15.Ph.D. Progress Review Format

Department of Mechanical Engineering PES-BSE
PES Institute of Technology

BSC
DEPARTMENT OF MECHANICAL
ENGINEERING
III SEMESTER B.E
17MEL38A – FOUNDRY & FORGING LAB
ACADEMIC YEAR 2018 – 2019
LABORATORY MANUAL
NAM E OF THE STUDENT :
BRANCH :
UNIVERSITY SEAT NO. :
SEMESTER & SECTION :
BATCH :
FOUNDRY & FORGING LAB (06MEL38A) III SEMESTER

TABLE OF CONTENT
EXPT. PAGE
NAME OF THE EXPERIMENT
NO. NO.
PART – A: FOUNDRY PRACTICE – TESTS ON MOULD & CORE SAND
INTRODUCTION – FOUNDRY 01
PREPARATION OF SPECIMEN 04
1. COMPRESSION STRENGTH TEST 06
2. SHEAR STRENGTH TEST 08
3. TENSILE STRENGTH TEST 10
4. PERMEABILITY TEST 12
5. CLAY CONTENT DETERMINATION 15
6. SIEVE ANALYSIS TO FIND GRAIN FINENESS NUMBER 17
PART – B: FOUNDRY PRACTICE - MAKING MOULDS & CORES

INTRODUCTION 24
1. MAKING A SQUARE MOULD CAVITY (MODEL 1) 27
2. MAKING A MOULD CAVITY (MODEL 2) 28
3. MAKING A MOULD CAVITY (MODEL 3) 29
PART – C: FORGING PRACTICE
INTRODUCTION 30
1. PREPARATION OF SQUARE SHAPED (MODEL 1) 36
2. PREPARATION OF MODEL BY BENDING (MODEL 2) 37
3. PREPARATION OF SQUARE HEADED STUD (MODEL 3) 38
4. PREPARATION OF HEXAGONAL HEADED STUD (MODEL 4) 39
FOUNDRY & FORGING LAB (06MEL38A) III SEMESTER

Part – A
FOUNDRY PRACTICE – TESTS ON MOULD & CORE SAND
FOUNDRY
Introduction: Foundry is a process of forming metallic products by melting

metal, pouring it into a cavity known as mould and allowing it to solidify.
Practically, there is no limit to the size and shape of the casting that may be
made. Patterns are used for preparing the moulds. Pattern is the principal tool
used in the casting process. It may be defined as a model of anything when the
mould is filled up with molten metal and the molten metal is allowed to solidify
to form a replica of the pattern and it is called as casting.
The principal raw material used in foundry is the moulding sand. Moulding sand
is defined as granular particles resulting from the breakdown of rocks, due to the
action of natural forces, such as frost, wind, rain, heat and water currents. The
principal constituents of moulding sands are as follows.
i. Silica (SiO2): - Silica is the chief constituent in the moulding sand and
moulding sand has 86% to 90% of silica. It is in the form of granular quartz.
It is the product of the breaking up of quarts, rocks, or the decomposition of
granite. Silicon has high softening temperature and thermal stability.
ii. Clay: - Clay is defined as the particle of sand (under 20 microns is dia),that
fails to settle at 25 mm per minute when suspended in water. The mould has
6% to 10% of clay. The clay consists of two ingredients. Those are
¾ Fine silt
¾ True clay
Fine silt is a sort of foreign matter or mineral deposit, which has no bonding
power. It is the true clay, which imparts necessary bonding strength to the
mould sand. Too much of clay causes cracking of the mould after drying.
iii. Moisture: - Moisture in required amount of percentage furnishes the bonding

action of clay. When water is added to clay, it penetrates the mixture and
forms a microfilm which coats the surface of flake shaped clay particles. The
bonding action is supposed to be the best if the water content is exactly
enough to make the film. The moisture content required is about 3% to the
5% (for green sand).
iv. Miscellaneous Material: - In addition to Silica and Clay, the other

ingredients are present in the moulding sand. Those are Alumina (Al2O3)
(about 4% to 8%), Iron Oxide (Fe2O3) (about 2% to 5%), and limestone.
FOUNDRY & FORGING LAB (15MEL38A) 1 III SEMESTER

Smaller amounts of the oxides of Ti, Mn and Ca and some alkaline
compounds also.
Types Of Moulding Sand: Moulding sands are classified according to their

properties and usage into a number of varieties.
i. Green Sand iv. Facing Sand

ii. Dry Sand v. Backing Sand
iii. Loam Sand vi. Parting Sand
Properties Of Moulding Sand: A good moulding sand must possess the under
mentioned properties. These properties are not only determined by the chemical
composition, but also by the amount of clay, moisture content and by the shape
and size of silica grains in the sand.
i. Permeability vi. Chemical Resistivity

ii. Cohesiveness vii. Binding property
iii. Adhesiveness viii. Flowability
iv. Plasticity ix. Collapsibility
v. Refractoriness
Sand Testing: Periodic tests are necessary to determine the essential qualities
of foundry sand. The properties of the moulding sand depend upon shape, size,
composition and distribution of sand grain. The sand can be tested either by
chemical or mechanical method. Mostly in the fieldwork, mechanical tests are
conducted because they are simple and do not require elaborate equipment.
The most important test to be conducted for any foundry sand is grain fineness,
permeability and strength test. In addition to it, moisture content, clay content,
hardness and flowability tests are also conducted in special cases. In order, to
conduct the above-mentioned tests, sampling of sand is done and it usually
consists of three 1-quart samples (one each from the front, center and the rear
of sand heap). The samples may be taken directly from the sand mixer,
conveyor belt, or the hopper.
However, when the results of sand test are correlated with cleaning and
inspection room reports on the quality of castings, sand testing becomes a key
factor in determining and eliminating the cause of innumerable casting defects.
Sand tests indicate the moulding sand performance and help the foundry-men in
controlling the properties of moulding sands.
The basis for all tests is the evaluation of the properties of sand mixtures in a
standard and reproducible manner to permit the characteristics of the mixture to
be determined.

The Principle of Foundry Sand Testing: The principle of foundry sand testing is to
predict the behavior of sand mixtures during casting. Constant correlation of
casting quality with sand properties is a sound basis for prediction of the
behavior of sand mixture.
Sand Mixing
Procedure: - Test samples of synthetically bonded sand mixtures shall be

prepared in a mechanical mixer (Muller). Proper bonding properties of most
synthetic sand cannot be developed by hand mixing.
i. Mixing Procedure for Green Sands: - Weigh the correct amount of sand
and binder. Place the dried sand and dried bonding material in the muller.
Start it and allow it to mix for two minutes. Then, allow two minutes for dust
to settle down. Add the amount of water gradually, within 30 seconds to give
the required moisture percentage. Start the muller and allow it to mix for a
period of 10 minutes.
ii. Mixing Procedure for Core Sands: - The mixing begins with the addition of
sand first and then dry binders to the muller. The dry ingredients are mixed
for a short time and then the water is added. The total mixing time may take
about 6 minutes.

PREPARATION OF STANDARD SPECIMEN
a. Cylindrical specimen of 50.8 mm × 50.8 mm: The specimen forming

equipment is illustrated in the fig. (1). Weigh a sufficient quantity of
tempered sand from the prepared sample to make a specimen of 50.8-± 0.03
mm heights, when rammed. Place the sand carefully in the specimen
container. After leveling the sand in the container, gently lower the ramming
head into the specimen container until; the sand supports it. Slowly raise the
rammer weight (6670 gm) by cam to the full height of the specimen and let it
fall. Repeat twice, making a total of 3 rams to get the standard specimen.
b. Briquet type of the specimen for baked tensile strength test: -

Assemble the cleaned core box equipment. Place the required amount of
sand mixture in the core box assembly and level off. Most core mixtures
require 100 to 110 gm to produce a standard dimensionally correct tensile
specimen. The required weight of sand mixture will produce a core of 25.5 ±
0.4 mm thick after ramming. The correct weight must be determined by trial
and error. As in the case of cylindrical specimens this amount is to be
ascertained experimentally, and that brings the ramming bar to the markings
on the frame into line after the 3rd stroke. Place the core box assembly under
the rammer; place the rammer head on the sand surface and the ram three
times. The core specimen should not be struck off but be rammed to size.
After ramming, to be carried out as described, the ramming head is taken off
the sand and the cut-off plate is withdrawn. The filling box is removed and
the mould is turned over a drying plate, together with the moulding box and
the base plate. The same process is repeated by varying different
percentages of binder.
c. Bar type of Specimen for baked transverse strength test: - Assemble

the cleaned core box equipment. Place the required amount of sand mixture
evenly in the core-box assembly. The sand should be weighted to allow for
consistent excess to be used. The attempt must be made to use enough
sand so that 50-75 gm. will always be struck off. The amount should be as
constant as possible. Ramming would be by dropping the weight 4 times
through a height of 50 mm. Strike off the excess sand mixture on the top of
the core box and remove the test core from the box on a core plate. The
same process is repeated by varying different percentages of binders.
Universal Sand Strength Testing Machine:
The hydraulic type of Universal sand testing machine is illustrated in Fig.1. It

consists of a frame, made of cast iron that accommodates the hydraulic unit at
right hand side and at the left-hand side a bracket, to accommodate various
attachment inserts. The hydraulic unit, at one end has got a pressure piston
connected to spindle with hand wheel. On rotating the hand wheel, hydraulic
pressure develops on the main piston, which is inserted at the other end. The
main piston has got a suitable cover and provision to accommodate various
attachments. The hydraulic cylinder has got the provision for filling the oil and
fixing the pressure gauge.
Two pressure gauges are provided along with this machine. One for low-pressure
range, that is up to 15 Pa (15 N/cm2) and the for higher-pressure range, that is,
up to 130 Pa (130 N/cm2) so as to read compression strength of the standard
specimen. It has also got calibrated scale to read tensile, transverse and shear
strength of standard specimen. The gauges are provided with an idle pointer to
read the maximum breaking strength achieved.

Experiment No:01 Date:
COMPRESSION STRENGTH TEST
Aim: - To determine Green Compression Strength of the given specimen at

different percentages of clay and moisture.
Apparatus: - Universal Sand Strength Testing Machine, Compression heads,

Muller, Sand Rammer, Weighing Pan, Water Measuring Jar & Specimen Tube
with Base, Stripper.
Theory: - To find out the holding power of various bonding materials in the
green and dry sand moulds, strength tests are performed. Compression tests
are most commonly performed. The strength test is performed on the horizontal
hydraulic press. The green compression strength of sand is the maximum
compression stress, which a tempered sand mixture is capable of developing
when prepared, rammed and tested according to the standard procedure.
Experimental Procedure: -
1. Conduct the experiment in two parts. In the first part, vary the percentage
of clay and keep water percentage constant. In second case, vary the water
percentage and keep clay percentage constant.
2. Take weighed proportion of sand and clay and dry mix them together for 3
minutes. Then add required proportions of water and wet mix for another 2
minutes, to get a homogeneous sand mixture. Take the total weight of the
mixture between 150 – 200 grams. The correct weight has to be determined
by trial and error method.
3. Fill the sand mixture into the specimen tube and ram thrice using sand
rammer. Use the tolerance limit provided at the top end of the rammer for
checking the specimen size. If the top end of the rammer is within the
tolerance limit, the correct specimen is obtained. If the top end of rammer is
above the limit, reduce the weight of sand mixture and prepare a new
specimen. If it lies below the limit, increase the weight of sand mixture and
prepare a new specimen. The specimen conforming to within limits
represents the standard specimen required.
4. Now the prepared standard specimen is having a dia., 50.8 mm and height
50.8 mm.
5. Remove the standard specimen by the stripper and place it between

shackles, which are fixed, in the sand-testing machine.

6. Rotate the handle of the testing machine to actuate the ram. Thus hydraulic
pressure is applied continuously till the specimen ruptures.
7. Read the compression strength from the gauge and record the same.
Conduct the experiment for the above said two cases for five trials and tabulate
the results.
Sketches: -
Tabular Column
Trial Percentage Percentage Percentage Compression

Nos. of Sand of Clay of Water Strength N/mm2
01 Constant
02
03
04
01 Constant
02
03
04
Specimen Calculations: -
Percentage weight of the Sand Sample = 100 - % of Clay - % of Moisture
Net weight of Sand Sample =
Net weight of Clay =
Net weight of Moisture =
Graphs to be drawn: -
1. Plot the graphs Compression Strength Vs 2. Plot the graphs Compression Strength Vs
Percentage of Clay Percentage of Water
Results & Conclusions: -

Experiment No.:02 Date:
SHEAR STRENGTH TEST
Aim: - To determine the Green Shear Strength of the given specimen with
different percentages of clay and water.
Apparatus: - Universal Sand Strength Testing Machine, Shear heads, Muller,

Sand Rammer, Weighing Machine, Water Measuring Jar, etc.,
Theory: - The green shear strength of sand is the maximum shear stress which
a tempered sand mixture is capable of developing when prepared, rammed and
tested according to the standard procedure.
1. Conduct the experiment in two parts. In the first part vary the percentage of
clay and keep water percentage constant. In second case vary the water
percentage and keep clay percentage constant.
2. Take weighed proportion of sand and clay and dry mix them together for 3
minutes. Then add required proportions of water and wet mix for another 2
minutes, to get a homogeneous sand mixture. Take the total weight of the
mixture between 150 – 200 grams. The correct weight has to be determined
by trial and error method.
3. Fill the sand mixture into the specimen tube and ram thrice using sand
rammer. Use the tolerance limit provided at the top end of the rammer for
checking the specimen size. If the top end of the rammer is within the
tolerance limit, the correct specimen is obtained. If the top end of rammer is
above the limit, reduce the weight of sand mixture and prepare a new
specimen. If it lies below the limit increase the weight of sand mixture and
prepare a new specimen. The specimen conforming to within limits
represents the standard specimen required.
4. Now the prepared standard specimen is having a dia., 50.8 mm and height
50.8 mm.
5. Remove the standard specimen by the stripper and place it between

shackles, which are fixed in the sand-testing machine.
6. Rotate the handle of the testing machine to actuate the ram. Thus hydraulic
pressure is applied continuously till the specimen ruptures.
7. Read the shear strength from the gauge and record the same.

8. Conduct the experiment for the above said two cases for five trials and
tabulate the results.
Sketches: -
Tabular Column
Trial Percentage Percentage Percentage Shear Strength

Nos. of Sand of Clay of Water N/mm2
01 Constant
02
03
04
01 Constant
02
03
04
Percentage weight of the Sand Sample = 100 - % of Clay - % of Moisture
Net weight of Sand Sample =
Net weight of Clay =
Net weight of Moisture =
1. Plot the graphs Shear Strength Vs 2. Plot the graphs Shear Strength Vs
Percentage of Clay Percentage of Water

TENSILE STRENGTH TEST
Aim: - To determine the effect of binder content on baked tensile strength at

different temperatures.
Apparatus: - Universal Sand Strength Testing Machine, Muller, Water Beaker,

Weighing Balance, Sand Rammer, Specimen Forming Equipment, Baking Oven
and Tensile Strength Testing Accessory.
Theory: - The baked tensile strength of a core sand mixture is the maximum
tensile strength in N.mm2, which a core made out of this mixture, will break in
the baked condition. It is an index to core breakage and is a function of the type
of the binder used, percentage of the binder used and the baking temp.
Description for Tensile Core Strength Testing Accessory: This accessory is

an integral type consisting of movable jaw and a fixed jaw. The whole assembly
is screwed on to the left hand side bracket with the help of the gripping screw.
On rotating the hand wheel, the pressure piston pushes away the movable jaw
to break the specimen.
1. Conduct the experiment using core oil as binder.
2. Take proper proportions of base sand and binder then mix them together
thoroughly.
3. Assemble the core box and fill the mixture into it.
4. Place the core box under sand rammer and ram the sand thrice.
5. Using the wooden piece tap the core box gently from sides. Remove the core
box leaving the rammed core on a flat metal plate.
6. Bake the specimen (which is on a plate) for about 30 minutes at a

temperature of 150 –200ºc in an oven (when the binder is core oil).
7. Fix the tension shackles on to the sand-testing machine and place the
hardened specimen in the shackles.
8. Apply the load gradually by turning the hand wheel of testing machine. Note
down the reading when the specimen breaks.
Repeat the procedure for different percent of binder and tabulate the reading.

Sketches: -
Tabular Column: -
Sl. Percent of Percentage

Tensile Strength
No. Sand of core oil
Part A
01 Part B
Part C
Part A
02 Part B
Part C
Part A
03 Part B
Part C
Example for 4% Core Oil Mixture

Take 3.1% Part “A”
Then, Part “B” = 10 % of Part A
Part “C” = 20 % of Part A
Graph showing the effect of the binder content at different temperatures. Graph
to be drawn between tensile strength and % of binder.

PERMEABILITY TEST
Aim: - To find the effect of water content, clay content and degree of ramming
on green permeability.
Apparatus Used: - Standard Permeability Meter, Stop Watch, Standard

Specimen, Beam Balance, Sand Rammer, Weighing Pan, Steel Rule, Measuring
Jar, Specimen Tube, Stripper, Specimen Tube Cup.
Theory: - Permeability is defined as that physical property of the moulding sand

mixture, which allows gas to pass through it freely. Permeability depends on the
grain size, grain shape, grain distribution, binder and its content, degree of
ramming and water content of moulding sand. It is one of the most important
properties affecting the characteristics of moulds and thereby quality of castings
produced. Permeability number is defined as the volume of air in cc that will
pass per minute under a pressure of 1gm per sq cm through a specimen which is
1 sq cm in cross sectional area and 1 cm deep.
The sand used for casting must be porous enough, so as to allow the gaseous
material, water and steam vapors to escape freely when the molten metal is
poured into the mould. Insufficient porosity of moulding sand leads to casting
defects such as gas holes and pores. The moulder has some control over
permeability; hard ramming lowers the permeability, but this is relieved by
liberal venting.
1. Conduct the experiment in two parts. In the first case vary water percentage
keeping clay percentage constant. In the second case vary clay content
percentage and keep water percentage constant.
2. Take weighed proportions of sand and clay and dry mix them together in a
muller for three minutes. Then add water and wet mix for another two
minutes. A uniform sand mixture is obtained. Prepare the specimen by
ramming.
3. Place the standard specimen along with the tube in the inverted position on
the rubber seal or on the mercury cup of permeability meter.
4. Operate valve and start the stopwatch simultaneously. When the zero mark
on the inverted jar just touches the top of water tank, of the permeability
apparatus, note down the manometer reading.

5. Note down the time required to pass 2000cc of air through the specimen.
Calculate permeability number by using formula.
Sketches: -
Tabular Column: -
Table 1: Percentage of clay constant and vary the percentage of water
Sl. Percentage Pressure in Time in Permeability Number

No. of Water gm/cm2 min. Indicated Calculated
01
02
03
04
Table 2: Percentage of Water constant and vary the percentage of clay
Sl. Percentage Pressure in Time in Permeability Number

No. of Clay gm/cm2 min. Indicated Calculated
01
02
03
04
Specimen Calculation: -
VH
Permeability Number =
PAT
Where:
V = Volume of air passed through specimen = 2000 c.c.

H = height of the specimen = 5.08 cm
2
P = Pressure reading from monometer in g/cm
A = Area of the specimen i.e., π d2/4
d = Dia., of the specimen in mm = 5.08 mm
T = Time in minutes for 2000 c.c. of air pass through the sand specimen

Graphs to be Drawn: -
1. Graph drawn Permeability Number Vs Percent of Moisture
2. Graph drawn Permeability Number Vs Percent of Clay
Results & Conclusion: -

CLAY CONTENT TEST
Aim: - To determine the clay percentage in the given Foundry Sand.
Apparatus Used: - Clay washer, Syphon, Balance, Rapid direr, Base sand, 5%
NaOH solution and water.
Theory: - Clay is responsible for bonding sand particles together. Clay

influences strength, permeability and other molding sand properties. The A.F.S.
clay in a moulding sand is defined as “particles which fail to settle at a rate of 25
mm per minute when suspended in water. These are usually less than 20
microns, in diameter”. Clay is responsible for binding sand particles together and
also influence strength, permeability and other moulding sand properties.
1. Take 50 Gms of base sand in wash bottle and add 475 ml of distilled water
and 25 ml of NaOH solution to it.
2. Using mechanical stirrer, stir the mixture for about 3 min. Add distilled water
to make up the level to 6 inches height. Stir the mixture again for 2 min.
Now allow the mixture of the bottle to settle down.
3. Siphon out 5 inches level of uncleaned water using a standard siphon.
4. Add distilled water again up to 6 inches height and stir the contents again.
Allow the mixture to settle down for 5 min.
5. Siphon out 5 inches level of water from the bottom of the bottle. Repeat the
above procedure for 3-4 times till the water becomes clear in the wash bottle.
Transfer the wet sand from the bottle into a tray and dry it in an oven at 110°C
to remove the moisture. Note down the dry sand weight accurately. Using
calculation find the percentage of clay.

Sketches: -
Tabular Column: -
Sl. Weight of sand Weight of dried % Of clay =

No. sample W1 (gm) sand W2 (gm) (W1-W2)/W1 × 100
01
02
03
04
05
06
W1 = Weight of the dry sand sample

W2 = Weight of the dry sand sample after, removal of clay
(W1 – W2) x 100

Percentage of clay =
W1

SIEVE ANALYSIS TO DETERMINE GRAIN FINENESS NUMBER
Aim: - To find the distribution of sand grains using a set of sieves and find the
average GFN.
Apparatus used: - Beam balance, stop watch, sieve set, vibrator or sieve
shaker and wire brush.
Theory: - The grain fineness number of the sand is approximately 2.54 times
the number of meshes per centimeter of that sieve which would allow to pass
the sample if its grains were of a uniform size, i.e., the average of the sizes of
the grain in the sample. It is approximately proportional to the surface area per
unit weight of sand, exclusive of clay. The grain fineness number test
determines the grain sizes grain distribution and grain fineness. This number is a
convenient means of describing the relative fineness of sands, most foundry
sands being from about 40 to 220 in average fineness. The most sand
properties, however, depend on the size distribution as well as average size.
The fineness test makes it possible to evaluate both the factors.
Procedure: -
1. Take 50 Gms or 100 Gms of dry sand and place in the top sieve of a series of
sieves and close the lid.
2. Place the whole assembly of sieves on the vibratory sieve shaker and clamp
it.
3. Switch on the motor and allow the sieve assembly to vibrate for 15 min.
Then switch of the motor.
4. Collect the sand particles retained in each of sieves separately and weigh in
beam balance and enter into the tabular column. Calculate the percentage
weight retained by each of sieves. Multiply this value with the multiplier for
each sieve. Then calculate the average GFN using formula.

Sketches: -
Tabular Column: -
Sieve Weight of Percentage of

Sl. Multiplier Product Cumulative
Number sand Retained Sand Retained
No. (D) D×C percentage of Sand
(A) (B) (C)
01
02
03
04
05
06
07
08
09
10
Q
Average Grain Fineness Number (GFN) = =
P
Where P = ∑C =
Q = ∑ (D x C) =

1. Percentage of Sand Retained Vs Sieve Number
2.
Cumulative Percentage of Sand Retained Vs Sieve Number
Results & Conclusion: -

Part – B
F O U N D RY P R A C T I C E – M A K I N G M O U L D S & C O R E S
Introduction: A large number of tools and other equipments are used in

foundry for carrying out different foundry operations.
Foundry Tools & Equipments: The tools broadly classified into the following
categories.
1. Hand tools: Used for doing moulding operations by hand.

2. Containers: Used for containing sand moulds and molten metal.
3. Mechanical tools: These include all moulding machines, power riddles and
conveyors.
4. Sand testing and conditioning tools: To determine the properties of moulding
sand these equipments are used.
5. Metal melting equipment: These include furnaces and other used in melting
the metal.
6. Finishing equipments: These include equipments that are used for finishing
the metal from the mould cavity.
Hand Tools: - The common hand tools used in foundry work are:
1. Shovel: It consists of an iron pan fitted with a wooden handle. It is used in

mixing and conditioning the foundry sand by hand and transferring it to the
flask (container).
2. Hand riddle: It consists of a wooden frame fitted with a screen of standard

wire mesh at the bottom. It is used a screen of standard wire mesh at its
bottom. It is used for hand ridding of sand to remove foreign material from
it.
3. Rammers: Rammers are used for striking the sand mass in the moulding
box to pack it uniformly around the pattern. The common forms of rammers
used in hand ramming are:
¾ Peen rammer: Has a wedge shaped construction formed at the bottom
as in fig. Used for packing corners.
¾ Hand rammer: It is made of wood or metal. Used in bench moulding.
¾ Floor rammer: Has a peen at its one end and a flat portion at the other
end.
4. Strike off bar: It is a flat bar made of wood or iron, to remove excess sand
mass in the moulding box.
5. Vent wire: It is a thin steel rod or wire carrying a pointed edge at its one
end, used for making vent holes for the hot gases to escape.

6. Trowels: Trowels are used for finishing flat surfaces and joints in the mould.
They are made up of iron and handle in wooden material.
7. Slicks: They are used for repairing and finishing the mould surfaces and
after the patterns have been withdrawn.
8. Lifters and cleaners: They are used to remove the sand particles inside the
mould cavity
9. Draw spike: It is used to rap and draw patterns from the mould.
10. Draw screws: These are also used to remove pattern from the mould box.
11. Smoothers: Used for finishing the mould cavity after the pattern is
removed.
12. Mallet: Used for striking the draw spikes in to the pattern.
13. Swab: It is a hemp fiber brush used for moisturizing the edges of sand
mould, which are in contact with the pattern before removing it.
14. Sprue pin: It is a tapered rod or iron, which is embedded in the sand
mould, which are withdrawn to produce a hole called runner, through which
molten metal is poured inside the mould.
15. Sprue cutter: It is also used for the same purpose as a sprue pin, but there
is a marked difference between their use in that the cutter is used to produce
hole after ramming the mould. It is in the form of a tapered hollow tube,
which is inserted in the sand to produce the hole.
16. Gate cutter: It is a shaped piece of sheet metal to cut feeding edge to
connect the runner hole and mould cavity.

17. Soft brush: It is a fiber brush and is used for sweeping away the mould
sand from the mould surface.
18. Bellow: A hand-operated bellow is shown in fig. It is used to blow away the
loose sand from mould cavity.
Pattern: A pattern may be defined as a replica or facsimile model of the desired

casting, which, when packed in a suitable moulding material, produces a cavity
called mould.
Materials: Wood, plaster, Metals like aluminium, cast iron, brass and white
metal are used for making patterns.
Factors effecting pattern selection:
a. Number of castings to be made.

b. Method of moulding to be used.
c. Type of casting method to be used.
d. Design of casting.
Size Of Pattern: A pattern is always made larger than the required size of the
casting in order to allow for various factors such as a. shrinkage b. Machining c.
Draft e. Shake f. Distortion and g. Mould-wall movement.
Size of pattern = size of final casting to be made + shrinkage allowance

for material of which the casting is to be made +
Machining Allowance + Draft Allowance

MODEL – I: MAKING A SQUARE MOULD CAVITY
Aim: - To produce a mould cavity on green mould sand for given shape and
dimensions.
Materials Required: - Base sand
Apparatus Required: - Core box, shovel, trowels, slicks, rammers, strike off
bar, try square, steel rule, vent wire, lifters, smoothers, swab, bellow, soft brush
etc.,
Procedure: -
1. Take a core box, which is in proper condition and using shovel fill the box
with moulding or core sand.
2. Using rammers ram the sand gently under uniform pressure, till the box is
filled with sand.
3. Using strike off bar strike out excess sands on the box and finish the top
surface.
4. Using try square and steel rule takes the mid point and do the marking
according to the dimensions.
5. Using lifters and cleaners remove the sand from marking according to the
shape of the mould.
6. Remove unwanted sand particles using bellow.
7. Perform finishing on edges and mould surfaces.
Conclusion: - Thus mould cavity of required shape and dimensions is prepared

on green sand.

MODEL – II: MAKING A MOULD CAVITY
dimensions.

bar, try square, steel rule, vent wire, lifters, smoothers, swab, bellow, soft brush
etc.,
Procedure: -
filled with sand.
surface.
4. Using try square and steel rule takes the mid point and do the marking
according to the dimensions.
shape of the mould.
Conclusion: - Thus mould cavity of required shape and dimensions is prepared

on green sand.

MODEL – III: MAKING A MOULD CAVITY
dimensions.
bar, try square, steel rule, vent wire, lifters, smoothers, swab, bellow, soft
brush, divider etc.,
Procedure: -
filled with sand.
surface.
4. Using try square, divider and steel rule take the mid point and do the
marking according to the dimensions.
shape of the mould.
Conclusion: Thus mould cavity of required shape and dimensions is prepared on

green sand.

Part – C
F O R G IN G P R AC T IC E
FORGING
Introduction: - A blacksmith's work involves heating of a metal to a desired

temperature; enable it to acquire sufficient plasticity, followed by the operations
like hammering, bending, pressing etc., to give it to the required shape. This
process is termed as forging. If the operations are done by means of hand-
operated tools then that type of forging is termed as hand forging.
Importance Of Forging: - The forging process is very important and has an

indispensable position among the various manufacturing processes in workshops
since it provides a number of advantages.
1. It refines the shape of the metal.

2. It renders the metal stronger by setting the direction of the grains.
3. It effects considerable saving in time, labor and material as compared to the
production of similar items by cutting from a solid stock and then shaping it.
4. Since the production of articles with reasonable degree of dimensional
accuracy is possible the machining operations can be avoided in most of the
cases. This also results in a considerable saving of time and labor.
Heating Steel For Forging: - Heating the metal to the required temperature
carries a vital role in forging as affects the overall efficiency, economy of fuel
and power consumption. Steel when heated, becomes oft with a simultaneous
reduction in its tensile strength and increase in its plasticity and malleability.
When heated in a furnace oxidation takes place and scale is formed on its
surface whose thickness increases with temperature. This results in loss of metal
called as waste. Some scale may pressed into the metal surface, is affecting the
quality of the steel. At elevated temperatures the oxidation on steel surfaces is
accompanied by simultaneous decarburization due to the burning of carbon.
When steel is heated over its higher critical point its grain size grows larger and
this growth is accelerated with rise in temperature. When the grain size becomes
too large the steel is termed as overheated which will tear and crack. If it is
heated further that may result in burning of steel and the burnt steel cannot be
rectified and has to be rejected.
Tools & Equipments Used In Forging: - Principal tools and other equipments
used in hand forging are described as follows.

Smith's Forge Or Hearth: - A figure of smith's forge or hearth is shown in
figure. It has a robust cast iron structure consists of 4 leg supports, an iron
bottom known as hearth. The metal to be heated is placed over this hearth along
with coal. The air from blower that enters the hearth through the tuyere
enhances firing of coal. The hearth is provided with firebricks to withstand
extensive heat. The gases so produced due to the combustion escapes through
the chimney.
Anvil: - In order to carry out forging operations successfully, a proper

supporting device is needed which should be capable of withstanding heavy
blows rendered to the job. An anvil as in figure stands as the best and most
appropriate choice for this purpose. Its body is made of cast steel, wrought iron
or mild steel provided with a hardened top, about 20 to 25 m thick. This
hardened plate is welded to the body on the top. The horn or beak is used in
bending the metal or forming curved shapes.
The flat step provided, between the top and the horn is used to support jobs
during cutting is known as chipping block. The flat projecting piece at the back of
the anvil is termed as tail. It carries a square hole to accommodate the square
shank of the bottom part of the various hand tools like swages, fullers, and bick
iron and hardie hole. The circular hole provided near the hardie hole is known as
pritchel hole.

Swage Block: - It is a block of cast iron carrying a number of different shapes

and sizes along its four side faces and through holes from its top face to bottom
face, which also vary in shapes and sizes. The holes are used in punching.
Hammers: - These are the principle striking tools, made of forged steel used in
forging work. They are classified according to the size and weight used for
forging. A smith's hand hammer is a small sized hammer used for small jobs
whereas a sledgehammer is a larger one for heavy jobs

All hammers are mainly divided into four parts namely: peen, eye, cheeks and
face. The peen is the top part made slightly tapered from the cheeks and
rounded at the top. The eye is made normally oval or elliptical shape to
accommodate shaft. To avoid slipping of the hammer a steel wedge is always
provided into the handler in a sledgehammer.
Sledgehammers can be of straight peen, cross peen and double-faced

sledgehammer. The straight peen hammer is one, which carries the peen formed
parallel to the axis of eye and flat surface at the other end. Cross peen hammer
is similar to straight peen except that the peen runs at right angles to the axis of
eye. If the hammer has no peen edges and having both ends as flat surfaces, it
is known as double-faced sledgehammer.
Tongs: - Tongs are used to hold the jobs in position and turning over during
forging and made of mild steel. They are usually made in two pieces, riveted to
form a hinge. One side having a holding jaws, which are made in different
shapes and sizes to suit jobs of various sizes and shapes. They are named
according to the shape of jaws.
Flat tongs are used for holding small flat pieces; Round tongs are used for
holding small round i.e., cylindrical objects. Tongs that are in common use are
shown in fig.
Chisels, Hardie And Gouges: - Chisels are used to cut metals in hot or cold
state. Those used in hot state are called as hot chisels and those used in cold
state are called cold chisels. The main difference between these chisels is the

included angle at the cutting edge. The cold one having an included angle of 60
degrees and for hot chisel is 30 degrees.
Hardie is also a cutting tool having wedge shape and also having square shank,
which can be fitted, in the hardie hole, provided in the tail of the anvil to hold in
upright. Gouges are also wedge shaped tools having curved cutting edge. They
also used to cut metal along the curve.
Punches & Drifts: - Punches are tapered tools made in various shapes and
sizes. They are used for producing holes in red-hot jobs. The job is placed on the
anvil and the punch is hammered through it up to half its depth. It is then
turned over and the punch is made to pass through it. A drift is a large sized
punch to expand the hole to the desired size.
Fullers: - These tools are made of high carbon steel in different sizes to suit the
various types of jobs. They are used for making necks by reducing the cross
section of a job. Their working edges are normally rounded.
Swages: - They are made of high carbon steel in two parts called top and
bottom swages. They are usually employed to increase the length of a circular
rod for finishing the circular surface after forging.
Flatters: - They are also called as smootheners. They are made of high carbon
steel and having a flat square bottom.
Set Hammer: - It is made of tool steel and hardened. The term hammer used
for this is used as a flatter. For finishing corners, formed by two adjacent
surfaces at right angles.

Bick Iron: It is said to a small facsimile of an anvil. It is made of tool steel and
hardened. All operations performed on anvil can be done here also when the job
is small.
Some Basic Forging Operations:
1. Upsetting or Jumping:
2. Drawing out.
3. Cutting
4. Bending
5. Punching or Drifting
1. Upsetting or Jumping: - Upsetting is a process in which the cross-section

of a metal piece is sufficiently increased with a corresponding reduction in its
length. When a metal is heated to a sufficient temperature it becomes soft.
At this condition hard force is applied dimension will be changing right angles
to the force direction.
2. Drawing out: - This process is also known as drawing down. It is employed

when reduction in thickness is required. The desired effect is obtained by
using set of swages or fullers.
3. Cutting: - Removing the extra metal from job in both hot and cold conditions
using chisels is termed as cutting.
4. Bending: - The process of giving shapes like oval, angle and circle to the
jobs is termed as bending. For mass production of articles made through this
process, where dimensional accuracy is must jigs and fixtures are employed.
5. Punching or Drifting: - Making holes on the job is termed as punching.

After heating the job to the required temperature this process is done.
Enlarging a hole is called drifting.

FORGING MODEL – I: PREPARATION OF SQUARE SHAPED MODEL
Aim: - To prepare a model of square shaped cross section from the given
material.
Materials Required: - Mild steel rod (given material)
Apparatus Required: - Furnace, anvil, tongs, swage block, chisels, punches,

flatters and set hammer.
Procedure: -
1. The given material is heated in the furnace to the required temperature.

2. After sufficient heating it is take out of the furnace using tongs and
hammering is done using hammers by placing it on the anvil.
3. The process is continued till it gets the required dimensions.
4. Then using flatters and set hammer finishing is done on the given job.
5. Using steel rule and try square accuracy is checked.
Calculations: Given volume of metal, V =πd2/4x100

Volume of metal after shaping=102xL. L=(πd2/4x100)/102
Because volume of the Metal before Shaping = Volume of Metal after Shaping
Result: - Thus by performing the required forging operations on the given

material, job with required shape and dimensions is obtained.

FORGING MODEL – II: PREPARATION OF MODEL BY BENDING

Aim: - To prepare a model by bending operation on the given material
Procedure: -

3. The process of bending is continued till it gets the required dimensions.
Calculations: Volume of metal given V =πd2/4x100

Volume of metal shaped= volume of pyramid+102 × 50+ (L—30) × 102
Volume of pyramid= area of base × 1/3(perpendicular height)
Calculate for L
Result: - Thus by performing the forging operations on the given material, job
with required shape and dimensions is obtained.

FORGING MODEL – III: PREPARATION OF SQUARE HEADED STUD
Aim: - To prepare a model of stud with square shaped head from the given
material.

Procedure: -

Calculations: Volume of metal given V =πd2/4x100

Volume of the bolt=volume of head of bolt + volume of shank
V = 30x30x15 + π x 202/4 x L
L, length of shank can be calculated
Result: - Thus by performing the forging operations on the given material, job

FORGING MODEL – IV: PREPARATION OF HEXAGONAL HEADED STUD
Aim: - To prepare a model of stud with a hexagonal shaped head from the given
material

Procedure: -

L, length of the shank is to be calculated similar to the Previous model.
Result: Thus by performing the forging operations on the given material, job

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Department of Mechanical Engineering PES-BSE

PES Institute of Technology

17MEL38A – FOUNDRY & FORGING LAB

ACADEMIC YEAR 2018 – 2019

NAM E OF THE STUDENT :

UNIVERSITY SEAT NO. :

SEMESTER & SECTION :

FOUNDRY & FORGING LAB (06MEL38A) III SEMESTER

PART – B: FOUNDRY PRACTICE - MAKING MOULDS & CORES

FOUNDRY & FORGING LAB (06MEL38A) III SEMESTER

FOUNDRY PRACTICE – TESTS ON MOULD & CORE SAND

Introduction: Foundry is a process of forming metallic products by melting

iii. Moisture: - Moisture in required amount of percentage furnishes the bonding

iv. Miscellaneous Material: - In addition to Silica and Clay, the other

FOUNDRY & FORGING LAB (15MEL38A) 1 III SEMESTER

Types Of Moulding Sand: Moulding sands are classified according to their

i. Green Sand iv. Facing Sand

i. Permeability vi. Chemical Resistivity

FOUNDRY & FORGING LAB (15MEL38A) 2 III SEMESTER

Procedure: - Test samples of synthetically bonded sand mixtures shall be

FOUNDRY & FORGING LAB (15MEL38A) 3 III SEMESTER

PREPARATION OF STANDARD SPECIMEN

a. Cylindrical specimen of 50.8 mm × 50.8 mm: The specimen forming

b. Briquet type of the specimen for baked tensile strength test: -

c. Bar type of Specimen for baked transverse strength test: - Assemble

Universal Sand Strength Testing Machine:

The hydraulic type of Universal sand testing machine is illustrated in Fig.1. It

FOUNDRY & FORGING LAB (15MEL38A) 5 III SEMESTER

COMPRESSION STRENGTH TEST

Aim: - To determine Green Compression Strength of the given specimen at

Apparatus: - Universal Sand Strength Testing Machine, Compression heads,

5. Remove the standard specimen by the stripper and place it between

FOUNDRY & FORGING LAB (15MEL38A) 6 III SEMESTER

Trial Percentage Percentage Percentage Compression

Results & Conclusions: -

FOUNDRY & FORGING LAB (15MEL38A) 7 III SEMESTER

SHEAR STRENGTH TEST

Apparatus: - Universal Sand Strength Testing Machine, Shear heads, Muller,

5. Remove the standard specimen by the stripper and place it between

FOUNDRY & FORGING LAB (15MEL38A) 8 III SEMESTER

Trial Percentage Percentage Percentage Shear Strength

Results & Conclusions: -

FOUNDRY & FORGING LAB (15MEL38A) 9 III SEMESTER

TENSILE STRENGTH TEST

Aim: - To determine the effect of binder content on baked tensile strength at

Apparatus: - Universal Sand Strength Testing Machine, Muller, Water Beaker,

Description for Tensile Core Strength Testing Accessory: This accessory is

1. Conduct the experiment using core oil as binder.

6. Bake the specimen (which is on a plate) for about 30 minutes at a

FOUNDRY & FORGING LAB (15MEL38A) 10 III SEMESTER

Sl. Percent of Percentage

Example for 4% Core Oil Mixture

Results & Conclusions: -

FOUNDRY & FORGING LAB (15MEL38A) 11 III SEMESTER

Apparatus Used: - Standard Permeability Meter, Stop Watch, Standard

Theory: - Permeability is defined as that physical property of the moulding sand

FOUNDRY & FORGING LAB (15MEL38A) 12 III SEMESTER

Table 1: Percentage of clay constant and vary the percentage of water

Sl. Percentage Pressure in Time in Permeability Number

Table 2: Percentage of Water constant and vary the percentage of clay

Sl. Percentage Pressure in Time in Permeability Number

V = Volume of air passed through specimen = 2000 c.c.

FOUNDRY & FORGING LAB (15MEL38A) 13 III SEMESTER

1. Graph drawn Permeability Number Vs Percent of Moisture