Small Scale Foundries for Developing Published by: Intermediate ...

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Zattcrr. on .flate Frame placed over the heated pattern Filled with resin coated sand W!II& cures against the hot pattern Excess sand removed leaving cured shell on pattern Completed half shell mould stripped f;Oiil pattern ~ Shell M&ding 25
The powdered resin may be simply mixed with the sand but it is more effective to use sand whose grains have been coated with resin. It is possible to purchase coated sand: although the coating process is not very complicated, it requires careful technical control and is not usually worthwhile for small quantities. Shell moulding requires relatively little skili from the operators although it demands high skills from the pattern makers. The process can produce accurate, smooth, high quality castings in most types of metal. Shell moulds can be stored for long periods without damage and the process can be mechanised in many ways for high production. Shell moulding is not a cheap method, especially if resin coated sand has to be purchased from a distance. It is suitable only when reiati\d~~ highly priced castings are to be made which justify the cost of the resins and the expensive metal patterns. Plaster Moulds Castings can be made of aluminium and other low meiting point aiioys in mouids made of carefully dried plaster. These moulds are not re-usable. Castings produced in this way are accurate although the prOCess iS expensive. S@ai t)p?S Cf PliXStei are available with which it is possible to make iron and even steel castings when exceptional accuracy is required. Cement Sands Sand may be bonded with cement. Ordinary Portland cement may be used, although for thick section castings or those that must be poured at a high temperature, heat resisting cement (ciment fondu) is necessary. About 7% to 9% of cement and 6% to 7% of water is mixed with the sand. Before pouring cement moulds must be carefully dried. Cement-bonded sand moulds are strong and are suitable for producing heavy castings; however the sand does not break down easily and this can cause problems with cleaning the castings and with cracking of thin metal sections. The process is not used by foundries producing small castings, but is one of the processes to be considered for heavy products. Loam Moulding A variation of the dry sand moulding process for large castings is the use of loam: this is sand mixed with a very large amount of clay such as fire clay, so that it can be applied by hand in a plastic form against a pattern. Loam moulds are thoroughly dried before pouring. This is the traditional process for making heavy castings (pipes, bells etc.); it demands a high degree of skill and training and is not likely to be useful for small scale foundries in normal circumsiances. Other Binders With recent developments in chemistry a great variety of compounds has been used for bonding sand for foundry purposes. Many of these chemicals are expensive and present few advantages over conventional materials. One interesting experiment has been to use ice. Sand is mixed with a little water and the mould is frozen. The metal is poured before the frozen mould has had time to collarse and good castings can be produced. However the necessary high capacity deepfreezing apparatus is very expensive to buy and to operate. Un-bonded sand may also be held in place by vacuum suction between special thin plastic films. This (V) process is expensive to engineer and is not usually suitable for small scale foundries. It is used for repetition production of large flat castings. Mould Assembly and Pouring Moulds must be correctly prepared for pouring, by whatever process they have been produced. They should be inspected for damage and any loose sand or dirt blown away with compressed air or bellows. The cores are laid in the core prints which hold them in the correct position. The top half of 26
Page 1: A project of Volunteers in Asia Sma
Page 4: Acknowledgements The printing of th
Page 7 and 8: List of illustrations Using a ladle
Page 9 and 10: Object Of This Book This book is no
Page 11 and 12: production oi >;~??a11 quantities o
Page 13 and 14: Top half mounted pattern Bottom hpl
Page 15 and 16: Pouling basin Weight Top half mould
Page 17 and 18: titularly in regard to the location
Page 19 and 20: Corner location system Snap - flask
Page 21 and 22: A Dowel and bush location cavity :o
Page 23 and 24: clay-bonded sand should be dried be
Page 25 and 26: Sand shovel Ladle and carrier loose
Page 27 and 28: ~4. fitis+able ,. :,:e;e Jolting ta
Page 29 and 30: . ...... . . . . ....... :::: ....
Page 31: Sand hopper Continuous Mixer-Filler
Page 35 and 36: . CHAPTER 4 COREMAKING Certain type
Page 37 and 38: cy? .: : 6 I.-. :‘. 1. - -: :...,
Page 39 and 40: “Cast iron” is a general term u
Page 41 and 42: Cupola Furnaces A large number of d
Page 43 and 44: solidify inside the cupola. Some sm
Page 45 and 46: Chimney Heated air Heat exchanger R
Page 47 and 48: 2. Timing The melting furnaces in n
Page 49 and 50: with Raw Materials The easiest way
Page 51 and 52: Tongs for lifting crucible Chimney
Page 53 and 54: for each type of alloy being melted
Page 55 and 56: CHAPTER 8 CLEANING CASTINGS After c
Page 57 and 58: The production of castings is alway
Page 59 and 60: CHAPTER 11 Specification The first
Page 61 and 62: Purpose-Built Equipment Many indust
Page 63 and 64: AINING It is often difficult to fin
Page 65 and 66: I. Sources of information on specia
Page 67 and 68: 1 Tonne : 0.984 Long tons 1 Tonne :
Page 69 and 70: DROSS DRY SAND FACING SAND FEEDER F
Page 71 and 72: ASSISTANCE QUESTIONNAIRE No general
Page 73 and 74: 8.2. 8.3. 8.4. 8.5. 8.6. 8.7. 8.8.

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