HAND MOLDING

DEMOSTRATION
PROCESS
GONZALVO, Zaira D.

Different tools used in Hand Molding

Ramming
Venting
Sprue making
Riser putting
Putting powder in parting line
Gate Making
Cores placement
Safety and Precautions

MOLDING

is the process of manufacturing by shaping

pliable raw material using a rigid frame

TOOLS USED IN HAND

MOLDING

TOOLS USED IN HAND MOLDING

o

FLASKS are wood or metal

frames in which the mold is
made.

BELLOWS are used to blow

excess parting materials
from the pattern and also
to blow loose sand and dirt
from the mold cavity.

TOOLS USED IN HAND MOLDING

RIDDLES are used for sifting the

sand over the surfaces of the pattern.
The size of the riddle is given by the
number of meshes to the inch.

RAMMERS used to compress the

moulding sand

TOOLS USED IN HAND MOLDING

STRIKE-OFF BAR are used

to scrape the extra sand from
the top of the cope or drag
after ramming.

DRAW SPIKES are

tapered steel rods having a
loop at one end and a
sharp point at the other.
to

draw pattern from the

mold

TOOLS USED IN HAND MOLDING

TROWELS are made of

iron and wooden handle.
for

making joints
for finishing, smoothing
cutting ingates
Giving shape
Repairing molds

VENT WIRES Thin

steel rod or wire used for
making holes(vents) in
the rammed sand molds

TOOLS USED IN HAND MOLDING

SWAB is a small brush

having long hemp fibers
used for applying water
around the edges of a
pattern

SHOVEL is like a
rectangular pan fitted with
a handle used for mixing the
molding sand and for
moving it from one place to
the other.

TOOLS USED IN HAND MOLDING

CLAMPS are used to hold

the cope and drag of the
complete mold together so
that the cope may not
float or rise when the
molten metal is poured
into the mould.

LIFTERS are used for

removing loose sand
from deep cavities in
molds.

TOOLS USED IN HAND MOLDING

SPIRIT LEVEL is used

to check that the sand
bed, moulding box or
table of moulding
machine is horizontal.

SPRUE CUTTERS used to

cut openings in the sand
mold for downsprues

TOOLS USED IN HAND MOLDING

GAGGERS are iron rods

bent at one or both ends.
These are used to reinforce
the moulding sand in the
top portion of the
moulding box and for
supporting hanging sand

CHAPLETS are metal

supports used to hold a
core in place when core
prints are inadequate.

TOOLS USED IN HAND MOLDING

SLICKS are used for

repairing and
providing finishing to
mold surface and
edges after the
pattern has been
withdrawn.
Heart

and leaf slick,

Square and heart
slick, spoon and bead
slick, Heart and
spoon slick, Leaf and
spoon slick

TOOLS USED IN HAND MOLDING

GATE CUTTERS are

pieces of sheet brass bent
to a semicircle on one
edge. They are used to
cut the in gate in the
drag leading from the
base of the sprue to the
mold cavity.

TOOLS USED IN HAND MOLDING

RAPPING PLATE (OR) LIFTING PLATE is used

to facilitate shaking and lifting large pattern from
the mold.

RAMMING

RAMMING

Hand ramming is the method of packing sand to

produce sand mold.
Uniform

throughout the mold

Firm enough to consolidate the sand, but
not hard enough to reduce the porosity
which may prevent gases from escaping
when the mold is poured.

Never strike the pattern forcibly because it may

damage it or dislodge the pattern from its
position.

RAMMING
Sprinkle some parting dust or graphite powder on the
pattern.
Use the riddle to sift some molding sand over the
pattern until it is covered.
Ram more sand in place over and around the pattern,
eventually filling the drag with rammed sand above the
top edge.

VENTING

VENTING
Venting is a process that is used to remove
trapped air from the closed mold and volatile
gases from the processed molten material.
Concept: provide many pathways to allow
trapped air and volatile gases to escape from the
mold quickly and cleanly

VENTING
Pathways

should

lead directly from the edge of the cavity

image of the mold, to the outside atmosphere
surrounding the mold
to be deep enough
to let air and gases
out easily, but not
deep enough to
allow the molten
metal to escape
through them.

VENTING

1.
2.
3.

There are three major dimensions for the vent.

D- Depth
W-Width - 1/8 inch wide or more.
L- Length - minimum of 0.030 inch and a
maximum of 1/8 inch

VENTING

HOW MANY VENTS ARE NEEDED?

have at least 30% of the perimeter of the
cavity image in vents, equally spaced
around that perimeter

Vent the runner

SPRUE MAKING

SPRUE MAKING

Sprue- the hole through which plastic or metal is

poured or cast into gate or reservoir and then
into the mold.

SPRUE MAKING
Place

a sprue pin in the sand adjacent to the

pattern and about one inch away from it.
The location of sprue is not important to
symmetrical patterns because metal can be fed
anywhere around the edge with equally good
results
If pattern has some thin sections which are
hard to fill completely, 2 or more sprues may
actually be required

RISER PUTTING

RISER PUTTING

Riser (Feeder Head)

A passage of sand made in the cope during
ramming
Molten metal rises in the riser after mold
cavity is filled up
The metal compensates for the shrinkage as
the casting solidifies
Size depends on the freezing ratio

RISER PUTTING

1.
2.
3.

Effective if:
The riser cools after the casting,
The riser has enough material to compensate
for the casting shrinkage, and
the casting directionally solidifies towards the
riser.

PUTTING POWDER IN THE

PARTING LINE

PUTTING POWDER IN THE PARTING

LINE
A

parting line, or
seam in moldmaking is the
place where two or more
parts of the mold meet.
Parting

Powder: is used
to release cope from drag and
over pattern preventing the
molding sand from sticking
and ruin the mould finishing.
(Talc, Graphite, Dry
silica powder)

Dust bag

GATE MAKING

GATE MAKING

Gate - is a channel which connects runner with

the mould cavity and through which molten
metal flows to fill the mould cavity.
- should not have sharp edges
- thin cross section

GATE MAKING
The Gating System
Minimize turbulent flow so absorption of gases,
oxidation of metal and lessen the erosion of
mould surfaces
Regulate entry of molten metal
Ensure complete filling of mould cavity
Promote temperature gradient within casting
so all sections could solidify properly

GATE MAKING
Pouring Basin: where the molten metal enters the
mold.
Down Sprue: Path from the pouring basin, where
molten casting travels; Tapered
Sprue Base: Where the casting's inner cavity begins.
Ingate/Choke Area:
Runners: Are passages that distribute the liquid
metal to the different areas.
Main Cavity: The impression of the actual part to be
cast is often referred to as the main cavity.
Vents: Assist in the escape of gases
Risers: Risers are reservoirs of molten material.

GATE MAKING

GATE DESIGN RULES

Gate symmetrically to avoid warpage
Gate into thicker sections for better filling and
packing
Gate long, narrow parts from an end for
uniform flow
Multiple gates shorten flow lengths
Locate gates on either side of a weak core

CORES PLACEMENT

CORES PLACEMENT

Core
used in casting and molding processes to
produce internal cavities and reentrant angles.
Normally a disposable item that is destroyed to
get it out of the piece.

CORES PLACEMENT

Cores
Created from sand and a binder(resin) that cures
through heat or gasification
Once prepared, they are set in place in the mold.

CORES PLACEMENT

Cores
1. Horizontal Core- used in horizontal position always
at the paarting line between two mold boxes
2. Vertical Core- set in its vertical position.
Top and bottom ends are supported in the
seats formed by the core prints in molding
sand
3. Balanced core- has one core to maintain alignment
1. - often used to produce blind cavity
4. Drop core (Stop-off core)- used when cavity either
above or below the parting line

CORES PLACEMENT
5. Hanging core (cover core)- hangs vertically in the
mold with no support at its bottom end
- mold cavity in the drag only

SAFETY AND PRECAUTION

SAFETY AND PRECAUTUION

Wear clothing suited for the job, wear shoes with thick
soles
Do not play with the tools and equipment
Always see that work and cutting tools on any machine
are clamped securely before starting.
Keep the floor clean of metal chips or curls and waste
pieces, put them in container provided for such things.
Put tools always when not in use
Think about what you are doing at all times. Focus on
the job at hand and the next step. Have all moves
planned and rehearsed prior to any operation.
Educate yourself beforehand and always be careful of
your own and bystander safety