A mould is a hollowed-out block that is filled with a liquid like plastic, glass, metal, or ceramic raw materials .The liquid hardens or sets inside the mould, adopting its shape. A mould is the counterpart to a cast. Mould or Mould cavity contains molten metal and is essentially a negative of the final product. Mould is obtained by pattern in moulding material (sand). Mould material should posses refractory characteristics and withstand the pouring temperature.

1. Moulding and Core Making
Prepared by,
Ankit Saxena
Assistant Professor
ADGITM,NEW DELHI

2. Mould?
A mould is a hollowed-out block that is filled with a liquid like
plastic, glass, metal, or ceramic raw materials .The liquid
hardens or sets inside the mould, adopting its shape. A mould is
the counterpart to a cast.
• Mould or Mould cavity contains molten metal and is essentially a
negative of the final product.
• Mould is obtained by pattern in moulding material (sand).
• Mould material should posses refractory characteristics and withstand
the pouring temperature.

3. Types of moulding:
1.Hand moulding- are used for odd castings generally
less than 50 no. and ramming is done by hands which
takes more time.
2.Machine moulding- are used for simple castings to be
produced in large numbers. Ramming is done by
machine so require less time.
3.Bench moulding- moulding is done on a bench of
convenient height to the moulder and is used for small
castings.
4.Floor moulding-moulding is done on the foundry floor
and is used for all medium and large castings.
5.Pit moulding- moulding is done in a pit which act as
drag and is used for very large castings

5. Characteristics
1.Should have the desired shape and size.
2.Must be produced with due allowances for shrinkage of the solidifying
material.
3.Any geometrical feature desired in the finished casting must exist in
the cavity. Consequently, the mould material must be able to
reproduce the desired detail.
4.Should have are refractory character so that it will not contaminate the
molten material.
5.The mould must be made from a material that can with stand repeated
use.
Types of Moulds
Basically moulds are two types:
1.Expendable moulds- are made of sand and is used for single casting
which break upon solidification.
2.Permanent moulds- are made of metal or graphite (costly) and used
repeatedly for large number of castings which do not break upon
solidification.

7. Open Mould Close Mould

8. Method of moulding
SANDMOULDING
Hand ramming is the preferred method of mould making when only a few castings are to be
made from any given design, and some small foundries still make their moulds by hand
moulding. In most cases sand moulds are made by specially designed moulding machines.
Various moulding methods differ in following aspects:
1) Type of flask required,
2) Method of packing the sand with in the flask,
Whether mechanical assistance is provided to turn or handle the mould. In all cases the
moulding machines greatly reduce the labour and Skill required, and give to castings with
better dimensional accuracy and consistency moulding usually begins with a pattern and a
flask. Sand is generally packed in the flask by following basic techniques.
Machine Moulding
Moulds are produced by machines for mass production of castings.
A moulding machine performs following functions:
1) Filling of sand 2)Ramming of sand 3)Lifting of pattern from mould 4) Rolling mould section
Following are the main moulding machine:
1) Jolt M/c 2) Squeezing m/c 3) Sand slinger 4) Diaphragm moulding m/c 5) Stripper plate
m/c
M/c moulding requires mounted patterns and is faster and more uniform than bench moulding

9. JOLTING:
i. Sand is placed on top of the pattern.
ii. Pattern flask, and sand are then lifted and
dropped several times.
iii. Kinetic energy of the sand produces optimum
packing around the pattern.
iv. Jolting machines can be used on the first half of
a match-plate pattern or on both halves of a
cope-and-drag operation.
SQUEEZING:
i. Uses either an Air operated squeeze head, or a
Flexible diaphragm to compact the sand.
ii. Squeezing provides firm packing near the
squeeze head, but the density diminishes
farther into the mould.
iii. High pressure machines with a flexible
diaphragm (commonly called Tac cone
machines) can produce a more uniform
density around all parts of an irregular pattern.

10. i. Combination of jolting and squeezing is often used to produce a more uniform
density through out the mould.
ii. A match plate pattern is positioned between the cope and drag sections of a flask,
and the assembly is placed upside down on the moulding machine.
iii. A parting compound is sprinkled on the pattern, and the top section of the flask is
filled with sand.
iv. Entire assembly is then jolted a specified number of times to pack the sand around
the pattern.
v. A squeeze head is then swung into place, and pressure is applied to complete the
upper portion of the mould.
vi. Flask can be inverted and operation repeated on the cope half, or the cope and drag
can be made on separate machines using cope-and-drag patterns.
vii. Except for small moulds, moulding machines usually provide mechanical assistance
for inverting the heavy molds.
viii. Gating system and runners can be hand cut or can be made part of pattern.
ix. After completing themold, tapered flask may be removed to prevent possible
damage to the flask during the pour.
x. As lip jacket, an inexpensive metal band, may be positioned around the mould to
hold the sand in place.
xi. Heavy metal weights are often placed on top of the moulds to prevent the sections
from separating as the hydrostatic pressure of the melt presses the cope upward.

28. Core making procedure

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