1. Foundry-Basics
By
Mr.B.Ramesh, M.E., (Ph.D.),
Research Scholar, CEG, Anna University, Chennai.
Associate Professor,
Department of Mechanical Engineering,,
St. Joseph’s College of Engineering,
Jeppiaar Trust, Chennai-119

2. What is a Foundry?
• Casting is one of the oldest industrial processes
• There are different casting processes.
The focus here is: “GREEN SAND” CASTING
A foundry is:
a factory that pours molten metal into molds,
producing cast metal objects.
Some
typical cast
metal
objects:
Turbine blades
in jet engines
Engine blocks,
axles
Aluminum
pots

3. SAND-CASTING
Sand,
mixed with clay binder &
water (so it will hold its
shape) plus coal dust to
improve surface finish
Pattern
(a copy of the shape
you want to produce,
made of wood, plastic
or metal)
Basic materials & equipment for green sand-casting
Container of molten metal
(filled from furnace) Top and bottom mold forms
(made of metal, open at top and bottom)
Rammer (tool to compact the sand;
often a pressing machine is used)

4. SAND-CASTING
MOLDING:
Sand placed
into bottom mold
form &
compacted
MOLDING:
Pattern placed into mold
A very basic summary of the sand casting
process. . .
First of all,
mix the sand.
2
1THEN

5. SAND-CASTING
MOLDING: Add
the top mold
form
3
4 MOLDING: Fill top form
with compacted sand.
A tube or pipe provides
a path to pour the
metal in
Pattern is still inside!

6. SAND-CASTING
MOLDING:
Take the top
mold off and
remove pattern
& pipe or post
5
6 MOLDING: Replace the
top mold and fasten
securely!
Pouring
hole
In the middle of the
sand is a cavity
shaped like the
pattern!

7. SAND-CASTING
7 CASTING:
Pour the metal (container is
filled from furnace immediately
before you are ready to pour)
8 Wait for the metal to cool
(minutes to days,
depending on the size of
the casting)

8. SAND-CASTING
8 SHAKE OUT: Break apart the two
halves of the mold & take out the
part—usually requires vibrating or
striking the mold to break apart the
sand
CLEANING. Sand is
cleaned off the part, the
“tab” where metal flowed
in must be removed.
9
A copy of the pattern
has now been made
in metal
10 Mold forms are reused
11
Sand is broken up,
screened to remove
debris and clumps, and
sent for remixing

9. SAND-CASTING
Sand-casting is simple
in concept, but
demanding in
execution. It is a
process essential to
making basic and
advanced products. . .
it is also hazardous
and energy-intensive!

10. Sand Casting: Parts of a Sand Mold (expendable mold)
Key terms:
Flask, Cope, Drag, Sprue, Runner, Gate, Riser, Mold Cavity, Core, Parting
Line, Draft (not shown).

11. Casting Terminology
Parting line

12. Sand Casting Configuration

13. Patterns
What is pattern?
• Approximate duplicate of product
• Patterns are made in the shape of the casting
• Pattern Materials: Wood, Plastic or metal.
• One piece or multiple piece pattern

14. Types of Patterns
Types of patterns used in sand casting:
(a) solid pattern
(b) split pattern
(c) match plate pattern‑
(d) cope and drag pattern

15. Pattern Making
One piece or Solid Pattern
Cope & Drag PatternMatch Plate Pattern
Split Pattern

16. Pattern Allowances
Shrinkage Allowance
Patterns are made larger than the casting to compensate
contraction of the liquid while freezing.
For internal cavities the allowances should be negative.
Machining Allowance
Allowance required to remove the rough cast surface. 2 to 25 mm
(0.1 to 1’)
Draft Allowance
To facilitate ease of removal, usually ½ to 2 deg.
Shrinkage allowance
Normal shrinkage: Cast iron 0.83 to 1.3%
Aluminum - 1.3%

17. Cores
Cores
• Cores are used to create internal cavities.
• Should have similar properties as the mold.
• Shaken out after casting is produced.

18. Process
1
Mould

19. 2

20. 3
Dolly

21. 4

22. 5Sprue
Pins

23. 6

24. 7

25. 8

26. 9

27. 10

28. 11

29. 12

30. 13