sand casting
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The document discusses the student's training report on mechanical workshop activities at Tanganyika Planting Company (TPC) Ltd, a sugar company in Tanzania. It describes TPC's history and operations. It then details the processes of pattern design, mold making with sand casting, melting brass, and pouring the molten metal into molds to produce castings. The student learned new technical skills like machining, metal fabrication, pattern design, and molding during the training.
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Moulding sand
Molding sand is a mixture used to make molds for metal casting. It consists mainly of silica sand, clay, and water. Different types of molding sand exist for various applications, including green sand, dry sand, and loam sand. Green sand is the most common and contains 15-25% clay and 6-8% water. The sand provides strength and permeability while the clay acts as a binder when hydrated by water. Proper control of the sand mixture and its ingredients is important for characteristics like strength, permeability, and thermal stability of the resulting mold.
Foundry
This document provides information on foundry processes and sand casting. It defines important casting terminology like flasks, drags, copes, patterns, and parting lines. It describes the tools used in sand mold making like molds, hammers, and trowels. It explains the procedure for making a sand mold in steps from preparing the bottom board and drag to applying facing sand in the mold cavity. It also defines different types of molds like green sand molds, dry sand molds, and skin dried molds. The document outlines properties of molding sand and types of patterns used in casting.
Sand Casting
This ppt is about one type of Casting called Sand Casting in Basic Manufacturing Process.This ppt covers almost everything about sand Casting.
Sand casting
This document provides information on conducting a sand casting demonstration or lab. Sand casting is an inexpensive way to make metal parts and is commonly used in industries like automotive and aerospace. In sand casting, molten metal is poured into a mold cavity formed in sand. While inexpensive, sand casting often results in flaws that can affect material properties. The demonstration aims to introduce students to sand casting and show how processing can influence defect formation and properties. It outlines objectives, procedures, equipment needed and safety considerations for an instructor to replicate the sand casting process in the classroom.
Injection moulding
Injection molding is a manufacturing process that uses molds to produce plastic or rubber parts. Molds are hollow blocks that give the part its shape and allow it to cool. Thermoplastics can be molded repeatedly while thermosetting plastics set permanently after one molding. Injection molding machines consist of a hopper, barrel with a reciprocating screw, nozzle, and molds. The process involves melting plastic in the heated barrel and injecting it into the mold under pressure before allowing it to cool into the final shape.
INTRODUCTION TO MOULDING , LECTURE NOTES
INTRODUCTION TO MOULDING , LECTURE NOTES ANKIT SAXENA Asst. Prof. @ Dr. Akhilesh Das Gupta Institute of Technology and Management, New Delhi
Production Technology Lecture Notes as per GGSIPU SYLLABUS FOR UNIT 1.
Casting is a process in which molten metal is allowed to solidify in a predefined mould cavity. After the solidification by breaking the mould the component is taken out. This is known as CASTING.
Pattern is a replica of a object to be made with some modifications.
Pattern Materials
Difference between Pattern and Casting
Types of Patterns
Pattern Design Considerations
Pattern Allowances
Pattern Making
Pattern Layout
Properties of moulding sand
Testing of Moulding Sand
Special casting processSand Casting
This document discusses sand casting and provides details on:
- The types of casting sand including green sand, water glass sand, and resin sand.
- The key properties of casting sand such as strength, permeability, grain size, thermal stability, and reusability.
- Common casting defects related to issues with the sand mold like sand blow, pinholes, and sand wash.
- How to test sand properties including measuring moisture content, clay content, and grain size distribution.
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this is the presrntation which i made when i was in traning in ultratech cement hirmi , i got project on studying the process and operations of grinding process of ball mill in the cement industry , after the clincker formation.
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Moulding sand
Molding sand is a mixture used to make molds for metal casting. It consists mainly of silica sand, clay, and water. Different types of molding sand exist for various applications, including green sand, dry sand, and loam sand. Green sand is the most common and contains 15-25% clay and 6-8% water. The sand provides strength and permeability while the clay acts as a binder when hydrated by water. Proper control of the sand mixture and its ingredients is important for characteristics like strength, permeability, and thermal stability of the resulting mold.
Foundry
This document provides information on foundry processes and sand casting. It defines important casting terminology like flasks, drags, copes, patterns, and parting lines. It describes the tools used in sand mold making like molds, hammers, and trowels. It explains the procedure for making a sand mold in steps from preparing the bottom board and drag to applying facing sand in the mold cavity. It also defines different types of molds like green sand molds, dry sand molds, and skin dried molds. The document outlines properties of molding sand and types of patterns used in casting.
Sand Casting
This ppt is about one type of Casting called Sand Casting in Basic Manufacturing Process.This ppt covers almost everything about sand Casting.
Sand casting
This document provides information on conducting a sand casting demonstration or lab. Sand casting is an inexpensive way to make metal parts and is commonly used in industries like automotive and aerospace. In sand casting, molten metal is poured into a mold cavity formed in sand. While inexpensive, sand casting often results in flaws that can affect material properties. The demonstration aims to introduce students to sand casting and show how processing can influence defect formation and properties. It outlines objectives, procedures, equipment needed and safety considerations for an instructor to replicate the sand casting process in the classroom.
Injection moulding
Injection molding is a manufacturing process that uses molds to produce plastic or rubber parts. Molds are hollow blocks that give the part its shape and allow it to cool. Thermoplastics can be molded repeatedly while thermosetting plastics set permanently after one molding. Injection molding machines consist of a hopper, barrel with a reciprocating screw, nozzle, and molds. The process involves melting plastic in the heated barrel and injecting it into the mold under pressure before allowing it to cool into the final shape.
INTRODUCTION TO MOULDING , LECTURE NOTES
INTRODUCTION TO MOULDING , LECTURE NOTES ANKIT SAXENA Asst. Prof. @ Dr. Akhilesh Das Gupta Institute of Technology and Management, New Delhi
Production Technology Lecture Notes as per GGSIPU SYLLABUS FOR UNIT 1.
Casting is a process in which molten metal is allowed to solidify in a predefined mould cavity. After the solidification by breaking the mould the component is taken out. This is known as CASTING.
Pattern is a replica of a object to be made with some modifications.
Pattern Materials
Difference between Pattern and Casting
Types of Patterns
Pattern Design Considerations
Pattern Allowances
Pattern Making
Pattern Layout
Properties of moulding sand
Testing of Moulding Sand
Special casting processSand Casting
This document discusses sand casting and provides details on:
- The types of casting sand including green sand, water glass sand, and resin sand.
- The key properties of casting sand such as strength, permeability, grain size, thermal stability, and reusability.
- Common casting defects related to issues with the sand mold like sand blow, pinholes, and sand wash.
- How to test sand properties including measuring moisture content, clay content, and grain size distribution.
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this is the presrntation which i made when i was in traning in ultratech cement hirmi , i got project on studying the process and operations of grinding process of ball mill in the cement industry , after the clincker formation.
Steps involved in sand casting process
The document discusses the process of sand casting. It describes the key steps which include preparing the mould and molten metal, pouring the molten metal into the mould, solidification, and removing the cast part. Several types of patterns are discussed along with their materials and uses. The document also covers moulding sand properties and testing methods. Common defects in castings are described. The overall document provides details on the sand casting manufacturing process.
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1. The document describes the process of preparing and managing green sand in a cast iron foundry. It involves mixing sand, clay, water, and other additives to form green sand that is then used to create molds in molding machines.
2. The green sand is then used in the molding process where molds are produced and molten metal is poured. After solidification, the molds are shaken to separate the casting from the sand for reclamation.
3. The returned sand is processed to remove impurities before being dried and mixed with new sand in preparation for reuse in the molding process. Proper management of foundry sand includes reclamation, recycling, and disposal to reduce waste.
Explosive forming
Explosive forming is a metal shaping technique that uses an explosive charge to generate high forming pressures. There are two main methods - the stand off method places a metal plate over a die and positions an explosive above the plate, while the contact method places the explosive in direct contact with the workpiece. The rapid conversion of the explosive to gas produces a shock wave with pressures up to several million psi that can form metal sheets into complex shapes in a single operation, making it suitable for aerospace applications requiring large or low-quantity customized parts.
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Portland cement is produced through a four step process:
1) Limestone and other raw materials are quarried and crushed
2) The raw materials are ground and blended to ensure proper chemical composition
3) The raw materials are heated in a kiln to over 1400°C, undergoing chemical reactions to form the four main compounds that make up cement
4) The resulting clinker is ground with gypsum to produce the fine powder that is Portland cement
Transfer moulding
Transfer molding is a manufacturing process where a casting material is forced into an enclosed mold under pressure to form a casting. There are different types of transfer molding including resin transfer molding (RTM) and vacuum assisted resin transfer molding (VARTM). Thermoset polymers and fibers are common materials used. The transfer molding process involves placing the preheated molding compound in a transfer pot, closing the mold, and forcing the compound into the mold cavity under pressure where it cures. Applications include parts for the natural gas, electrical, and automotive industries. Advantages are uniform products and simpler production compared to other molding processes, while disadvantages include more material waste.
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Slip casting is a process used to mass produce ceramic items like figurines, dishes, and flower pots. A liquid suspension of ceramic powder called a slip is poured into a plaster mold. Water from the slip is absorbed by the porous mold, leaving a solid ceramic layer. Excess slip is drained out. The piece is then dried and fired. There are two main methods - drain casting produces hollow items while solid casting allows the entire mold cavity to solidify. Key factors that affect the process include the viscosity and setting rate of the slip as well as shrinkage and strength of the final piece. Slip casting allows intricate shapes and sizes but the process is slow with limited commercial applications.
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This document discusses Portland cement and the cement manufacturing process. It begins with an overview of what cement is and how it is used to make concrete. It then describes the industrial process for manufacturing cement, involving grinding raw materials like limestone and clay at high temperatures in a kiln to form clinker, which is then pulverized with gypsum to become Portland cement powder. The document also provides a brief history of cement development and explains how cement kilns can beneficially reuse solid and hazardous wastes as a source of energy and raw material replacement due to the kilns' high temperatures and long retention times.
Rolling process
Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and change the cross section of the metal. There are both hot and cold rolling processes. The metal is compressed between the rolls through frictional forces, changing the shape of the metal. Rolling processes can produce shapes like plates, sheets, rods, bars, pipes and rails. Rolling mills can have two, three, four or multiple rolls depending on the specific application and required shape. Rolling is used to mass produce metal products and form complex cross sections.
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The document discusses various properties of moulding sand including porosity, plasticity, adhesiveness, cohesiveness, and refractoriness. It describes different types of moulding sand such as green sand, dry sand, loam sand, and core sand. It also discusses functional requirements of moulding materials including flowability and green strength. The document covers mould hardening techniques and sand testing methods including compression, shear, tensile, and transverse tests.
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The document summarizes the manufacturing process of ceramic tiles. Raw materials like clay, silica, and talc are ground into a slurry using a continuous ball mill. The slurry is spray dried into a fine powder and stored in silos. The powder is pressed into tiles using hydraulic presses and dried. Tiles are glazed, printed, and fired in a roller kiln to increase strength. The finished tiles are sorted, packaged, and shipped for use in floors, walls, roofs, and ceilings.
Squeeze Forming or Squeeze Casting Process
It is a near net shape process in which casting and forging is done in single step.
It is Referred by many names such as “squeeze casting” , “pressure infiltration”, “liquid metal forging”, “extrusion casting”, “liquid pressing'', “pressure crystallization”.
3.expendable mold casting
The document discusses various metal casting processes that use expendable molds. It describes sand casting as the most common casting method, where a sand mixture is packed around a pattern and then melted metal is poured in. Different types of patterns are discussed, including one-piece, split, match plate, and cope and drag patterns. The key molding sand ingredients and their properties are also summarized.
TYPES of moulding processes used in casting-MP2
- There are four main types of moulding used in casting processes: floor moulding, bench moulding, pit moulding, and machine moulding. Floor and pit moulding are used for large heavy castings, bench moulding for smaller light items, and machine moulding for mass production.
- The main moulding sands used are green sand, dry sand, loam sand, and core sand, which differ in their mixture proportions and required drying. Green sand moulding is most common and adaptable but provides lower strength.
- Other moulding methods include shell moulding, which produces molds from resin-bonded sand in two halves
G9 Lab Project Report -Injection Molding
This laboratory report examines the influence of injection molding parameters on the mechanical and physical properties of a polymer blend made of 50% polypropylene and 50% polyethylene. The report describes injection molding experiments conducted to produce "dog bone" test specimens while varying injection pressure, temperature, and speed. Tensile tests and Rockwell hardness tests were performed on the specimens to analyze properties. Microscopic analysis was also conducted. The results were analyzed using Taguchi methods to determine the most influential parameters and optimize the injection molding process.
Green sand mould
Green sand moulds are made from a mixture of silica sand, bentonite clay, water, and additives. This mixture, known as green sand, remains damp and can be easily shaped by hand to form moulds. Green sand moulding is widely used and more affordable than other moulding methods. It is suitable for producing small to medium sized moulds and can accommodate complex patterns at reasonable costs. The green sand properties of flowability, plasticity, green strength, permeability, dry strength, refractoriness allow it to form moulds that can be poured with molten metal.
Casting process
This document discusses various manufacturing processes and provides details about casting processes. It describes:
1) Casting as one of the earliest metal shaping techniques known to humans involving pouring molten metal into a refractory mold and allowing it to solidify.
2) The six basic steps in the casting process including creating a mold cavity, incorporating gating systems, filling with molten metal, and allowing the metal to cool.
3) Common molding sand types used in casting like green sand, dry sand, and loam sand.
3 foundry
- Foundry engineering involves making castings through the molding process using patterns. It is an ancient practice dating back 5000 years.
- The casting process has five main stages: pattern making, molding and core making, melting and casting, fettling, and testing and inspection.
- Foundries can be classified by type (jobbing, production, etc.) or materials produced (ferrous, non-ferrous). Patterns come in various types like split patterns, gated patterns, and are made from materials like wood, metal, plastic to suit different production needs.
Permanent mold casting
This document discusses permanent mold casting. Permanent mold casting uses metal molds that are repeatedly used to produce many castings of the same form. The liquid metal enters the mold by gravity. It is used for high volume production of small, simple parts made of non-ferrous metals like aluminum alloys. Common applications include gears, housings, and automotive and aircraft parts. The process yields castings with good mechanical properties, dimensional tolerances, surface finishes, and production rates. However, it requires expensive tooling for low volumes and some part shapes cannot be molded.
Moulding and core making
Moulding and core makingANKIT SAXENA Asst. Prof. @ Dr. Akhilesh Das Gupta Institute of Technology and Management, New Delhi
A mould is a hollowed-out block that is filled with a liquid like plastic, glass, metal, or ceramic raw materials .The liquid hardens or sets inside the mould, adopting its shape. A mould is the counterpart to a cast.
Mould or Mould cavity contains molten metal and is essentially a negative of the final product.
Mould is obtained by pattern in moulding material (sand).
Mould material should posses refractory characteristics and withstand the pouring temperature.
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The document discusses concerns that cements ground in vertical roller mills may not meet quality requirements for the market. It summarizes that testing over the past 15 years has shown these concerns to be unfounded, as the quality of cement from vertical roller mills is as good as or sometimes better than cement from ball mills. The key areas of previous concern - water demand, strength development, and setting times - have all been shown to meet market standards for cement ground in vertical roller mills.
Sand casting
The document discusses the history of sand casting, including early uses by the Assyrians in the 8th century BC and developments in the early 20th century with the invention of the sand slinger and sand mixer. It then provides details about the group's project to produce an exhaust manifold using sand casting, including explaining the process, materials, defects, and alternative manufacturing methods. Within the group, members will explain the different types of casting processes, the function of an exhaust manifold, suitable materials for an exhaust manifold, and details about the sand casting process.
Sand Casting
Sand casting is an old casting method still widely used today to make metal products like wall plaques and nut crackers from steel and aluminum. The process involves creating a sand mold with sprue pins and feeders, pouring molten metal into the mold cavity, and removing runners, risers, and feeders after solidification before dispatching the product.
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Steps involved in sand casting process
The document discusses the process of sand casting. It describes the key steps which include preparing the mould and molten metal, pouring the molten metal into the mould, solidification, and removing the cast part. Several types of patterns are discussed along with their materials and uses. The document also covers moulding sand properties and testing methods. Common defects in castings are described. The overall document provides details on the sand casting manufacturing process.
ppt project
1. The document describes the process of preparing and managing green sand in a cast iron foundry. It involves mixing sand, clay, water, and other additives to form green sand that is then used to create molds in molding machines.
2. The green sand is then used in the molding process where molds are produced and molten metal is poured. After solidification, the molds are shaken to separate the casting from the sand for reclamation.
3. The returned sand is processed to remove impurities before being dried and mixed with new sand in preparation for reuse in the molding process. Proper management of foundry sand includes reclamation, recycling, and disposal to reduce waste.
Explosive forming
Explosive forming is a metal shaping technique that uses an explosive charge to generate high forming pressures. There are two main methods - the stand off method places a metal plate over a die and positions an explosive above the plate, while the contact method places the explosive in direct contact with the workpiece. The rapid conversion of the explosive to gas produces a shock wave with pressures up to several million psi that can form metal sheets into complex shapes in a single operation, making it suitable for aerospace applications requiring large or low-quantity customized parts.
Cement manufacturing process new
Portland cement is produced through a four step process:
1) Limestone and other raw materials are quarried and crushed
2) The raw materials are ground and blended to ensure proper chemical composition
3) The raw materials are heated in a kiln to over 1400°C, undergoing chemical reactions to form the four main compounds that make up cement
4) The resulting clinker is ground with gypsum to produce the fine powder that is Portland cement
Transfer moulding
Transfer molding is a manufacturing process where a casting material is forced into an enclosed mold under pressure to form a casting. There are different types of transfer molding including resin transfer molding (RTM) and vacuum assisted resin transfer molding (VARTM). Thermoset polymers and fibers are common materials used. The transfer molding process involves placing the preheated molding compound in a transfer pot, closing the mold, and forcing the compound into the mold cavity under pressure where it cures. Applications include parts for the natural gas, electrical, and automotive industries. Advantages are uniform products and simpler production compared to other molding processes, while disadvantages include more material waste.
Slip casting
Slip casting is a process used to mass produce ceramic items like figurines, dishes, and flower pots. A liquid suspension of ceramic powder called a slip is poured into a plaster mold. Water from the slip is absorbed by the porous mold, leaving a solid ceramic layer. Excess slip is drained out. The piece is then dried and fired. There are two main methods - drain casting produces hollow items while solid casting allows the entire mold cavity to solidify. Key factors that affect the process include the viscosity and setting rate of the slip as well as shrinkage and strength of the final piece. Slip casting allows intricate shapes and sizes but the process is slow with limited commercial applications.
Cement manufacturing process
This document discusses Portland cement and the cement manufacturing process. It begins with an overview of what cement is and how it is used to make concrete. It then describes the industrial process for manufacturing cement, involving grinding raw materials like limestone and clay at high temperatures in a kiln to form clinker, which is then pulverized with gypsum to become Portland cement powder. The document also provides a brief history of cement development and explains how cement kilns can beneficially reuse solid and hazardous wastes as a source of energy and raw material replacement due to the kilns' high temperatures and long retention times.
Rolling process
Rolling is a metal forming process where metal stock is passed through one or more pairs of rolls to reduce the thickness and change the cross section of the metal. There are both hot and cold rolling processes. The metal is compressed between the rolls through frictional forces, changing the shape of the metal. Rolling processes can produce shapes like plates, sheets, rods, bars, pipes and rails. Rolling mills can have two, three, four or multiple rolls depending on the specific application and required shape. Rolling is used to mass produce metal products and form complex cross sections.
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The document discusses various properties of moulding sand including porosity, plasticity, adhesiveness, cohesiveness, and refractoriness. It describes different types of moulding sand such as green sand, dry sand, loam sand, and core sand. It also discusses functional requirements of moulding materials including flowability and green strength. The document covers mould hardening techniques and sand testing methods including compression, shear, tensile, and transverse tests.
Manufacturing process of ceramic tiles
The document summarizes the manufacturing process of ceramic tiles. Raw materials like clay, silica, and talc are ground into a slurry using a continuous ball mill. The slurry is spray dried into a fine powder and stored in silos. The powder is pressed into tiles using hydraulic presses and dried. Tiles are glazed, printed, and fired in a roller kiln to increase strength. The finished tiles are sorted, packaged, and shipped for use in floors, walls, roofs, and ceilings.
Squeeze Forming or Squeeze Casting Process
It is a near net shape process in which casting and forging is done in single step.
It is Referred by many names such as “squeeze casting” , “pressure infiltration”, “liquid metal forging”, “extrusion casting”, “liquid pressing'', “pressure crystallization”.
3.expendable mold casting
The document discusses various metal casting processes that use expendable molds. It describes sand casting as the most common casting method, where a sand mixture is packed around a pattern and then melted metal is poured in. Different types of patterns are discussed, including one-piece, split, match plate, and cope and drag patterns. The key molding sand ingredients and their properties are also summarized.
TYPES of moulding processes used in casting-MP2
- There are four main types of moulding used in casting processes: floor moulding, bench moulding, pit moulding, and machine moulding. Floor and pit moulding are used for large heavy castings, bench moulding for smaller light items, and machine moulding for mass production.
- The main moulding sands used are green sand, dry sand, loam sand, and core sand, which differ in their mixture proportions and required drying. Green sand moulding is most common and adaptable but provides lower strength.
- Other moulding methods include shell moulding, which produces molds from resin-bonded sand in two halves
G9 Lab Project Report -Injection Molding
This laboratory report examines the influence of injection molding parameters on the mechanical and physical properties of a polymer blend made of 50% polypropylene and 50% polyethylene. The report describes injection molding experiments conducted to produce "dog bone" test specimens while varying injection pressure, temperature, and speed. Tensile tests and Rockwell hardness tests were performed on the specimens to analyze properties. Microscopic analysis was also conducted. The results were analyzed using Taguchi methods to determine the most influential parameters and optimize the injection molding process.
Green sand mould
Green sand moulds are made from a mixture of silica sand, bentonite clay, water, and additives. This mixture, known as green sand, remains damp and can be easily shaped by hand to form moulds. Green sand moulding is widely used and more affordable than other moulding methods. It is suitable for producing small to medium sized moulds and can accommodate complex patterns at reasonable costs. The green sand properties of flowability, plasticity, green strength, permeability, dry strength, refractoriness allow it to form moulds that can be poured with molten metal.
Casting process
This document discusses various manufacturing processes and provides details about casting processes. It describes:
1) Casting as one of the earliest metal shaping techniques known to humans involving pouring molten metal into a refractory mold and allowing it to solidify.
2) The six basic steps in the casting process including creating a mold cavity, incorporating gating systems, filling with molten metal, and allowing the metal to cool.
3) Common molding sand types used in casting like green sand, dry sand, and loam sand.
3 foundry
- Foundry engineering involves making castings through the molding process using patterns. It is an ancient practice dating back 5000 years.
- The casting process has five main stages: pattern making, molding and core making, melting and casting, fettling, and testing and inspection.
- Foundries can be classified by type (jobbing, production, etc.) or materials produced (ferrous, non-ferrous). Patterns come in various types like split patterns, gated patterns, and are made from materials like wood, metal, plastic to suit different production needs.
Permanent mold casting
This document discusses permanent mold casting. Permanent mold casting uses metal molds that are repeatedly used to produce many castings of the same form. The liquid metal enters the mold by gravity. It is used for high volume production of small, simple parts made of non-ferrous metals like aluminum alloys. Common applications include gears, housings, and automotive and aircraft parts. The process yields castings with good mechanical properties, dimensional tolerances, surface finishes, and production rates. However, it requires expensive tooling for low volumes and some part shapes cannot be molded.
Moulding and core making
Moulding and core makingANKIT SAXENA Asst. Prof. @ Dr. Akhilesh Das Gupta Institute of Technology and Management, New Delhi
A mould is a hollowed-out block that is filled with a liquid like plastic, glass, metal, or ceramic raw materials .The liquid hardens or sets inside the mould, adopting its shape. A mould is the counterpart to a cast.
Mould or Mould cavity contains molten metal and is essentially a negative of the final product.
Mould is obtained by pattern in moulding material (sand).
Mould material should posses refractory characteristics and withstand the pouring temperature.
Cements Ground in the Vertical Roller Mill Fulfil the Quality Requirements of...
The document discusses concerns that cements ground in vertical roller mills may not meet quality requirements for the market. It summarizes that testing over the past 15 years has shown these concerns to be unfounded, as the quality of cement from vertical roller mills is as good as or sometimes better than cement from ball mills. The key areas of previous concern - water demand, strength development, and setting times - have all been shown to meet market standards for cement ground in vertical roller mills.
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Cements Ground in the Vertical Roller Mill Fulfil the Quality Requirements of...
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Sand casting
The document discusses the history of sand casting, including early uses by the Assyrians in the 8th century BC and developments in the early 20th century with the invention of the sand slinger and sand mixer. It then provides details about the group's project to produce an exhaust manifold using sand casting, including explaining the process, materials, defects, and alternative manufacturing methods. Within the group, members will explain the different types of casting processes, the function of an exhaust manifold, suitable materials for an exhaust manifold, and details about the sand casting process.
Sand Casting
Sand casting is an old casting method still widely used today to make metal products like wall plaques and nut crackers from steel and aluminum. The process involves creating a sand mold with sprue pins and feeders, pouring molten metal into the mold cavity, and removing runners, risers, and feeders after solidification before dispatching the product.
Casting
The document discusses the process of sand casting. It begins by defining foundry and casting as the process of producing metal parts by pouring molten metal into a prepared mold. It then provides terminology used in casting such as flask, pattern, parting line, pouring basin, sprue, runner, riser, gate, core, and chaplets. The steps of sand casting are outlined as making the pattern, preparing sand mixtures, making the mold and cores, melting metal, pouring, cleaning, inspecting, and heat treating. Common casting materials and applications are also listed.
Founding and Casting
The document describes the foundry processes at Porwal Auto Components Ltd. It discusses their facilities for casting, molding, melting, and testing. The company manufactures automotive and earthmoving parts using sand casting and cold box molding processes. Equipment includes induction furnaces, molding machines, sand plants, and testing facilities for chemical analysis, hardness testing, and non-destructive testing of castings.
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The document summarizes the lost foam casting manufacturing process for producing a flag stand base. The key steps are:
1) A polystyrene foam pattern is cut for the part geometry.
2) Patterns are clustered and attached to gating for pouring.
3) The cluster is coated with refractory material and dried in an oven.
4) The dried cluster is embedded in compacted sand in a mold.
5) Molten aluminum is poured, vaporizing the polystyrene and leaving an aluminum casting.
The lost foam process is advantageous as it requires no cores, binders, or post-machining, and the sand can be reused.
Classification of sand ppt shivam omar
This document discusses different types of sand used in foundry processes and centrifugal casting methods. It describes green sand, dry sand, loam sand, facing sand, baking sand, parting sand, system sand, and core sand used for moulding. True centrifugal casting produces axis symmetrical parts without a core. Semi centrifugal casting uses a central core to produce parts like gears. Centrifuge casting casts irregular shapes in groups by rotating molds around a central point.
Manufactring technology
The document discusses two manufacturing technologies: centrifugal casting and shell moulding. Centrifugal casting involves pouring molten metal into a rotating mould, where centrifugal force pushes the metal against the mould walls to form the casting. Shell moulding uses resin-coated sand to form a mould around a metal pattern, which is then used to produce castings through pouring, cooling, and removal from the mould. Both processes allow for automated mass production of castings but shell moulding requires an integrated gating system and uses expensive resin.
shell moulding
Shell moulding is a casting process that uses a sand-resin mixture to form a disposable mould around a reusable pattern. This allows for higher production rates than sand casting while also enabling more complex part geometries. The process involves creating a metal pattern, heating it, applying a sand-resin mixture to form shell halves, joining the shells to create the mould, pouring molten metal, and removing the casting after solidification. Shell moulding provides better dimensional accuracy, higher productivity, and lower labor costs than sand casting for small to medium precision parts.
Casting process and moulding process file for trainning report complet trainn...
The document provides information about sand casting and sand testing methods used in casting industries. It discusses the basic sand casting process which involves creating a mold from sand, pouring molten metal, and allowing it to solidify. It then describes various tests conducted on molds sands to evaluate properties like moisture content, clay content, grain size, permeability, and strength. These sand tests help control mold sand composition and ensure required properties are achieved.
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Here is a heat treatment that could help determine the carbon content of the steel:
1. Reheat the steel to above its upper critical temperature to fully austenitize it.
2. Quickly quench it in oil or water to transform the austenite to martensite.
3. Measure the hardness of the resulting martensite. Higher carbon steels will have a higher hardness.
4. Compare the measured hardness to known hardness values for different carbon contents after a similar heat treatment. This could provide an estimate of the carbon content.
The idea is that the hardness of the martensite is dependent on the carbon content. By inducing a full martensitic transformation, the carbon content
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Unit 1 manufacturing technology I Metal casting process
This document discusses various metal casting processes and techniques. It covers topics like sand casting, pattern making, molding sand properties, core making, and casting defects. Sand casting involves pouring molten metal into an expandable sand mold and allowing it to solidify. Different types of sand and patterns are used depending on the application. Properties of molding sand like permeability and strength are important. Cores are used to create internal cavities and angles in castings.
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casting ppt
This document provides information on various metal casting processes. It discusses the history of casting and defines the basic casting process as pouring liquid metal into a mold to solidify. It describes the main features of casting like molds, risers, gates, and cores. It categorizes casting processes as open mold or closed mold casting. It further classifies casting into expandable mold casting like sand casting and investment casting, and permanent mold casting like die casting and centrifugal casting. For each process, it provides details on the mold material, advantages, disadvantages and recommended applications. It emphasizes the importance of selecting the right casting process based on the alloy, shape, tolerance and cost requirements of the final part.
Metal casting process
Metal casting involves pouring liquid metal into a mold to produce parts of a desired shape. The key steps are melting metal to create a liquid, pouring it into a mold to achieve a solid shape as it cools and extracts heat, and then removing the solidified part from the mold. The quality of castings depends on factors like the flow of molten metal into the mold, the solidification and cooling process, and the type of mold material used. Common casting methods include sand casting, die casting, and investment casting.
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Unit 1 manufacturing technology I Metal casting process
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- 1. IPTR 1- REVIEW ST JOSEPH UNIVERSITY COLLEGE OF ENGINEERING AND TECHNOLOGY COMPANY NAME : TANGANYIKA PLANTING COMPANY (TPC) Ltd. STUDENT NAME : AMRAN HASHIM ALLY REGISTRATION NO. : 14171052003 MECHANICAL ENGINEERING
- 2. ABSTRACT My training report is about Workshop activities during industrial maintenance which involves difference mechanical process such as machining(drilling,milling,turning,threading ect.),metal fabrication and pattern design and molding(sand casting).
- 3. TANGANYIKA PLANTING COMPANY (TPC) Ltd. Is one of the sugar industry in Tanzania which is located at Moshi established in early 1930s. The company was registered in Tanzania as TPC on 29th June 1973 and shareholders remained the same M/s A.P.Moller of Denmark. Sukari Investment Company Ltd purchased 75% of shares of TPC limited in March 2000, and became the majority shareholders of the company; the government retained the remaining 25%. . The factory crushing capacity has been increased from 125TCH to 160 TCH, the area under sugarcane was extended from about 6000ha to 8000ha. The harvests season at Tpc lasts for 8.5 months from July to mid- March because of the long rains which usually hindering the harvesting and transportation of cane, the sucrose content also falls to the lowest level during the rainy season. COMPANY DETAILS
- 4. SAND CASTING PATTERN DESIGN AND MOULDING PROCESS
- 5. PATTERN DESIGN Pattern making: 1. Motor fan 2. Bush 3. Hollow shaft 4. Ejector 5. Square nut
- 6. MOULDING Molding or moulding ; is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or matrix. This itself may have been made using a pattern or model of the final object
- 7. MOLD MATERIALS There are four main components for making a sand casting mold: base sand, a binder, additives, and a parting compound. Molding sands, also known as foundry sands, are defined by eight characteristics: refractoriness, chemical inertness, permeability, surface finish, cohesiveness, flow ability, collapsibility, and availability/cost Binders are added to base sand to bond the sand particles together (i.e. it is the glue that holds the mold together). A mixture of clay and water is the most commonly used binder. There are two types of clay commonly used: bentonite and kaolinite
- 8. PREPARATION OF MOULDING SAND Required to mix 1. Non mineral sea sand 2. Bentonite 3. Water Mixing of water was gradual process for proper wetness (low wet sand was required) ,the mixture allowed to settle while little water spread.
- 9. MOULDING PROCESS Selection of moulding box 1. Drag and 2. Cope Selection was base on type of pattern either: 1. Split or 2. Solid For split one piece was put on drag and another on the cope and then joined with proper alignment and the molding sand was introduced and compact together to give the shape required For solid pattern the moulding box was selected which fit the height of the sample. All before pattern were insert graphite was polished first and the pattern carefully removed The boxes were placed near high heat to fasten the drainess and proper binding The boxes was allowed to cool for 5-6 hours .
- 11. EXAMPLE OF SPLIT PATTERN(EJECTOR)
- 12. MELTING OF BRASS MATERIALS Furnace used was Diesel and Air furnace First it was lighted for Cleaning of the furnace, by allow it to get heated for some time and remove the molten slag waste. Introduction of brass material to the furnace The material was heated between temperature 1600°c to 2000°c The crucible were prepared placed near the furnace After the brass was properly melted it was poured into the crucible and then into the mold boxes to give the required shape and allowed to cool and solidify.
- 13. DIESEL AND AIR FURNACE
- 14. POURING OF MOLTEN BRASS IN THE MOLDS After cooling the mold was defragmented by carefully removing the sand part The remaining part was the workpiece required It was further taken for machining operation
- 15. FOLLOWING SAFE PRACTICES Wear heat-safe gloves, apron, and boots Wear cotton or wool clothing Protect your face and eyes Consider a respirator
- 16. CONCLUSION I am well satisfied with my training. I have learned many new technical subjects, acquired a number of new technical skills and improved another group of existing skills such as: Increased skills in repairing faulty in machine process Large steps in improving my abilities in designing and repairing of materials Most important is how team work create high efficiency and excellent work performance.
- 17. THANK YOU