DEPARTMENT OF TECHNICAL EDUCATION

ANDHRA PRADESH
Name : P. Ramulu
Designation : Work Shop Supdt.,
Branch : Mechanical Engineering
Institute : Govt.Polytechnic for women,
Medak.
Year/semester : I year
Subject : Work shop Technology
Subject Code : M-105
Topic : Foundry
Duration : 100 Minutes
Sub. Topic : Appreciate Foundry advantages.
List of moulding tools
Teaching Aids : Animation Clips & Images

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 Objectives:

On the completion of this period, you would

be able to know:

• Importance of castings

• Advantages of castings

• Disadvantages of castings

•List of various hand molding tools

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What is manufacturing ?
• Manufacturing is the process of transferring the raw
material into finished products.

List out the different manufacturing processes

•Metal Cutting (Machining)
•Metal forming
•Casting
•Powder metallurgy
 What is Machining

• Machining is the process of removing excess

materials from the work piece to make it into finished

products:

eg:- shafts, bolts , nuts etc.

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 What is foundry?

The process of making products from molten

metal is called “foundry” and products obtained are
called castings..

eg:- Fly wheel , gears ,engine cylinder block

Fig. 1 Cylinder block Fig.2. Valve

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 Advantages of foundry

• It is cheapest manufacturing process

• It is very fast.
• Intricate shapes can be produced.
• No wastage of material .
• Suitable for mass production
 Limitations of Foundry

• Only suitable for materials with castability such

as C I , aluminum, Al alloys, gold etc

• Needs Furnace to produce molten metal

• Usually casting are brittle and not to tough.

 Steps of Operations

The sequence of steps involved in casting are :

• Pattern making

• Mould and core making

• Melting and pouring

• Fettling, and

• Inspection
 Molten Metal

• Cast Iron, Aluminum etc. are melted in Various

furnaces.

Fig 4. Melting in furnace

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 Mould
• It is a hollow cavity of casting.
• Made of moulding sand .
• Moulding sand is natural sand or synthetic
sand .
• Pattern is kept in the moulding sand to prepare
mould.

Fig 5. Mould
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 Pattern

• A model of required casting .

• Made of light materials like wood , plastic.
• Used to make Mould.

Fig 6. Pattern
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 List of Hand Moulding Tools

Moulding Flask:
• Used for small castings.
• Made of wooden or metal frame.
• Made into two parts (cope and drag).
• It is rigid frame.

Fig 7. Moulding flask Fig 8 Moulding tools

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 List of Hand Moulding Tools(contd..)

Moulding Boxes:

• Used for large castings .

• Made of wooden frame.

Fig 9. Moulding Boxes

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List of Hand Moulding Tools (contd..)

Moulding Board:
• It is a smooth wooden board.
• Pattern is placed on board.
• Moulding box also is placed on it.
• Moulding sand is poured and rammed to make
compact.

Fig 10. Moulding Board

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 Summary

In this class , we have stated that,

• Manufacturing is the process of making products from raw

materials.
•Casting is the process dealing with molten metals
•Advantages of casting as fast and cheapest manufacturing
method
•Disadvantage as it is suitable to some metals
•Pattern ,moulding box, board etc are casting tools

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 Quiz

1. The Top part of Moulding Box is

__________________ .
Ans(Cope)
2. Bottom part of Moulding Box is ___________.

Ans(Drag)

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 Quiz

3.The mould material is _________________.

(Moulding sand)
4. Mould is made by using _____________ which is
model of casting .
(Pattern)

17
Frequently Asked Questions

1. What is meant by mould?

2. What is meant by casting?

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