H Kingdom of Saudi Arabia Ministry of Higher Education Umm Al-Qura University College of Engineering and Islamic Architecture Mechanical Engineering Department Sand Molding Arrangement , Design and Production B.sc Project Prepared By : 1-Ahmad Mohammad Tarmom. 2- Naief Ali Al-Malki 3-Abdullah Abdurrahman Al-Faqasi 4- Meshari Eidhah Al-Juaid 5-Faisal Mohammad Bashaikh 6-Assaf Saleh Al-Khathami 7- Ali Ahmad Al-Omari Supervised By : Dr. Ahmed Hassan
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H. Sand Casting Types Of Sand Mold Uses and Advantages Disadvantages of Sand Casting.
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H
Kingdom of Saudi Arabia Ministry of Higher Education
Umm Al-Qura University College of Engineering and Islamic Architecture
Mechanical Engineering Department
Sand Molding Arrangement , Design and Production B.sc Project
Prepared By : 1-Ahmad Mohammad Tarmom. 2-Naief Ali Al-Malki
5-Faisal Mohammad Bashaikh 6-Assaf Saleh Al-Khathami
7- Ali Ahmad Al-Omari
Supervised By : Dr. Ahmed Hassan
Casting is a liquidus for process, includes
melting the metal, pouring it in a pre-shaped mould and allowing it to solidify.
Sand casting process is a metal process in which natural sand, containing a proportion of clay to bind the grains of sand together and water, or a
pure silica sand with an artificial binder added to it, is contained in a flask
ABSTRACT
(the name given to a pair of matching molding boxes) and compressed by
hand, or mechanical ramming, around a pattern.
In this project a sand molding arrangement was designed and
produced to simulate the automatic sand molding machine.
INTRODUCTION
MOLDING MACHINES
EXPERMENTAL WORK
CONCULOUSION
CHAPTER ONE
INTRODUCTION
INTRODUCTION
Sand Casting
Types Of Sand Mold
Uses and Advantages
Disadvantages of Sand
Casting
INTRODUCTION
* Casting is a liquidus for process, includes : melting the metal, pouring it in a pre-shaped mould and allowing it to solidify.
Sand Casting
* Sand casti ng process is a metal casti ng process in which a natural sand , containing a proporti on of clay and water to bind the grains of sand together.
When two fl asks are parted, the patt ern and the dowels forming the sprue system are removed, a negati ve mould shape is left in the sand. The molten metal is poured into this cavity.
Types Of Sand Molds
Types Of Sand Molds
Green sand mold:
It is the most common mold
Green mold sand is a
mixture of sand,
clay, and water Green sand
molding is the least expensive
method "of making 'molds.
Cold-box mold:
In this process, various organic and inorganic
binders are blended into the sand to
bond tae grains chemically for
greater strength
No-back mold :
In this process, a synthetic
liquid resin is mixed with the
sand, and mixture
hardens at room
temperature Because
molding of the mold in this
and the cold-box process takes place
without heat
Uses and Advantages
It can be used to produce complex and huge shapes, such as cast-iron engine
blocks and very large propellers for ocean liners.
Sand casting can be economical for relatively small production runs, and
equipments cost are generally low
Disadvantages of Sand Casting
1- The surface finish obtained is largely a function of the materials used in making the mold.
2- Dimensional accuracy is not so good as that of other casting processes.
CHAPTER Two
Sand Molding Machines
Sand Molding Machines
Introduction.
Advantages of Sand Molding
Machines
Automatic Molding Methods
Introduction
•The objective of automatic molding is to produce accurate parts able to withstand lifting and handling .
• Molding Machine enables moulds to be produced at high rates .
• The principal feature of molding machine is the use of power operated mechanisms for mould compaction; this mechanization can extend in varying degrees to pattern withdrawal and mould part manipulation
Advantages of Sand Molding
Machines
•1- Eliminate labor cost.
• 2-Offer high quality casting by improving the application and distribution of forces.
• 3-Manipulate the mold in a carefully controlled fashion .
• 4-Increase the rate of production
Automatic Molding Methods
Automatic Molding Methods
Jolt and squeeze
compaction
vertical flaskless molding
Impact molding
Jolt and squeeze compaction
Vertical Flaskless Molding
Impact Molding
CHAPTER THREE
Experimental Work
Experimental Work
Introduction.
Project Parts
Assembly and
Operation
Process Procedure
Introduction
•Sand molding process was a hand process. And it is developed to be an automatic process.
•In this project a sand molding arrangement was designed and produced to simulate the automatic sand molding machine
Project Part
Project PartsPneumatic cylinder and its
squeeze
heads
Frame
structure
Flasks Pattern
Riser,
sprue and runn
er
Plate
Pneumatic cylinder and its squeeze heads
lWe select pneumatic cylinder with bore
D = 10 cm
that is available Commercially and to be more efficient , while the stroke is taken
L= 10 cm .
Frame structure
Flasks
Pattern
Riser, sprue and runner
Plate
Assembly and Operation
Process Procedure
•1- All parts are assembled on the plates including the flasks for making cope and drag . •2- The flasks were filled with sand
•3- The two assembled flasks then placed under the squeeze head of the arrangement one by one.
•4- The sand was compacted using the repeated impact of the squeeze head
•5- After squeezing, the plate with pattern, sprue and riser removed .
• 6- The flasks (cope and drag ) were bolted together .
•7- The molten metal is poured through the sprue to fill the mold .
• 8- The molten metal is left to cool, the casting extracted from the sand mold and cleaned
Conclusion
4.1 Conclusions :
1 - T h e s a n d m o l d o b t a i n e d h a v e a g o o d f o rc e d i s t r i b u t i o n b e t t e r t h a n t h e m a n u a l l y r a m m e d
2 - T h e s a n d m o l d i n g p ro c e s s t a k e s m a l l t i m e c o m p a re d w i t h t h e m a n u a l l y o n e .
3 - T h i s m e a n t h a t t h e p ro d u c t i o n r a t e i s i n c re a s e d . 4 - T h i s a r r a n g e m e n t w i l l b e g o o d e x a m p l e f o r t h e s a n d m o l d i n g m a c h i n e f o r t h e
s t u d e n t s o f t h e f o u n d r y c o u r s e .
Recommendation
4.2 Recommendation :
1 - T h e f o rc e t h a t f o r m t h e m o l d i s a s s u m e d d e p e n d i n g o n e x p e r i e n c e a n d n e e d s e v e r a l e x p e r i m e n t s t o f i n d t h e o p t i m u m f o rc e .
2 - T h e o p e r a t i n g v a l v e s i s w o r k i n g m a n u a l l y a n d c a n b e c h a n g e d t o o p e r a t e a u t o m a t i c a l l y .
3 - U s e t h e c o m p re s s o r w i t h h i g h e r p re s s u re r a t e w i l l h e l p t o re d u c e t h e m o l d i n g t i m e .