good morning friends in the previous classes
we have been learning about the moulding sands
core sands and the patterns now in this lecture
let us see the steps involved in making a
sand casting so these are the steps involved
in making a sand casting
the first step is the pattern making the second
step core making third step moulding with
the moulding sand next one melting and pouring
next one after we melt and pour the molten
metal after sometime the molten metal solidifies
inside the mould after solidification we have
to break the sand and take the casting outside
this process is known as knockout after knockout
we do the heat treatment but this is an optional
it depends upon the case and the application
of the casting the next step is cleaning finally
the inspection then it will be shipped to
the customer
now we will be learning a little bit more
about these steps first let us see the pattern
making so in the previous class only we have
learned about the different types of the patterns
and the elevenses to be given to the patterns
and the materials of the patterns we have
seen so in the same way depending upon the
geometry of the casting depending upon the
what say ah what say case and the size of
the casting we have to choose the right what
say pattern and with the right material
so that is about the pattern making so these
are all the different types of the patterns
we have seen in the previous class right so
now we any of these patterns we have to make
the next step is yes here we can see this
is a big pattern right sometimes patterns
are even given what say painting so to enhanced
their life here we can see this is the pattern
of your pump housing and we can see ah yes
it is being painted at the final stage of
its preparation
so thats all about the pattern making next
one let us see the core making core making
also we have seen is ah two lectures before
and we have seen the different ingredients
of the core sands and ah right different materials
used for the core sands ah additives right
and core coatings and types of the coatings
we have seen so similarly and depending upon
the case depending upon the casting we have
to choose the right core material and we have
to make the right core
next one is the moulding so this takes time
and this has to be done with extreme care
with extreme skill let us see the steps involved
in the moulding process first of all it is
ah broadly classified as the manual moulding
and machine moulding moulding can be done
manually this skilled labor used to do this
right they put the pattern inside the moulding
box and they take the green sand and the compacted
inside the box so this is done manually but
this requires skill and this moulding can
also be done using moulding machines so this
is known as the machine moulding
now let us see first the manual melding moulding
the different steps involved in the manual
moulding how to carry out the manual moulding
now we will see here you can see first of
all moulding of the drag drag means lowered
moulding box what we have to do so we have
two mould the drag box and we have mould the
cope box also
now this is the drag box and this is the moulding
board and this is the pattern so initially
we have to take the moulding board and on
the moulding board we have to place the pattern
then we have to place the drag box around
the pattern and on the moulding board so that
is the first step
second step now we can see here this is the
moulding board over the moulding board we
have kept the pattern and around the pattern
we have kept the drag box now we have to sprinkle
dry facing sand over the pattern for creating
a non sticky layer why we are what say sprinkling
this ah dry facing sand so this is a carbonaceous
sand fine sand very fine sand then what we
what happens when we sprinkle this sand around
the pattern because afterwards we are going
to place the moulding sand on the pattern
so the moulding sand contains the moisture
and it is possible and ah it is also contains
the clay and the additives
so and we will be compacting the moulding
sand over the pattern it is possible that
the moulding sand may be sticking to the pattern
and while withdrawal of the pattern it may
break the mould cavity so we dont want such
thing to happen thats why we are creating
a non sticky layer between the pattern and
the mould and the moulding sand so we will
be sprinkling this ah what say dry facing
sand so this is the second step
next one after what say sprinkling the what
say carbonatious ah facing sand over the pattern
now we are facing the moulding sand over the
pattern so this is this red colored one is
the moulding sand so with the both the hands
they are putting the moulding sand into the
moulding box so this is the third step
now after placing the what say sufficient
moulding sand arrow above the pattern and
inside the drag box now the sand has to be
compacted so this is the rammer you see this
is the hand rammer using the hand rammer manually
it has to be rammed all over initially around
the pattern then at the corners of the box
then everywhere it should be a rammed and
it should be rammed till the moulding box
is full and the moulding box should be compacted
with the moulding sand
next one what happens as we keep what say
what say compacting the moulding sand at one
stage the sand will be excess the excess sand
must be leveled off the excess sand must be
removed for that purpose we are using a striking
bar you see this is the striking bar using
the striking bar we have to level off the
excess sand so that the level comes in exactly
with the level off the moulding box so this
is the level off the moulding box even the
level off the moulding sand is same as that
of the level off the moulding box
after what say leveling the excess sand what
we have to do we have to make the pattern
box ups and down because remember that the
pattern is now on the moulding board now we
will be turning it ups and down so what happened
say we have turned it ups and down now this
pattern has come upwards so this is the pattern
ok
now with this the moulding of the drag box
is over now we are starting the moulding of
the cope box what to do how to do the moulding
of the cope box now this is the drag box this
drag box we have already compacted with the
moulding sand inside yes there is moulding
sand and the pattern is at the center now
over the what say drag box we will be placing
the cope box right
but the thing is ah sometimes it may not be
aligned properly so to ensure that there is
proper alignment so we use the what say locating
pins are these are also known as the dovetail
pins means both the cope box and the drag
box have handles like this you can see here
these are the handles so these are magnified
here these both these handles have a hole
of a particular diameter and we will be inserting
the locating pin or the dovetail pin into
that hole then what happens when we insert
that pin pin into those holes there wont be
any misalignment the cope will be perfectly
aligned over the drag box
now we have to place the sprue and riser pins
so when we are what say compacting the ah
cope box remember that we have to make a provision
for the sprue passes sprue means the vertical
passes of the molten metal and it goes through
the sprue then it passes through the runner
of course runner will be creating manually
right then it fills the cavity then it rises
through the riser hole
so we have to create frozen for sprue and
the riser so this is the a riser pin and this
is the sprue pin so these are the wooden pins
so we will keep them above the what say drag
box if it is this sprue pin it is just outside
the pattern if it is the riser pin it is a
almost at the center of the ah pattern above
pattern now this is the cope box now again
we start timing the moulding sand
now you see then we have to compact the cope
box with the moulding sand here we we can
see the cope box is also compacted same way
place the moulding sand and take the rammer
and remit all over around this sprue pin around
the riser pin compacted and once the sand
level is excess take the strike bar and level
off the excess sand
now after the sand is leveled off we can see
the mould is like this the mould in the cope
box is like this and if we see the section
the section looks like this see this is the
drag box and this is the cope box and this
this is the pattern and this is the what say
this is the sprue pin and this is the riser
pin now what we have to do inside remember
inside these two boxes pattern is there sprue
pin is there and the riser pin is there and
we have to withdraw them
in order to withdraw this first we have to
separate them so we are separating the cope
box and the drag box now we have separated
after separating is the cope what say this
is the drag box the drag box looks like this
right so here only the drug box only this
is not the cope box the drag box is here shown
the section so we can see at the center this
is the pattern now we have to cut the gate
using the gate cutter this is the gate cutter
so here we are cutting the gate then we have
to withdraw the pattern see this is the withdrawal
of the pattern so this pattern must be withdrawn
very carefully for that purpose what we do
we use a ah what say draw spike so this is
the draw spike so the draw spike is a long
what say pin right at the end it has a screw
now we what say see that the screw little
bit goes inside the pattern then what we do
we ramp the pattern on all the four sides
thats why there was a rapping allowance in
the previous class we have seen
so when we are rapping the pattern the mould
cavity expands a little bit on all the four
sides then there is a clearance between the
pattern and the mould cavity then using the
draw spike we have to carefully withdraw the
pattern now the drag box is free from the
pattern similarly from the cope box we have
to remove the sprue pin and the riser pin
generally this sprue pin and the riser pin
will have a tapper and because of the tapper
and ah it is easy to withdraw them so now
in this case we can see even this sprue pin
and the riser pin from the cope box are withdrawn
now this is the section of the total mould
right so this is the drag box and this is
the cope box right so this is the mould cavity
this is the mould cavity this is the pouring
basin and this is the sprue the we pour the
molten metal like this and the molten metal
goes this way and it fills the cavity then
it passes it rises through the riser riser
is also known as the feeder
now here we can see vent holes you can see
these are additionally created using the vent
pins because the riser is there the riser
hole enables the escape of the hot gases only
during the filling once the mould cavity is
filled with the molten metal it cant allow
any escape of the hot gases at such times
these vent holes will help us to escape the
ah hot gases thats why using the vent pins
we are creating the vent holes these vent
holes are created from the outside surface
of the mould and such that they touch the
inner surface of the cavity
so thats all about the manual moulding so
we have seen how to cope the ah what say how
to ram the drag box and how to ram the cope
box and how to withdraw the patterns and and
how to withdraw the ah what say riser pin
and the cope ah sprue pin and how to cut the
gate and again we have to assimilate now that
is about the manual moulding so let us see
little bit about the machine moulding machine
moulding is used for the larger castings
now friends let us see the methods of the
machine moulding in the machine moulding the
important one of the important machine moulding
process is the jolting right in the jolting
what happens this is the moulding box yes
ah inside the we place the pattern and this
is the moulding sand we place the moulding
sand
now here there is a table stop right its a
strong table stop is there and the machine
raises this box and suddenly it falls down
again it raises and suddenly falls down and
because of this repeated raise and for what
say fall down raise and fall the moulding
sand which is placed in the moulding box will
be compacted and this will be done within
few minutes and this can be used for the what
say moulding larger moulds
then the next one we see the squeezing and
the squeezing is also a faster method and
this is also used for the making larger moulds
and this is the these are the moulding boxes
and inside this pattern and of course we place
the sprue and the what say riser pins and
we place the moulding sand you see here so
we place the calculated amount of moulding
sand now here there is squeezed platon is
there this squeeze platon will be coming from
the top and it squeezes the sand which is
above the moulding box and this pressure is
applied hydraulically and this is a very high
pressure and because of that the moulding
sand in the box will be squeezed and it will
be compacted tightly then we separate these
two moulding boxes and the pattern is withdrawn
by creating vibrations to the pattern so this
mould mean both the cases the moulding is
done within few minutes and there is another
machine called jolt squeeze machine right
and one more is there that is the sand slinger
machine what is this sand slinger machine
we we here we can see this is the moulding
these are moulding boxes this is the drag
box and this is the cope box and this is the
pattern and here we can see the sand is here
the moulding sand and there is a system which
ensures that the sand will be falling above
the pattern with a high pressure at a very
high pressure
now you see the sand is falling on the pattern
at a high pressure as the sand is falling
on the pattern because of the pressure it
will be compacted while it is falling above
the pattern so after on time that what say
moulding box will be full with the moulding
sand if there is any excess sand that will
be leveled off so this is the sand slinger
machine
so here we can see this a mechanized what
say foundry where there will be moulding machines
will be there and the moulds will be ah moved
automatically to the place of pouring so we
have seen so far we have learnt about the
pattern making core making moulding now let
us see the melting and pouring
so these are the important furnaces used in
the melting crucible furnace cupola furnace
electric arc furnace induction furnace resistance
furnace rotary furnace and reverberatory furnace
using any of these furnaces and again some
furnaces are suitable for certain metals and
certain alloys so depending upon the alloy
and depending upon the size right we have
to choose the right furnace and we have to
melt the metal and after we melt the metal
we do the pouring and after pouring the metal
inside the mould solidifies after the metal
solidifies we have to break the sand and take
the casting outside this process is known
as knockout and here you can see this is the
what say after pouring right we have broken
the sand and this is the casting which has
been taken outside
so this is a knockout process right here you
can see this is a casting which is just brought
outside the moulding sand after breaking the
mould right casting after knockout with the
runners and risers still attached remember
that when we do this a knocking out process
there will be metal will be solidified in
the sprue also metal will be solidified in
the riser also metal will be solidified in
the gating also so these solidified projections
will be still attached to the casting when
we do the knockout so afterwards we have to
cut them and we have to separate them from
the casting
next one the process step is the heat treatment
so this is the an optional process it depends
upon the application so these are all the
different heat treatment process right so
all may not be used may be anyone um what
say process can be used that to it is the
optional right annealing normalizing stress
relieving aging quenching tempering select
to heat treating differential hardening flame
hardening induction hardening case hardening
cold and cryogenic treatment so these are
the ah some of the important heat treatment
process so we can use any of this to enhance
ah say ah certain properties
next one the cleaning after we do the knockout
right after we give the heat treatment process
the casting should be cleaned so this cleaning
is to remove the residual sand though we have
broken the sand taking the casting outside
still some sand particles are attached to
the casting so this residual sand particles
are to be removed and some oxides will be
there on the surface right some scales will
be there and these are to be removed this
is done by short or tumble blasting there
are other process called pneumatic blasting
means ah what say air will be released at
a very high pressure and with this high pressure
air will be exposed to the casting and it
will be made to fall on the casting say then
all the residual sand particles oxides will
be removed
next one finally the inspection right so far
the inspection is very important because the
casting may look very ah what say perfect
outside but internally it may have some defects
internal cracks or the what say blow holes
or the shrinkage cavities may be inside for
that purpose we need to inspect the casting
so these are the common inspection methods
one is the visual inspection it will enable
us to find out the external defects
next one x ray inspection ah in internal defects
can be identified next one ultrasonic testing
using this we can identify the internal defects
magnetic particle inspection testing so using
this we can identify the say small cracks
which are on the surface of the casting but
are not visible to the naked eye next one
dye penetrant inspect inspection sorry this
magnetic particle inspection can also be used
for ah finding out the internal cracks
now this dye penetrant inspection this can
be used for identifying the what say cracks
that are on the surface but are not visible
to the naked eye so with that we are completing
the inspection afterwards if any painting
is required the painting will be done then
the casting will be ah shipped to the customer
so these are the important steps we can see
in a table form so this is the moulding and
this the right and a pattern making core making
and gating system so they all are done parallel
to the moulding right
so this is the mould and using the sand we
do the moulding and here we are melting the
metal and here you see we are pouring the
molten metal into the mould and solidification
takes place and here we get the solidified
casting and that casting has to be taken out
by doing the knockout operation it is also
known as shakeout operation then there is
a heat treatment process again this is optional
thats why we can see like this and next one
cleaning and finishing and a additional heat
treatment if required it will be given next
one the inspection right so thats all about
the sequence of the steps involved in making
a sand casting
friends now let us go to ah our laboratory
and we will see the demonstration of all the
steps ah how the mould is made right and how
the metal is melted and how it is poured and
how it the casting is taken out we will have
a demonstration now let us see a demonstration
in our laboratory
friends now we are the foundry engineering
laboratory of iit roorke we have been learning
about how we prepare the green sand we have
seen that the ingredients of the green sand
are been base sand the second ingredient is
the clay third ingredient is the ah the additive
and the fourth ingredient is the moister of
the bottom so all these ingredients will be
mixed to gather in a machine or sand motor
so this is the sand motor you can see it has
got a cylindrical drum and it has got two
roller are there one roller is here and another
roller is here and inside there are two plates
are there
now when we drop all the ingredients of the
green sand and this will rotate in the roller
will be rolling warm up the ingredients of
the molding sand and the blades will be sprue
pin so that no sand will be left out without
getting mould so this is how we prepare the
green sand now i request mister anil kumar
dhiru a research scholar in our department
to come here and show the green sand preparation
mister anil kumar dhiru please come here
yes
so please show me yes this this is the ah
the base sand
yes
so this is the ah main ingredient of the green
sand so this is the base sand in fact this
is the silica sand so the silica sand looks
like this so this is the main ingredient of
the green sand ok ah next one ah we will see
the second ingredient that is the clay so
this is the clay you can see yes
this is the bentonite and i have already told
you the what say source of the bentonite and
from way it would be comes and its classifications
and this is the bentonite the bentonite looks
like this so this is the clay this induces
the what say cohesion between the sand purpose
next one we have seen the third ingredient
the third ingredient is the additive right
so this is the we have already seen different
types of the additives and today we are using
the coal dust the coal dust looks like this
oh what coal dust coal dust is the pulverized
coal so this is the third ingredient and the
fourth ingredient is the moister moister will
be added so we have what say kept these in
the ah proportions these proportions we have
already seen earlier now we are going to add
all these ingredient in this ah puller sand
puller and we will prepare the green sand
now he will be doping the base sand into the
sand puller yes
so the we can see that is a small what say
showel a this is a small showel in his hand
which is use to carry the sand now he has
completed doping the base sand in to the motor
next he will be doping the bentonite (( )) now
he is doping the bentonite this is the bentonite
yes next he is doping the coal dust the additive
into the system into the motor this is a coal
dust now this is the water calculated amount
of water he is pouring into the motor
friends until now we were bullying the green
sand right we have taken all the ingredients
of the green sand and we have moulding to
the sand motor now the green sand is ready
so this is the green sand ready for moulding
friends until now i was explaining you how
to prepare the green sand mould what are the
stages involved in ah in the preparation of
the green sand mould now we are again the
foundry engineering laboratory of the iit
roorkee now we will see a demonstration how
to make the green sand mould and ah we have
ah miss kyathi she is a mtechs scholar and
we have mister ganapati rai and he is a research
scholar and they will be showing as the demonstration
of the 
green sand mould and before that i will try
to show you the important tools of the green
sand moulding
now you can see here so this is the moulding
box and this is the ah yes this is the drag
box this is a metallic box you see it is opened
at the top and bottom so this is the drag
box now you can see here this also a moulding
box metallic box it is opened both at the
top and bottom so this is the cope box
next one so this is the pattern which we are
using in the todays demonstration so this
pattern is similar to the component which
we are going to produce next one so this is
the rammer sand rammer and this is another
rammer this is the round rammer and when we
are making the mould we need to make the sprue
hole and also we need to make a riser hole
here you can see two pins one can be used
as the riser pin and the other one can be
used as the sprue pin
next one and this is the a draw spike i told
you 
the withdrawal of the pattern is very important
so manually if you if you try to withdraw
the pattern it is very difficult thats why
we inside this draw spike into the pattern
then with a we will moving pattern and this
is the vent pin of the compacting sand inside
the moulding boxes to ensure that the hot
gases escape from the mould we make tiny and
narrow holes in the mould so for that purpose
we use the vent pin with the vent pin we make
narrow box so this is the brief introduction
and this is the squared for cleaning purpose
right
so this is the brief introduction of the tools
now we will go for the demonstration of the
green sand mould now miss kyathi and mister
ganapati rai will show as the demonstration
of the green sand mould
ah that is a pattern and 
this is the moulding box and she has kept
it pattern inside the moulding box now she
is sprinkling the facing sand so this is the
facing sand very fine sand you can see that
is the facing sand so that after that ah we
will be what say operating the moulding sand
this moulding sand should not stick to the
pattern and the moulding box
now there are putting the green sand into
the moulding box initially the box should
be filled ah to some extent not fully and
see she is ramming initially the ramming should
be done at the corners then slowly the ramming
should be coming inside
now the initial compaction is over now we
are putting more and more green sand into
the moulding box again the compaction now
you can see she is using the round rammer
remember that the compaction should be uniform
no way it should be irregular now you see
we have compacted the moulding box with sand
now you can notice that the sand is more there
is excess sand so this excess sand has to
be removed using the striking bar so this
is the striking bar with which ah she will
be removing the excess sand
now the compaction of the drag box is over
now she is sprinkling the parting sand on
the drag box this parting sand will happens
so that we are going to what say compacting
the cope box the sand in the cope box and
with the sand in the drag box will not stick
to each other for that purpose we have stickle
the parting sand so these are the ah bentroots
now the moulding box will be made ups and
down you see it could be made ups and down
so that the pattern comes upwards you see
now heels the pattern this is the pattern
the sands come out now how this will be placing
the cope box and the again will be compacting
the sand in the cope box parting sand
(( ))
again that is the parting sand so that is
the ah one is the riser pin and ah other one
is the sprue pin the location of the riser
pin and sprue pin is very important again
you can see the standing (( )) care has to
be taken for that the sand around the ah sprue
pin and the sand around the riser pin are
compacted very carefully again the excess
sand is being removed using the striking bar
friends until now the compaction of the sand
put in the drag box and coke and column now
we are removing the pins the riser pin and
the sprue pin that should be run with extreme
care now we are cutting the what say pouring
cup above the sprue so that it will an appears
to pour the molten metal very easily so that
is the pouring hole any excess sand or rue
sand will be removed by using the swap this
is the swap again she is making the vent moulds
to facilitate easiest step of the hot gases
from the mould
now the step means we come to separate the
two boxes and inside (( )) that the pattern
is inside the pattern means the withdrawn
and also we need to cut the (( )) she is applying
the water around the a pattern so the ah the
withdrawal of the pattern would be easier
now she is using the draw spike to withdraw
the pattern yes how she is withdraw the pattern
(( )) them now she has withdrawn the pattern
yeah he (( )) say moulding stamens right and
it should be prepared again you will be closing
the ah two boxes now she is making the ah
gate she is cutting the gate see ah care has
to be taken while cutting the gate around
the sprue around the sprue so this is the
gate cutter and there it should be limit inside
the surface and this side we have the risering
so we are linking a passes for the riser
now gate cutting is over again we are replacing
the cope over the drag
(( ))
now you see again the cope box is kept over
the drag and ah we have to separate ah and
if we have kept the cope over the drag and
to ensure the proper arrangement of the drag
and cope and here we can see and these are
all the dovetail pins are there right here
is the dovetail pin and here is the one dovetail
pin and they will be cutting us two properly
arrange the two boxes next we will see the
pouring of the molten metal into this mould
friends until now we have seen how to prepare
the green sand mould now the green sand mould
is ready now it is ready for pouring let us
see how to pour the molten metal into the
mould we have with our (( )) misses saroul
sen patnayak and she is a research scholar
in our department and mister b k sharma and
he is a technical staff in our laboratory
and they will show us how to pour the molten
metal into the mould you can see that is the
molten metal some stack is there at the top
so that has to be removed so thats a graphite
(( )) in which we can see the molten metal
that is the aluminium that is the aluminium
so that is the pouring cup he is pouring through
the pouring cup you see and it fills the cavity
then it rises through the rise
hence now you can see most you can see withdraw
poured molten metal through the pour for and
it has drawn to this sprue and it has entered
into the ah what say mould cavity then it
has raise to the riser so this is the metal
it has raised through the riser so that is
how we used to pour the molten metal into
the green sand mould after some time it will
be solidified then we break the sand and take
the casting outside
friends until now we have seen how to make
the green sand mould we have processing how
to pour the molten metal in to the mould now
when we have we have pour the molten metal
into the (( )) now the molten metal is solidified
now i request misses saroul sen patnayak the
research scholar and mister sukram the technical
staff in our laboratory to carry out the shakeout
operation shakeout operation means we have
to break the sand and take the solidified
casting outside now we will see the shakeout
operation
(( ))
we can see the solidified solidified casting
inside but remember that the metal is also
solidified in this sprue and the riser hole
which are cant the part of the casting these
are to be cut and separated
this is the solidified casting you can see
this is the solidified casting and this is
the casting this is the casting and this is
the metal which is solidified in this sprue
and this is the metal which is solidified
in the riser later ah we have clean the casting
and wing the cutting here so that these unwanted
portions will be removed from the solidified
casting
friends until now we have seen the preparation
of the sand mould pouring and solidified casting
finally we have seen the shakeout operation
with that we are closing the how to the different
steps involved in making the sand casting
friends now the shakeout operation is over
we have broken the sand mould and we have
taken the casting outside so this is the solidified
casting you can see this is the actual casting
but this is the what says what say pattern
which is solidified with the sprue core and
this is the metal which is solidified with
the riser so later these are the cut here
so that we will get the required casting
friends now we have remove the the metal is
solidified in this sprue and the riser now
this is the final casting after removing the
unwanted projections and unwanted ah the sprue
and the riser so with this ah we are completing
the procedures for making the sand mould so
in this lecture we have seen how to prepare
the sand mould we have seen different steps
involved in making the sand mould and we have
seen how to pour the molten metal into the
mould and we have seen the shakeout operation
how to break the sand mould after the solidification
is over then we will may cutting the unwanted
metal which is solidified in the sprue and
the riser finally we have obtain the required
casting
thank you
