lab casting

FACULTY OF MECHANICAL ENGINEERING

BMM 3611

MANUFACTURING PROCESSES LABORATORY

SOLIDIFICATION PROCESSING LAB (Casting)

Laboratory Date

Submission Date

Lecturer

JP/PJP

1)

2)

3)

Learning objectives By the end of semester, students should be able to: 1. Know safe practices in manufacturing processing area. 2. Know tools, equipment and raw material for the respective lab. 3. Know standard operating procedure for the demonstrated machine. 4. Analyzed specific case study related to manufacturing process.

Members ID Section Signature

BMM3611(1112)_SPL ( Casting Lab ) Prepared by:

MZS@FKM,UMP(2012)

1. Introduction The objective of this laboratory is to provide hands on experience of sand casting

process. Casting generally means pouring molten metal into a refractory mold with a cavity of the shape to be made, and allowing it to solidify. When solidified, the desired metal object is taken out from the refractory mold either by breaking the mold or taking the mold apart. The solidified object is called casting. This process is also called founding. Casting required fabrication of pattern, mold constructions and pouring of molten metal 2. Lab activities

Activity Task Form Safety Each student gather in group

In sequence, each student read the saftety clause. If not understand, put a note and JP/PJP will explain later.

Sign the acknowledgement forms

Acknowledgement of safety

requirement form

Know tools, equipment and

materials

JP/PJP will give 10 questions about raw material, tool and equipment application in this lab.

Student must find out the answer. (Eg. tool name & their purpose, raw material description and the final product, etc..)

Give your answer in lab report

Intro to SPL JP/PJP give brief explainaton on all machines in SPL ( their function advantages & limitation)

Student must give attention. Prefer to take a note.

JP/PJP brief

Case study A case study requires student to find out an answer on the specific problem in production.

Based on the chosen case study, JP/PJP will explain and demonstrate process sequence (SOP) for the selected process.

In certain cases, student will be asked to do spesific task. Student must explain thoroughly on outcome of their

investigation

Describe in details in lab report

Safety in lab

Know tools and processes materials

Brief on all machines

Case study


MZS@FKM,UMP(2012)

3. Case study : Sand casting Process sequence

o Based on the completed sand casting mould, investigate; Quality of the mould and pattern such as radiused corners, drafted sides (tapered),

shrinkage allowance and good surface finish. o Get full specification of the furnace used in this lab. Check how temperature of molten metal is controlled prior to pouring process

1) Discussion o Sketch internal sand casting’s mould configuration. o What is green sand mold? State the physical and mixture composition of green sand. o State the essential ingredient of molding sands. o Discuss the effect of molding parameters. What are the desirable properties of molding

sand required from stand point of view of sound casting?

4. Lab report For your project report, provide the following: 1. Use a cover page similar to the labsheet format. 2. Contents for the report are;

Introduction, Raw materials, Process tools, Machines and their applications, Case study – Process setting / Design consideration/ Product defect & countermeasure, Conclusion/Lesson learned, References

3. Discuss the strengths and weaknesses of this laboratory. Did the laboratory help you to learn the material better? Explain why or why not.

4. The report should be done in MS Word and an equation editor should be used for all equations.

5. Equations should be numbered and plots should be numbered and referenced with a descriptive caption.


MZS@FKM,UMP(2012)

BMM 3611 Process Sheet

(Casting)

Sand casting mould details

Type:________________ Number of cavity :_______________________

Mould cheklists

# Cheklists

1 The sand needs to be damp enough to hold its own shape when clenched in the hand. If it is too wet it can be dangerous when casting and dry sand should be added and mixed. It should be sieved thoroughly and all lumps removed.

2 The drag (the bottom half of the casting flask) should be placed upside down on a moulding board and one half of the pattern should be placed flat side down on it.

3 The sand should be sieved over the pattern to a depth of at least 30 mm and it should then be rammed down firmly. Once compact the drag should be filled and rammed once again before finally being leveled off.

4 The drag should be turned over and the cope fixed in place and the pattern should be assembled and lightly dusted once again. Sprue pins should now be inserted and these will ultimately create a cavity for the metal to run into. The sieving process is repeated and once again the sand should be compacted. Finally, a small well should be created around the top of one of the sprue pins.

5 The sprue pins should be removed and the cope and drag separated. Gates and basins should be cut into the sand in both the cope and the drag before the pattern is removed.

6 The mould box should now be reassembled and placed on the floor ready for pouring.

7 With the metal in a molten state, it should be fluxed and degassed to remove any impurities. These will form on the surface and should be removed before pouring commences.

8 The melt should be poured slowly and with an even flow into the small well. Once the metal has solidified, the sand can be broken but great care should be taken because the components and sand may still be hot.

9 Finally the casting will need to be fettled which involves cutting off the runners and risers and any flashes.

List of Tools Used 1. _________________________

2. _________________________ 3. _________________________

4. _________________________ 5. _________________________

6. _________________________ 7. _________________________

8. _________________________ 9. _________________________

10. _________________________


MZS@FKM,UMP(2012)

Casting product

1) Draw the designed casting product

2) Casted part inspection

Type of defects

Inspection (Visual/NDT Test)

Sketch of the part defects

Countermeasure

lab casting

Documents