevent the specimen from rupture.
e) Right amount of water must be added to the sand to ensure the sand
specimen is not too wet or too dry for the bonding of the green sand.
f) Sand specimen must be rammed only three times to obtain accurate height
for strength testing.
References
1. American Foundry Society. (2001). Mold And Core Handbook Third Edition.
2. Bureau Of Indian Standards. (1997). Methods Of Physical Tests For Foundry
Sands.
3. Pn Rao. Manufacturing Technology