4.

1 LAB REPORT

 SYMMETRIZING THE VIDEO

VIDEO [1]

 In this video explain the procedure of the mould making of the sand casting process.
 Firstly, he makes the position of the drag on the flat surface, then after adjusting the bottom
section of the mould on the flat surface.
 Apply the parting powder on the setup to release cope from drag and over pattern preventing
the molding sand from stick in again grand ruin the mould finishing.
 Sieve the oil sand on the mould till the mould cover fully
 Press the sand down carefully.
 Once the mould has been covered add unsieved sand to drag section filled full.
 Compress the unsieved sand in to the drag using temper for pack all the sand into the flask
eliminating air pockets and lose sand that might ruin the final mould after pouring the molten
metal.
 To ensure the flat drag base straight edge is used to strike all the extra sand from the flask top
or bottom.
 After complete the drag part, turn it and add the top of the mould and cope. Locate this all
with the help of pins.
 Apply the parting powder to release cope from drag and over pattern preventing the molding
sand from stick in again g and ruin the mould finishing.
 Cover the mould with sieved oil sand and compress it properly with the help of temper and
make flat surface with straight edge.
 After cleaning the work place, separate the mould with carefully and cutting the runner and
riser holes with the help of hollow pipe. During making hole it should be very accurate and
without destructed wall so eliminate the casting defects.
 Making channels for the aluminum to filling the cavity of mould and remove the loose sand
from cavity.
 Using metal wire make a push holes through the mould to prevent an air-lock forming. cut
the pouring pool and the channel for pouring the material. Separate the mould and remove
any loose sand.
 Mould is ready for casting.

VIDEO [2]

 In this video explain the procedure of the sand casting process.

 On the beginning, he makes the position of the drag on the flat surface, then after adjusting
the bottom section of the mould on the flat surface.
 Apply the parting powder on the setup.
 Sieve the oil sand on the mould till the mould cover fully Press the sand down carefully.
 Once the mould has been covered add unsieved sand to drag section filled full.
 Compress the unsieved sand in to the drag using temper.
 To ensure the flat drag base straight edge is used to strike all the extra sand from the flask top
or bottom.
 After complete the drag part, turn it and add the top of the mould and cope. Locate this all
with the help of pins.
 Apply the parting powder to release cope from drag and over pattern preventing the molding
sand from stick in again g and ruin the mould finishing.
 Cover the mould with sieved oil sand and compress it properly with the help of temper and
make flat surface with straight edge.
 After cleaning the work place, separate the mould with carefully and cutting the runner and
riser holes with the help of hollow pipe. During making hole it should be very accurate and
without destructed wall so eliminate the casting defects.
 Making channels for the aluminum to filling the cavity of mould and remove the loose sand
from cavity.
 Using metal wire make a push holes through the mould to prevent an air-lock forming. cut
the pouring pool and the channel for pouring the material. Separate the mould and remove
any loose sand.
 Metal is melted in the furnace. Metal temperature is measured from time to time.
  molten metal is poured into the pouring ladle at a higher temperature than the pouring
temperature.
 Metal is allowed to have sufficient time for complete solidification. Mould is broke carefully
and casting is removed. Riser and gating system is cut-off from the casting and cleaned from
any sand and finish the product using some grinding on it by removing extra burr.
 casting is inspected visually. surface and dimensional defects is observed and recorded.
Finishing process will be carrying out at the end of the process.

VIDEO [3]

 in this video guideline of safety during sand casting moulding process explained.
 At the beginning we should wear safety glasses. Temperature was 700℃ -2200℃ during
process so welding jacket is also essential. Jacket is made of leather so can resist ignite.
 Then we have to wear metalized apron for safety due to high temperature casting. It
protects the whole body.
 To protecting the face, one should wear the fore face shield
 Hand gloves are also required to carry the hot metal for pouring the molten metal.
 The next accessories of this process is safety shoes, not any canvas or regular shoes it
can’t resist the ignite of molten metal.
 In case of accident, if molten metal fired toward the operator, he should not hesitate and
remove the all safety accessories quickly one by one.
 Sand casing process is hazards process so operator must follow the safety rule guideline.

 WORKING ENVIRONMENT
 First I had visited foundry lab and learnt the sand casing process and safety parameter during
process in detail. We were aware about tool and accessories which are required for process.
 First I made pattern of the product which was to be made then go for sand selection as per
required. Then after making mould of the pattern.
 For making mould its divided into two parts cop and drag. Starting with drag pattern is feet
into the drag part then apply the parting powder on the setup to release cope from drag and
over pattern preventing the molding sand from stick in again grand ruin the mould finishing.
and it covers by sand and press carefully and when it fully filled it was compress by temper
tool.
 Using the straight edge tool, produced flat surface and removes extra sand through the drag.
 Same operation was followed for cop part which was the top part of the mould and assemble
the both part. Then we have made for riser and runner with the help of hollow circular pipe.
 Then we provide the channel for easy pouring of molten metal. Too much care required for
making channel so it can not affect the wall or surface of mould.
 Then we move to furnace section, as per safety instruction we wear glass, jacket, hand
gloves, and metallic apron.
 Aluminum scrap was poured in to furnace and melt them on constant temperature. This
molten metal was poured into the mould until the molten metal was run out the mould
surface.
 After solidification of the metal it come out the mould is broke carefully and casting is
removed. Riser and gating system is cut-off from the casting and cleaned from any sand and
finish the product using some grinding on it by removing extra burr.
 casting is inspected visually. surface and dimensional defects is observed and recorded.
Finishing process will be carrying out at the end of the process.
 FLOW OF WORK

Fig 1. Filling the mould

After feeting the pattern, fine sand required to fill the mould to cover the pattern. It should be
dry for proper casting.

Fig 2. Compress the sand

Filling the sand in mould, it should be compress well to minimize casting defect with the
help of temper tool
 Fig 3. Assemble the mould
Compressing the mould well, the mould part; drag and cop should be assembling for casting
with the help of locating pins. Also making gate and runner in mould.

Fig 4. Melting the material

After making the mould molten metal is required. For that heating the alluminium at the
temperature of 700℃ -2200℃ for uniform viscosity.
 Fig 5. Pouring the metal
Molten metal is pour to the mould and keep allow to solidification. During pouring safety
accessories must be weared for proper casting.

Fig 6. Final product of sand casting process

After solidification product is removed and extra surface, runner and gate are removed also
clean it properly. Also apply machining for accurate dimension and finishing.
 Conclusion
The product is casted successfully based on the proper techniques and methods which started
from the making of the mould using sand, the removal of the pattern, melting of the aluminum
metals and pouring it to the mould through the sprue and pouring cup. 'he finishing $or& should
be done to remove the gate and runner however, there are some defects that occurred on our
product which are porosity and cavities. But, there are some defects can be minimized or
eliminated by proper design and preparation of the mould, and pouring procedures. the examples
of defects occur are blow, scar, blister, scab, $ash, misrun, cold shut and etc.