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Molding and Casting



Hello, friends, I will show you how to do casting easily.
The casting is the quickest way to produce a complicated shape. The casting is the mechanism that produces a new shape that you want. Let us start the casting from starting. First of all, we are produce a mold with the help of sand. The mold is a cavity that is created by some particular patterns. The cavity that is produced in the sand is called mold.
In a simple way, if we talk about casting, the casting is completed in two parts.

1 To make a mold.

2. To pouring the molten metal into the mold.

So we are going to start the 1st process.

Molding

moldFirst of all, we collect the sand which is required. So when we are making a mold we required Silica sand, Clay, and some moisture. When we go to technically we follow all the rules. I mean for molding purposes we use some tools. The tools details are given below.
If you learn about casting you must know about the tools. And I also mention that all work that is covered in this topic comes under the foundry shop. If you learn more about the foundry shop you can click here.

 In this link, I also explain some other topics which are related to the Foundry shop.

So the details of the tools are.

1.   Flask 
2.   Showel
3.   Trowel
4.   Lifter
5.   Hand Riddle
6.   Strike of Bar
7.   Vent Wire
8.   Draw spike
9.   Rammer
10. Slicks
11. Smoother
12. Sprue Cutter
13. Bellow
Let's start to make a mold.
simplemechanismFirst of all, set the flask on the floor. Set the lower part whose name is a drag . If we are talking about the sand mold we also knowledge about sand. For sand casting, we use green sand but the sand used for casting available in many types. If you want please visit the Foundry shop. So we work with only green sand. The green sand is natural sand. In this case, we produce green sand. We collect Silica sand. The silica sand is the content of sand. It means in single sand has different content of sand. So we collect only silica sand. How to understand about silica sand. Simply the silica sand is the water-absorbing sand, which means the sand is dry in condition and brown in color. So if we work with green sand we collect silica sand and then clay. After completing the two content we mix properly the sand. We mix with hands. Ater mix the sand properly we add moisture. In green sand, we use the molasses. The molasses is a binder which increases the strength of green sand. When we complete all the processes then next we place the pattern in the drag part. The pattern is the same copy of our product which we want to produce. But some allowance is provided in the pattern. After placing the pattern in the drag part put the green sand and fill all sides of the pattern. The pattern that is used for molding is split. So we can use easily in two parts. The 1st part is used for the drag and the second part is used to cope. Fill the drag part completely and rammed it with the help of the Rammer tool. After complete ramming removes the excess sand from the outer face of the drag part. The removal of this sand we can use the tool which name is Strike off bar. Then next sprinkle the parting sand. I also remind that this post is only about the molding and casting process if you can learn about sand and their type or any other information about the foundry shop please visit our official website Simplemechanism After sprinkling the parting sand we place the second part that copes part. Similarly, place the remaining part of the pattern as same as a mirror. Then next fill with sand and also rammed it properly. After rammed remove the excess sand by Strike of Bar. Our molding process is almost complete. Now we provide some vent for proper ventilation. We provide two-hole

1st is Runner

2nd Riser.


This is important for the exam point of view. The runner is provided for pouring the molten metal into the mold. On the top of the runner provide the pouring basin. The second hole Riser is used for removing the gases which are producing during the casting. The molding is done.

The 2nd is pouring the molten metal into the mold.

FurnaceI mention that the whole casting is done in two parts. So we complete the 1st part that includes the tools and molding. The second part is to pouring the molten metal into the mold. The second part is done on the furnace. In my case, this is not my case in engineering college basically in the workshop we use an open-heart furnace. The furnace is used to produce the heat. The furnace we can use according to the requirements. If you can use solid fuel that we use coal furnace and if we use liquid that called oil furnace. And if use gas furnace so it called the Gas furnace.
We use a coal furnace. So the furnace name is open heath furnace. So for producing heat, we can use
coal.
1. Wooden coal
Furnace
2. Steam coal
3. Charcoal
We add some woods part or you can use wooden scraps for easy burn the fire. If the fire starts to burn we add some wooden coal. When wooden coal start burns then next we add steam coal and charcoal but remember before placing the coal in the furnace's hearth, place the crucible. The crucible has a solid piece of your products for example if you are doing casting and make a spanner of aluminum. So you add a solid part of aluminum in the crucible. Place the crucible on the coal and center in the hearth. Before this, you must complete the brick lining around the hearth. The main function of the brick lining is to prevent heat transfer. If you are performing aluminum casting the material will melt within 35 to 45 minutes. You can check the material by poker tool. The poker tool is a simple wire that is bent at the end. If your material converts into the liquid you can pour this material into the mold. After completion, the pouring the finishing will remain. At this position your casting almost complete.

If you understand about this basic mechanism please comment below and any other questions or suggestions, please comment to me.
Thanks


1 comment

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