Sand is used in various casting techniques ,In this paper efforts are made to evaluate the same of the sand properties which can be used in producing casting etc. Tests conducted compression test,shear test, tensile test.

1. EVALUATION OF ELIGIBILITY
OF FOUNDRY RAW
MATERIALS
PRESENTED BY:
MECHANICAL DEPARTMENT
POCHAM SAIRAM-13D41A0368

2. ÌNTRODUCTION…..?

3. INTRODUCTION
Sand is the raw material required for various
purposes in the modern era right from
electronic goods, construction, extraction,
addition for various alloys and other
manufacturing products.
Sand is used in various casting techniques like
investment casting, liquid sand casting,
conventional sand casting etc.
Study of various sand properties helps to
produce intricate castings.

4. Sand casting is a metal casting process done by using sand as the
mould material. It is relatively cheap and sufficiently for making many
foundry process.
In this paper efforts are made of evaluate the same of the sand
properties which can be used in producing casting etc.
The properties are evolved from various sand available like river, pit,
nallas and open ground.
While experimenting such as delivered good results considering
usual additives like bentonite, pitch, sodium silicate, red iron oxide
etc.

5. MOULDING MATERIAL
• A suitable and workable material possessing high
refractoriness in nature can be used for mold making.
Thus, the mold making material can be metallic or non-
metallic.
• For metallic category, the common materials are cast
iron, mild steel and alloy steels.
• In the non-metallic group molding sands, plaster of
paris, graphite, silicon carbide and ceramics are
included.

6.  But, out of all, the molding sand is the most common
utilized non-metallic molding material because of its
certain inherent properties namely refractoriness,
chemical and thermal stability at higher temperature,
high permeability and workability along with good
strength. Moreover, it is also highly cheap and easily
available.

7. REFRACTORY SANDS
Different types of refractory sands used for
molding are:
• Silica sand
• Magnesite
• Zircon
• Silimanite
• Olivine
• Graphite / carbon

8. Sources of Molding Sand
Molding Sand used in foundries is available in
• River beds.
• Sea.
• Deserts.
• Lakes.

9. TYPESOF MOLDINGSAND
Depending upon the purity and other
constituents present, sand is classified into
• Natural sand.
• Synthetic sand,
• loam sand

10. CLASSIFICATIONOF MOULDINGPROCESS:
A. GREEN SAND MOULDING:
Among the sand casting processes, moulding is most often done
with green sand. The sand is called "green" because of the presence
of moisture.
B. DRY SAND MOULDING:
Dry sand moulds are actually made with moulding sand in green
condition. The sand mixture is modified somewhat to give good
strength and other properties after the mould is dried. The entire
mould is then dried in an oven at 300 to 650 F by circulating heated
air through the mould.

11. MOULDINGSANDPROPERTIESAND ITS
CLASSIFICATION
Natural sand which is found on the bed and banks of river has high
quantity silica and is also mixed.
Ordinary river sand contains a percentage of clay, moisture, non metallic
properties etc.
A good well prepared moulding sand should have the following
properties.
1) Permeability
2) Flowability
3) Cohesiveness
4) Strength
5)Adhesiveness
6)Sand texture
7)Refractoriness
8)Green strength
9)Dry strength

12. SAND ADDITIVES
1.Bentonite
2.Dextrin
3.Water
4.sodium silicate
5.Red oxide
6.Graphite powder

14. SAND TESTING
Moisture content test:
The moisture content of the moulding sand mixture may
determine by drying a weighed amount of 20 to 50 grams
of moulding sand to a constant temperature up to 100°C in
an oven for about one hour. It is then cooled to a room
temperature and then reweighing the moulding sand.
Clay content test:
The amount of clay is determined by carrying out the clay
content test in which clay in moulding sand of 50 grams is
defined as particles which when suspended in water

15. Compression test:
A rammed specimen of tempered moulding sand is
produced that is 150 inches in diameter and 150 inches in
height. The rammed sample is then subjected to a load
which is gradually increased until the sample breaks. The
point where the sample breaks is taken as the compression
strength.

16. Shear test:
The compressive loading system is modified to provide offset
loading of the specimen. Under most conditions the results of
shear tests have been shown to be closely related to those of
compression tests, although the latter property increases
proportionately more at high ramming densities.

17. Tensile test:
A special specimen is loaded in tension through a pair
of grips.

18. Permeability test:
Permeability is determined by measuring the rate of flow of
air through a compacted specimen under standard conditions.

19. FACTORS AFFECTING PROPERTIES
Factors affecting permeability:
Particle size
Impurities in the water
Void ratio
The degree of saturation
Absorbed water
Entrapped air and organic material.

20. Factors affecting hardness:
Testing also should quantify the effectiveness of
mould making equipment to produce uniform filling
and consistent compaction, density and hardness
throughout the mould.
Moulds that are too soft can lead to:
• broken sand moulds;
• mould crush;
• sand wash during pouring;
• mold erosion

21. Excessively hard moulds can produce:
• veining defects;
• hot tears;
• hard ram defects

22. COMPOSITIONS RANGE
1. Bentonite - 4 to 6%
2. Dextrin - 0.5 to 1.5%
3. Moisture - 5 to 7%
4. Sodium silicate - 0.5 to 1.5%
5. Red oxide - 0.5%
6. Graphite powder - 0.5%

23. PROCEDURE
 First of all the sand sample is prepared with respective
composition and it is been thoroughly mulled for 5 minutes in
a Sand Muller/Mixer.
 Then the sample is been taken out for weighing two 150
grams samples and each sample is been rammed 50*50
dimension using Sand Rammer (capacity 14 pounds) and it
is been rammed for 3 strokes.
 The samples made are used for testing:
Hardness (using Brinnel Hardness Tester)
Permeability (using Permeability-meter)
Compression (using Universal Sand Testing Machine)
Shear (using Universal Sand Testing Machine)

24. The data is recorded in a tabular format.
 Now one more sample is been made with 100
grams and is rammed in a tensile core box using
Sand Rammer.
 The tensile specimen or sample which is made is
now heated for 30 minutes to 1 hour at 135C-
150C in a Furnace.
 Then this sample is tested on Universal Sand
Testing Machine using tensile attachment and the
data is collected in a tabular form.

25. FORMAT APPLIED
SAMPLE
CODE
HARDNESS
(BHN)
PERMEABILITY
(NO)
COMPRESSION
STRESS
(Kg/mm2)
SHEAR
STRESS
(Kg/mm2)
TENSILE
STRENGTH
(Kg/mm2)
NOTE:
•By using above tabulated values the graphs are been plotted for
further analysis.

26. CALCULATIONS
S.NO. NAME OF
THE
CHEMICAL
PERCENTA
GE
QUANTITY
1 BENTONITE 4 100
2 DEXTRIN 0.5 1.5
3 MOISTURE 6 150
4 SODIUM
SILICATE
1.5 37.5
5 GRAPHITE
POWDER
0.5 12.5
6 RED OXIDE 0.5 12.5
7 SAND 87 2175

27. Hardness Permeability Compression Shear Tensile
RB4 (1) 75.33 398 5.8 2 0.3
RB4 (2) 80.33 650 4.5 3.2 0.2
RB4 (3) 85 1200 7.2 2.1 0.35
EXPERIMENTALRESULTSOF RB4 (1),RB4(2),RB4(3)
Graph:

28. Experimental results of PB4 (1),PB4(2),PB4(3)
Hardness Permeability Compression Shear Tensile
PB4 (1) 86.5 138 14.8 1.4 0.4
PB4 (2) 85.66 52 14.6 2 0.4
PB4 (3) 86 52 15.2 2.6 0.4
Graph:

29. Experimental results of KB4 (1),KB4(2),KB4(3)
Hardness Permeability Compression Shear Tensile
KB4 (1) 83.66 358 4.3 0.9 0.3
KB4 (2) 84.66 376 5.2 0.6 0.2
KB4 (3) 85 253 4.8 0.8 0.3
Graph:

30. conclusion
It is very difficult to achieve certain marks of results
whereas efforts have been made to use the available
products that are commercially viable in the market. It has
come to the conclusion that a special sand possessing
high refractoriness, high angularity, and other required
properties should be used. Our efforts shows that due to
the change in modification of containments of moulding
sand, available sand in Hyderabad and its surroundings
can be used successfully for small, intricate castings like
slush casting, non ferrous metal casting etc, but not
suitable for heavy castings of steels and the other alloys.