DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING

FACULTY OF ENGINEERING AND BUILDENVIRONMENT

Casting Assignment

SURNAME : Thobejane

INITIALS : LK

STUDENT NO : 222231672

COURSE : Mechanical Engineering

MODULE : Manufacturing & Material Technology

DATE : 31 March 2023

I confirm that this assignment is my own work, is not copied from any other person's work,
and has not previously submitted for assessment either at University of Johannesburg or
elsewhere.

Signed………………………………………. Date ………………………………………….

Table of Contents
Introduction and Background casting....................................................................................................3
Objective...............................................................................................................................................4
List of Equipment...................................................................................................................................4
Procedure..............................................................................................................................................5
Calculations...........................................................................................................................................7
Results...................................................................................................................................................9
Discussion............................................................................................................................................10
Conclusion...........................................................................................................................................10
References...........................................................................................................................................10
Introduction and Background casting

In the casting process, a cavity (mold cavity) that corresponds to the desired geometry is
filled with the liquid material. The liquid-state shape is typically stabilized by solidification
before being removed from the mold as a solid-state component. Typically, machining and
drifting allowances are also considered when designing a mold. The oldest method of
producing metallic and non-metallic complements is casting. For instance, it is used for
materials like metals, plastic, porcelain, etc.
The collection of materials, tools, and equipment needed to make castings is commonly
referred to as a "foundry." Furthermore, those who make castings are also referred to as
"foundrymen”.
Sand casting involves pouring molten metal into a previously prepared sand mold, which is
then dimensioned and shaped to fit the desired casting.
Castings' internal shapes are created by inserting supported cores made of silica sand and a
binder in the mold cavity. The molten metal is poured into the pouring reservoir and passes
through a gate or series of gates to reach the mold cavity. The melt then flows into the risers,
which serve as a storage area for extra metal to make up for shrinkage during solidification,
after filling the mold cavity. For every casting, a new mold needs to be created. To increase
productivity, the mold box can be designed to produce multiple components.
Sand's basic properties include resistance to high temperatures, strength to hold the shape of a
mold, endurance of mechanical loads from liquid metal, permeability (to allow gas escape),
and collapsibility. (to permit shrinkage).
Molding sand includes:
1. Silica (SiO2) or quartz sand is a common type of sand material because it is resistant to
high temperatures and has good permeability. (cheaper). Zircon and synthetic sands are also
used, but they are more expensive. Olivine sand is also used for steel castings.
2. The binder (which provides strength), for example, clay (bentonite, kaolin, etc.), cement,
sodium silicate (for the Co2 process), oil, and resin (shell molding).
3. Ingredients (gives collapsibility).
4. Water 4-8% (to activate the binder).
To get dry sand that helps reduce gas holes, blows, or porosity in castings, the mold is
occasionally baked in an oven between 100 and 300 C for a number of hours. (Samhan, 2020)
Objective
Notice the safety requirements for foundry work. Recognize the way standard foundry tools
and equipment operate. Notice the guiding principles, processes, and methods used in
foundry work. Understand the composition, characteristics, and use of materials used in
casting.

List of Equipment

Figure 1: Casting Equipments (Lesson, 2019)

1. Hand riddle
2. Shovel
3. Rammers
- Hand rammer
- Peen rammer
 - Floor rammer
- Pneumatic rammers
4. Sprue pin
5. Strike Off bar
6. Mallet
7. Draw Spike
8. Vent rod
9. Lifters
10. Trowels
11. Slicks
12. Smoothers
13. Swab
14. Spirit level
15. Gate cutter
16. Gaggers
17. Bellows
18. Clamps, cotters and wedges

Procedure

Mold Preparation

1) First, the desired sand is added to the sand milling device. The green sand is then
moistened with some water. The device is turned on.
2) The selected pattern is placed properly to the flask (make sure that the flask has been
aligned using alignment pins and locks).
3) After that, parting powder is added to the flask's drag side. The desired amount of
sand is sieved and added to the drag side. Bench rammers are used to compact it after
filling. The strike off bar is used to remove the extra sand.
4) Turning the flask to the cope side. The sprue and riser are positioned where they must
be. Repeat step three.
5) Leaf and a square spoon are used to make the gate and pouring basin.
 6) Lastly, the sprue, riser and pattern is removed. Mold halves are mated and prepared
for metal pouring process

Pouring Procedure

1. The metal is melted in the furnace. Metal temperature is frequently measured.

2. The molten metal is poured into the pouring ladle at a temperature higher than the pouring
temperature.

3. The metal is given enough time to fully solidify. The casting can be released from the mold
with caution.

4. The gating system and riser were separated from the casting, and any sand was wiped off.

5. The casting is given a visual inspection. Any surface and dimensional flaws are observed,
and they are noted.

6. The finishing process will be finished, if necessary.

Given Data

Ambient Temperature (T o) 25°C

Density ( p) 2710 (Kg.m-3)
Specific Heat (liquid) (C l) 0.18 (Kj/Kg °C)
Specific Heat (solid) (C s) 0.21 (Kj/Kg °C)
Heat of Fusion ( H f ¿ 389 (Kj/Kg)
Melting Temperature T m 660 °C
Solidification Time (T TS ¿ 20 min
Pouring Temperature (To) 130 °C
Height of the solid metal (h 100 mm
Big diameter (D) 200 mm
Small diameter (d) 100 mm
Calculations

Heat required ( H )

H= p V {C s ( T m−T o ) + H f + Cl ( T p−T m ) }

( )
n
V
Solidification and Cooling, Chvorinov’s Rule: T TS=Cm
A

1 2 2
Volume of a partial cone V = πh( R + Rr +r )
3

h : Height of the metal

R : Big radius
r : Small radius
Results

Total Surface Area of the cast 8066.29x10-3

Volume of the cast (m3) 227765.47x10-3
Volume of metal (m3) 296.095x10-6
Mass of metal heated (Kg) 0.802
Total heat required (Kj) 432.6
Casting mould constant 25092.368
Discussion

Sand casting is used to find casting flaws that are visible in the finished metal product. The
potential corrective actions that can be taken to lessen the flaws must be listed. The safety
precautions that must be considered when pouring the molten metal into the mold must also
be listed. must be familiar with all the tools and equipment used in the sand casting process.
Must understand the roles and applications in the relevant process. Once everything is
finished, write a detailed report on the sand casting process our group used, along with any
additional recommendations for improving the casting product. All casting flaws that could
affect the product must be known and identified for expandable-pattern (lost foam) casting. It
is necessary to list all potential remedies that could be used to reduce flaws. We offer our
recommendation for the ideal gate design for this process and support it with references to
relevant literature. The same as when we finish casting, we write a detailed report of our
activities. Plaster mold casting comes next. Similar to sand casting, plaster mold casting starts
with defect identification, followed by a list of corrective measures and a justification of the
ideal plaster of paris (POP) and water mixing ratio (1:1).

Conclusion
Using the proper techniques, including sand-casting the mold, removing the pattern, melting
the aluminum metals, pouring them into the mold through the sprue, and pouring a cup, the
product was successfully cast. The gate and runner cannot be removed until the finishing
work is complete. However, porosity and cavities have emerged as two flaws in our products.
These flaws can be reduced or even eliminated with the right mold design, preparation, and
pouring techniques. Blows, scars, blisters, scabs, washes, misruns, cold shuts, and other
errors are examples of issues that have occurred.

References
Lesson, S., 2019. StudentLesson. [Online]
Available at: https://studentlesson.com/types-of-sand-casting-tools/
[Accessed 28 March 2023].

Samhan, D. A. M. A., 2020. Faculty. [Online]

Available at: https://faculty.ksu.edu.sa/sites/default/files/metal_forming_v1_1.pdf
[Accessed 28 March 2023].