FOUNDRY

Lecturer : Madam Freddawati Binti Rashiddy Wong

Prepared by :-

Group Member Student ID
1. ELNOLG PUNGGA ANAK UNTOL 2012607864
2. MIRA FARAHIM BT. MAT HARUN 2012293636
3. MUHAMMAD FAIZ BIN MOHD ALI 2012282592
4. NADZMI BIN HARON 2012630684
5. MUHAMMAD FADHIL BIN MOHD NAZER 2012876378

Group Organization Chart and Work Distribution.
Objectives.
Introduction to Foundry.
Theory of Foundry.
Operation procedure.
Type of machine and component details.
Discussion.
Conclusion.
References.
Leader:
NADZMI BIN
HARON

Slide Production:
MUHAMMAD FAIZ
BIN MOHD ALI
MUHAMMAD
FADHIL BIN MOHD
NAZER
Presenter:
ELNOLG PUNGGA
ANAK UNTOL
MIRA FARAHIM BT.
MAT HARUN
At the end of this presentation you will know:

How metal products are made c0mmercially?
What is Foundry?
Two (2) type of main Foundry process.
Application of Foundry.






THESE ARE THE FINAL PRODUCT OF ...
HOW TO MAKE THESE???????????
3.Foundry
???
2.Forging
1.Machining
WHAT IS FOUNDRY?

Foundry , also known as casting is the process of producing metal/alloy
component parts of desired shapes.

Through Foundry, metals are turned into part by:
- Melting them into a liquid metal.
- Pouring the liquid metal into a specific shape mold.
- Removing the molded material or casting after the liquid
metal has solidified as it cools to room temperature.

The most common metals processed are Aluminum and cast Iron. (Bronze,
Carbon steel, Magnesium, Copper, Tin, and Zinc also can be processed).


>Metal products are highly important in the modern world. The needs to produce
these products are becoming one of the most demanding industry right now.
>All metals/steels are in solid form (block or powder form) except for Mercury (Hg).
>Casting idea comes from the study of liquid (e.g. water) behavior, where it will fully
fill the shape of the former that it been inserted into.
> Physical properties of all metals include that they can be melt at their respective
melting temperature (phase conversion from solid to liquid), hence they can behave
like the liquid where it can fill the former shape (mold) that it been inserted into
where then these metal will cool down to become into its solid form again at room
temperature.




TYPE OF CASTINGS PROCESS

1) SAND CASTING 2) INVESTMENT CASTING



1.SAND CASTING

- A cast part produced by forming a mold from a
sand mixture.
- Pouring molten liquid metal into the cavity in the
mold.
- Mold is then cooled until the metal has solidified.
- Last stage the casting is separated from the mold.


- An industrial process based on and also called lost-
wax casting.
- Generally used for small castings (but has produced
complete aircraft door frames, steel castings of up
to 300 kg and Aluminium castings of up to 30 kg.)
- Generally more expensive per unit than sand
casting.


Transportation vehicles
Turbine vanes
Power generators
Railway crossings
Agricultural parts
Aircraft jet engine parts
Sanitary fittings
Communication, Construction and
Atomic Energy applications

1.Mixing moulding
sand with binders &
adhesives
2.Filling sand in
moulding flasks
3.Melting in furnace
4.Pouring molten
liquid into mould










5. Knock out
6.Heat treatment
(casting cleaning)
7.Machining
8.Final products of
casting
- Flask: A metal or wood frame, without fixed
top or bottom, in which the mould is formed.

- Pattern: It is the replica of the final object
to be made.

- Parting line: This is the dividing line between
the two mould flasks that makes up the
mould.

- Core: A separate part of the mould, made of
sand and generally baked, which is used to
create openings and various shaped cavities
in the castings.




-Chaplets: Chaplets are used to support the
cores inside the mould cavity to take care of its
own weight and overcome the
metallostatic force.

-Riser: A column of molten metal placed in the
mould to feed the castings as it shrinks and
solidifies.

-Vent: Small opening in the mould to facilitate
escape of air and gases.



-Pouring basin: A small funnel shaped cavity at
the top of the mould into which the molten
metal is poured.

-Sprue: The passage through which the molten
metal, from the pouring basin, reaches the mold
cavity.

-Runner: The channel through which the molten
metal is carried from the sprue to the gate.
-
-Gate: A channel through which the molten
metal enters the mold cavity.


*CNC: Computer Numerical Control
No Area of comparison Sand Casting Investment Casting
1 Strength Good Good
2 Surface Finish Fair Best
3 Range of metal can be used Best Good
4 Size Limitation Best Fair
5 Cost per piece Good Poor
6 Mould Cost Best Good
Level of comparison: Best-> Good->Fair->Poor
A study by West Coast Casting Incorporation (USA) on
comparison between Sand and Investment casting are summarized
in table below:

From the study; Sand casting is better than investment casting in
term of range of metal that can be used, both mold and piece cost
as well as it has the best size range compared to investment casting

Casting defects: An irregularity in the metal
casting process that is undesired. Some effects can be
tolerated while others can be repaired otherwise they must
be eliminated.
Type: i) Surface defects ( crack)
ii) Internal defects (holes, inclusions)
Main categories : gas porosity, shrinkage defects, mould
material defects, pouring metal defects, hot tear, crack
and metallurgical defects.
Inspection (how to detect the problem?):
i)Dye Penetrant Test (detect surface imperfection)
ii)Radiography Test (detect internal imperfection)
Prevention: avoid sharp corners, avoid rapid changes in
cross-section areas , avoid large and flat areas


Dye Penetrant Test Radiography Test
Metal/Steel products are commercially produced by
Machining, Forming and Foundry/Casting.

Foundry , also known as casting is the process of
producing metal/alloy component parts of desired
shapes.

Two (2) type of Foundry processes are Sand Casting
and Investment Casting.

Casting products are widely used in automotive
industry, manufacturing, aerospace etc.


By websites :
- http://en.wikipedia.org/wiki/Sand_casting
- http://www.authorstream.com/Presentation/aSGuest5
7564-453780-foundry/
- http://en.wikipedia.org/wiki/Foundry
- http://www.westcoastcastings.com/why-sand-
casting.html

Books:
- ASME (American society of mechanical engineer)
section V (Non-destructive examination).