DEPARTMENT OF TECHNICAL EDUCATION

ANDHRA PRADESH
Name : P. Ramulu
Designation : Work Shop Supdt.,
Branch : Mechanical Engineering
Institute : Govt. Polytechnic for women,
Medak.
Year/semester : I year
Subject : Work shop Technology
Subject Code : M-105
Topic : Foundry
Duration : 100 Minutes
Sub. Topic : Moulding sand , their Properties
Types, Ingredients
Teaching Aids : Animation Clips & Images
 Recap

In the previous class , you have learnt …

Hand moulding tools and their uses

• Moulding flask – for making mould using pattern

• Shovel – used to lift and mixing the sand
• Riddle – for screening the sand
• Rammer – for packing the sand
• Bellow – for blowing the loose sand
Objectives

On completion of this period , would be able to

know about

 What is meant by Moulding sand

 Properties of moulding sands
 Types of Moulding sand
 Ingredients in Moulding sand

M105.81 TO 82 3
 What is Moulding sand

Consists of sand with clay or binder

Used to make mould

Can be re-used

Fig 1. Moulding Sand

M105.81 TO 82 4
 Properties of Moulding Sand

 Porosity (permeability) :
• A porous material.
• Gap between sand particles provides passage
for flue gases.
 Plasticity:
• Acquires the shape of pattern .
• Deforms to required shape.

Contd..

M105.81 TO 82 5
 Properties of moulding sand

 Flowability:
• It flows into corners and deeper into
moulding box.
 Collapsibility:
• Can be broken into particles and can be re-
used.

Contd..

M105.81 TO 82
 Properties Of Moulding Sand

 Adhesiveness :
• Adheres to surface of pattern and moulding box
 Cohesiveness :
• Ability of sand particles to stick each other .
 Refractoriness :
• Withstands high temperature .
• Withstands heat of molten metal .
M105.81 TO 82 7
 Types of Moulding sand

Natural sand

Synthetic sand

Special sand

M105.81 TO 82 8
 Natural sand
 Sand collected from river beds.
Sand collected from pits
Added with (5-20%) of clay.
Clay develops strength and plasticity.
Used for non-ferrous casting and gray cast iron
castings.

Also called greensand.

M105.81 TO 82
Fig 2. Natural Sand 9
 Synthetic sand
 It is clay –free sand.
 Mixture of sand ,bentonite(3 to 5%)(binder) ,water
(3 to4%).
 Used for ferrous castings.

Fig 3. Synthetic Sand

M105.81 TO 82 10
 Special Sand

 It is high refractory sand.

 Used for accurate castings
 Examples are

•Zirconium
•Olivinite
•Chromite
•Magnesite
•Chamott

M105.81 TO 82 11
Advantages of synthetic sand over natural
sand

 More uniform grain size.

 High permeability
 Mould ability
 Easier control of properties
 Suitable for variety of castings

M105.81 TO 82 12
 Limitations

 High initial cost

 Patching is difficult

 Dries out fastly

 Skilled labour is required

M105.81 TO 82 13
Classification according to the initial
condition

 Green sand
 Dry sand
 Loam sand .
 Facing sand
 Backing sand .
 System sand
 Parting sand
 Core sand

M105.81 TO 82 14
 Green sand

 Foundry sand containing moisture

 Green refers the moisture content.

 Silica sand (18-30%) of Clay+(6-8%) of water

 Can be re-used

 Used for small and medium castings

M105.81 TO 82 15
 Dry sand

 Moisture free sand

 Mixed with binder (bentonite ,water)

 Used for medium and heavy castings.

M105.81 TO 82 16
 Loam sand

 Mixture of sand and 50% clay.

 Used for large casting (pipes , rolls used in paper

mills)
 Facing sand

Applied to surface of the pattern.

Used for getting smooth surface

Layer thick ness in mould ranges from 20to30 mm

M105.81 TO 82 18
 Backing sand

 Used to support facing sand .

 To fill rest of flask.

 It is porous mixture of sand.

 System sand

 It is prepared from used sand.

 It is re-conditioned.
 Used to fill complete flask.
 It possess high strength , porosity ,
refracteriness.

M105.81 TO 82 20
 Parting sand

 A fine sand dust.

 Prevents sticking to pattern surface.

eg : brick powder
 Core sand

 Used for making cores

 Consists of silica sand ,binder (line-seed oil, resins)
and water.
 Possess high refracteriness

M105.81 TO 82 22
List of ingredients in foundry sand

 Sand (natural or synthetic)

 Binder
a) Clay
b) Organic binder (bentonite ,line-
seed oil,resines)
c) Inorganic binders (port land cement
sodium silicate)
 Water
M105.81 TO 82 23
 Sand additives

 These are added to moulding sand.

 They control sand properties.
 Widely used additives

1) Coal dust (to improve surface finish)

2) Wood flour (to improve collapsibility of
core)
3) Silica flour (reduce metal penetration)
4) Iron oxide (increase dry strength)

M105.81 TO 82 24
 Summary

In this class , we have learnt …

 Porosity, Refractoriness, Collapsibility, plasticity are

some of the properties of moulding sand.
 Natural Sand – used for non-ferrous and grey iron
 Synthetic Sand – used for steel casting
 Loam Sand – used for large cylinders
 Core Sand – used for making cores
 Sand additives – Coal dust, wood flour, silica flour,
M105.81 TO 82 25
 Quiz

1. Porosity is of ---------------------------------
(Gap between sand particles)

2. Cohesiveness means ----------------------------

(Attraction between sand particles)

M105.81 TO 82 26
 Quiz

3. Adhesiveness means -----------------------------

(Attraction between sand particles and moulding box)

4. Ingredients in moulding sand ------------------------

( Moulding sand, binder and water )

 Frequently Asked Questions

1. Describe the properties of moulding sand .

2. What are the various types of moulding sand

3. What are the ingredients in moulding sand

M105.81 TO 82 28