LAB SESSION NO 3 Material and Manufacturing

LAB SESSION # 3
Experiment # 2:
Objective:
To prepare a sand mold using a single piece pattern.
Apparatus:
Work material required:

• Molding Sand.
Tool required:
• Single piece pattern block.
• Cope.
• Drag.
• Rammer.
• Strike off bar.
• Sprue pin.
• Riser cut.
• Vent rod.
• Gate cutter.
• Trowels.
• Lifter.
Fig # 1 Tool and work material.

Related theory:
Sprue pin:
Sprue pin is a tapered rod of wood or iron which is placed or pushed in cope to join mold
cavity while the molding sand in the cope is being rammed. Later its withdrawal from cope
produces a vertical hole in molding sand, called sprue through which the molten metal is
poured into the mould using gating system. It helps to make a passage for pouring molten
metal in mold through gating system.
Strike off bar:

Strike off bar is a flat bar having straight edge and is made of wood or iron. It is used to
strike off or remove the excess sand from the top of a molding box after completion of
ramming thereby making its surface plane and smooth. It’s one edge is made beveled
and the other end is kept perfectly smooth and plane.
Mallet:
Mallet is similar to a wooden hammer and is generally as used in carpentry or sheet metal
shops. In molding shop, it is used for driving the draw spike into the pattern and then
rapping it for separation from the mould surfaces so that pattern can be easily withdrawn
leaving the mold cavity without damaging the mold surfaces.
Draw spike:
Draw spike is a tapered steel rod having a loop or ring at its one end and a sharp point at
the other. It may have screw threads on the end to engage metal pattern for it withdrawal
from the mold. It is used for driven into pattern which is embedded in the molding sand
and raps the pattern to get separated from the pattern and finally draws out it from the
mold cavity.
Vent rod:
Vent rod is a thin spiked steel rod or wire carrying a pointed edge at one end and a
wooden handle or a bent loop at the other. After ramming and striking off the excess sand
it is utilized to pierce series of small holes in the molding sand in the cope portion. The
series of pierced small holes are called vents holes which allow the exit or escape of
steam and gases during pouring mold and solidifying of the molten metal for getting a
sound casting.
Lifters:
Lifters are also known as cleaners or finishing tool which are made of thin sections of
steel of various length and width with one end bent at right angle. They are used for
cleaning, repairing and finishing the bottom and sides of deep and narrow openings in
mold cavity after withdrawal of pattern. They are also used for removing loose sand from
mold cavity.
Trowels:
Trowels are utilized for finishing flat surfaces and joints and partings lines of the mold.
They consist of metal blade made of iron and are equipped with a wooden handle. The
common metal blade shapes of trowels may be pointed or contoured or rectangular
oriented. The trowels are basically employed for smoothing or slicking the surfaces of
molds. They may also be used to cut in-gates and repair the mold surfaces.
Slicks:
Slicks are also recognized as small double ended mold finishing tool which are generally
used for repairing and finishing the mold surfaces and their edges after withdrawal of the
pattern. The commonly used slicks are of the types of heart and leaf, square and heart,
spoon and bead and heart and spoon. The nomenclatures of the slicks are largely due to
their shapes.
Smoothers:
According to their use and shape they are given different names. They are also known
as finishing tools which are commonly used for repairing and finishing flat and round
surfaces, round or square corners and edges of molds.
Swab
Swab is a small hemp fiber brush used for moistening the edges of sand mould, which
are in contact with the pattern surface before withdrawing the pattern. It is used for
sweeping away the molding sand from the mold surface and pattern. It is also used for
coating the liquid blacking on the mold faces in dry sand molds.
Spirit level:
Spirit level is used by molder to check whether the sand bed or molding box is horizontal
or not.
Gate cutter:
Gate cutter is a small shaped piece of sheet metal commonly used to cut runners and
feeding gates for connecting sprue hole with the mold cavity.
Spray-gun:
Spray gun is mainly used to spray coating of facing materials etc. on a mold or core
surface.
Casting:
Casting is a manufacturing process in which a liquid material is usually poured into
a mold, which contains a hollow cavity of the desired shape, and then allowed to
solidify. The solidified part is also known as a casting, which is ejected or broken out of
the mold to complete the process. Casting materials are usually metals or various time
setting materials that cure after mixing two or more components together; examples
are epoxy, concrete, plaster and clay. Casting is most often used for making complex
shapes that would be otherwise difficult or uneconomical to make by other methods.
Heavy equipment like machine tool beds, ships' propellers, etc. can be cast easily in the
required size, rather than fabricating by joining several small pieces. Casting is a 7,000-
year-old process. The oldest surviving casting is a copper frog from 3200 BC.
Fig # 1 & 2 Cast iron casting
Sand casting:
Sand casting, also known as sand molded casting, is a metal casting process
characterized by using sand as the mold material. The term "sand casting" can also
refer to an object produced via the sand casting process. Sand castings are produced in
specialized factories called foundries. Over 60% of all metal castings are produced via
sand casting process. Molds made of sand are relatively cheap, and sufficiently
refractory even for steel foundry use. In addition to the sand, a suitable bonding agent
(usually clay) is mixed or occurs with the sand. The mixture is moistened, typically with
water, but sometimes with other substances, to develop the strength and plasticity of
the clay and to make the aggregate suitable for molding. The sand is typically contained
in a system of frames or mold boxes known as a flask.
Fig # 3 Cope & drag with cores in place on the drag Fig # 4 two sets of castings from the sand mold
Single Piece Pattern:
Single piece pattern, also called solid pattern is the lowest cost casting pattern. It is very
suitable for simple process, and small scale production and the large casting
manufacturers prefer it because this kind of casting pattern make casting process just
needing simple shapes, flat surfaces like simple rectangular blocks. One flat surface is
used to separate planes.
Sequence of operation:
1. Sand Preparation
2. Preparation of Mold
3. Placing of Pattern
4. Preparation of Drag
5. Preparation of Cope
6. Making of Sprue & Riser
Fig # 5 Model of sand casting

Procedure:
• First we prepare molding sand. It is a refractory material used for making mold .it is
a mixture of different material like silica clay and water.
Fig # 6 Molding sand
• The Drag is first placed upside down a molding.
Fig # 7 Drag placed Fig # 8 Pattern into the drag
• The drag is filled with molding sand and rammed suitably by means of rammer.
Fig # 9 ramming of sand.

• After sand is rammed a strike off bar is used to remove the excess sand and the
surface is made half.
Fig # 10 Excess sand removed.
• The drag is then turned over and cope is placed on it. The two flasks are held
together rigidly by means of pins.
• The above procedure is repeated again after placing the sprue pin and riser at right
place.
Fig # 11 cope are prepared.
• After proper ramming the sprue and riser are removed from cope, vent holes are
made using vent rod.
Fig # 12 Remove sprue and riser.

• Now the cope and drag are separated and pattern is removed using draw spike
from drag.
Fig # 13 pattern removed.
• With the help of gate cutter the runner is prepared in the casing.
Precaution:
1. The Vent holes should not reach the pattern.
2. The Sprue and Riser should be removed very carefully.
3. Never pour over wet ground.
Result:
Thus the required mold cavity box is obtained.
Conclusion:
1. The pattern should be placed accurately.
2. The sand is pressed. We should carefully tilt the mold.
3. Making runner and riser it is necessary to handle carefully otherwise
mold dimension is not accurate.
4. Not heating the metal above its melting temperature.

LAB SESSION NO 3 Material and Manufacturing

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LAB SESSION NO 3 Material and Manufacturing

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LAB SESSION # 3

Work material required:

Fig # 1 Tool and work material.

Strike off bar:

Fig # 1 & 2 Cast iron casting

Fig # 5 Model of sand casting

Fig # 6 Molding sand

• The Drag is first placed upside down a molding.

Fig # 7 Drag placed Fig # 8 Pattern into the drag

Fig # 9 ramming of sand.

Fig # 10 Excess sand removed.

Fig # 11 cope are prepared.

Fig # 12 Remove sprue and riser.

Fig # 13 pattern removed.

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