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FOUNDRY AND FORGING LABORATORY MANUAL

III Semester (MEL38)

DAYANANDA SAGAR COLLEGE OF ENGINEERINGAccredited by National Assessment & Accreditation Council (NAAC) with ’A’ Grade

(An Autonomous Institution affiliated to Visvesvaraya Technological University, Belagavi &

ISO 9001:2008 Certified)MECHANICAL ENGINEERING DEPARTMENT

SHAVIGE MALLESWARA HILLS , KUMARASWAMY LAYOUTBENGALURU-560078

Name of the Student :

Semester /Section :

USN :

Batch :

Lab name: FOUNDRY AND FORGING LABORATORY [2016]

(Backside of cover page)

Vision of the Institute

To impart quality technical education with a focus on Research and Innovation emphasising on Development of Sustainable and Inclusive Technology for the benefit of society.

Mission of the Institute

To provide an environment that enhances creativity and Innovation in pursuit of Excellence.

To nurture teamwork in order to transform individuals as responsible leaders and entrepreneurs.

To train the students to the changing technical scenario and make them to understand the importance of Sustainable and Inclusive technologies.

ME Dept., Dayananda Sagar College of Engineering Bengaluru

FOUNDRYAND FORGING LABORATORY MANUALIII Semester (MEL38)

DAYANANDA SAGAR COLLEGE OF ENGINEERING(An Autonomous Institution affiliated to Visvesvaraya Technological University, Belagavi)

MECHANICAL ENGINEERING DEPARTMENTSHAVIGE MALLESWARA HILLS

KUMARASWAMY LAYOUTBENGALURU-560078

Name of the Student :

Semester /Section :

USN :

Batch :



DEPARTMENT OF MECHANICAL ENGINEERING, BENGALURU-560078

VISION OF THE DEPARTMENT

To impart quality technical education with a focus on Research



and Innovation emphasizing on Development of Sustainable and Inclusive Technology for the benefit of society.

MISSION OF THE DEPARTMENT To provide a platform that imparts scientific knowledge

and technical skills. To train students to demonstrate their technical and

managerial skills. To engage students in professional activities through

research, higher education and lifelong learning.

PROGRAMME EDUCATIONAL OBJECTIVES [PEOs]PEO-1: Graduates shall acquire the knowledge and competency for career in and related to Mechanical engineering.PEO-2: Graduates shall acquire the necessary skills to lead and manage professional teams.PEO-3: Graduates shall demonstrate their Engineering Profession by addressing Scientific and Social challenges. PEO-4: Graduates shall engage in Professional and Intellectual Development through Higher Education, Research and Lifelong learning in Engineering or related fields.

PROGRAMME SPECIFIC OUTCOMES [PSOs]PSO-1: PSO-2:


DEPARTMENT OF MECHANICAL ENGINEERING, BENGALURU-560078

FOUNDRY AND FORGING LABORATORY (SYLLABUS)

III SEMESTER B. E (ME)



Sub. Code: IA Marks : Hrs/Week : Exam Hrs : Total Hrs: Exam Marks :

Course Objectives:

1 Illustrate the preparation of sand specimens2 Demonstrate the technique of mould making using the moulding tools3 Evaluate the properties of mould subjecting the specimen to mechanical testing4 Summarize the principles and methodology of carrying out the forging

operation

Syllabus:

PART – A 1. Testing of Moulding sand and Core sand Preparation of sand specimens and conduction of the following tests: 1 Compression, Shear and Tensile tests on Universal Sand Testing Machine. 2 Permeability test 3 Core hardness & Mould hardness tests. 4 Sieve Analysis to find Grain Fineness number of Base Sand 5 Clay content determination in Base Sand

PART – B 2. Foundry Practice Use of foundry tools and other equipments. Preparation of moulds using two moulding boxes using patterns or without Patterns. (Split pattern, Match plate pattern and Core boxes). Preparation of one casting (Aluminum or cast iron-Demonstration only)

PART – C 3. Forging Operations: Calculation of length of the raw material required to do the model. Preparing minimum three forged models involving upsetting, drawing and bending operations. Out of these three models, at least one model is to be prepared by using Power Hammer.

Course Outcomes:

1 Interpret results of sand testing for preparing sand mixture properties for mould making

2 Develop skills for mould making using mould making tools3 Demonstrate open die forging skills through use of forging tools4 Analyze casting parameters which requires engineering knowledge , design,



production and environment aspects


DEPARTMENT OF MECHANICAL ENGINEERING

FOUNDRY AND FORGING LABORATORY (MEL38)

I - CYCLE

1. INTRODUCTION TO FOUNDRY



2. PREPERATION OF SQUARE MOULD CAVITY

3. PREPERATION OF HEXAGONAL MOULD CAVITY USING TWO MOULD BOXES 4. MOULD PREPERATION USING SPLIT PATTERN

5. MOULD PREPERATION USING SOLID PATTERN

II - CYCLE

6. INTRODUCTION TO FORGING

7. TO OBTAIN A SQUARE BAR FROM ROUND ROD BY FORGING

8. TO OBTAIN A HEXAGONAL BAR FROM ROUND ROD BY FORGING

9.TO OBTAIN GIB HEAD KEY FROM A GIVEN ROUND ROD BY FORGING

III – CYCLE10. SIEVE ANALYSIS OF BASE SAND

11. TO FIND THE AMOUNT OF CLAY

12. TO FIND THE COMPRESSION STRENGTH

13. TO FIND THE SHEAR STRENGTH

14. TO FIND THE EFFECT OF WATER AND CLAY ON THE PERMEABILITY OF GREEN SAND

15. TO FIND THE PERCENTAGE OF MOISTURE IN GREEN SAND

16. TO FIND THE TENSILE STRENGTH OF THE CORE SAND

17. TO FIND THE BENDING STRENGTH OF THE MOULDING SAND

18. TO FIND THE SAND MOULD HARDNESS

19. TO FIND THE CORE HARDNESS OF THE GIVEN CORE

DAYANANDA SAGAR COLLEGE OF ENGINEERINGDEPARTMENT OF MECHANICAL ENGINEERING

BENGALURU – 560078


DO’sWear prescribed uniform & shoes which is compulsory. Tie loose hair (for girls ) eith clip / band.

Safety equipments like apron, gloves and helmet must be worn while doing smithy / hand forging and operating LPG fired furnace.Use prescribed tools while doing models, as instructed by teaching staff and instructors.Observation book shall be used for recording lab work, calculations etc.Practical record book should be completed and get it valued every week by teaching staff to comply with CIE (continuous internal evaluations) format.Safety instructions as applicable must be followed.


Experiment No:________ Date:____________

Introduction to Foundry


DONT’sThe use of mobile/ any other personal electronic gadgets is prohibited in the laboratory.

Wear loose clothing, leave loose hair for girls.

Operate equipment without the consent of instructor.

Play with tools which may have sharp edges.

Absent from attending lab with valid reasons.

Give excuses for not bring the record.

Unsafe actions which may lead to accidents.


Introduction to Foundry:



Foundry is a manufacturing process where metal casting is produced. A shaped

cavity is formed in the sand bounded by cope and drag boxes. Molten metal is poured in to

the cavity through the spruce. After solidification, sand and metal are separated to get the

solid mass of metal which is called casting. Cavity corresponding to the component shape is

called as the mould. Mould is made out of refractory sand grains is called sand mould.

Moulding Sand Preparation

The constituents used for foundry sand preparation is

Silica sand or Base sand 70 – 80%Binder (Clay or Bentonite) 6 – 8 %Additive (coke Powder) 4 %Moisture (Water) 6 – 8 %

This sand is called green sand.

Dry Sand: Sand prepared without moisture.

Facing Sand: Sand used around the pattern.

Parting Sand: to avoid sticking of mould boxes, the dry silica sand is sprinkled between

two boxes is called parting sand.

Baking Sand: After taking castings from the sand, the sand left on the floor is called baking

sand. It is also called floor sand.

Core Sand: Sands used to prepare core, this contains high percentage of silica sand

Oil Sand: silica sand prepared by using oil binder

Molasses sand: sand prepared by using molasses as binders, used to prepare intricate

shape moulds.

FOUNDRY TOOLS:

Showel: It is used in mixing and conditioning of the sand by hand, and to transferring it to

the flask.

Hand Riddle: It consists of wooden frame fitted with a screen of standard wire mesh at the

bottom. It is used for hand riddling of sand to remove foreign materials from the sand.

Peen Ramer: It as a wedge shape in its bottom and it is used in packing of sand in pockets

and corners for uniformity.

Round Rammer: It is used after the peen rammer and it is used to strike the sand rigidly



Strike-off Bar: It is flat bar made of wood or iron. It is used to Strike-off excess sand from

the top of mould box after ramming to provide a level surface.

Vent Wire: It is thin steel wire carrying pointed edge at one end and wooden handle at the

other end or bend. After ramming and strike of excess sand it is used to make small holes

called vents in the sand which help in escaping of a gases and steam during casting.



Trowel: Trowel is used for finishing flat surfaces and joints in a mould. It is made of

different shapes like square, heart etc.

Slicks: They are used for repairing and finishing of mould edges after removing the pattern

from the mould and used to cut gates for flow of liquid metal in the mould.

Lifter and Cleaner: They are used to cut the mould to remove loose sand from the mould

cavity.

Draw Spike: It has loop at its end, used to draw pattern and shake the pattern in the mould

Swab: It is a fibre brush used to moisten the mould around the pattern before removing the

pattern from the mould.

Sprue pin: It is taper rod of wood which is embedded in the sand mould and later with

drawn to produce a hole called runner or raiser hole through which molten metal is poured

in to the mould.

Gaggers: They are bend pieces of wire, which are used for reinforcing downward

projection of sand mass in the cope.

Bellow: It is used to blow out the loose sands from the mould cavity.

Mould Boxes or flask: These boxes used in sand moulding, may be made of wood or cast

iron or mild steel .The lower box is called drag or upper box is called cope. If three boxes

are used, intermediate box is called cheek.

Laddle: They are used to receive the molten metal from the melting furnace, and are used

to pour the molten metal in to the mould.

Crucible:

They are made of refractory materials like silicon carbide or graphite. They are used in

melting metals and alloys.



Experiment No: __________ Date: ____________

Preparation of Square Mould CavityAim:

Prepare Square Cavity using single moulding box

Tools required:Mould Box, Showel, Peen Ramer, Round Rammer, strike-off bar, cleaner,

Square trowel, Steel scale

Operations:

Ramming, Cutting and Finishing operations

Procedure:

Prepare the sand and transfer the sand to working place using showel.

Take drag and keep it on the moulding table. Fill it with green sand and ram with

Peen Rammer and again fill the sand and ram with round rammer.

Remove excess sand from strike off bar

Spray parting sand and finish the surface with trowel

Mark the square on the surface using scale and vent wire.

Cut the required cavity using lifter and remove the loose sand from the cavity.

Cut the gate and pouring basin.

Square mould cavity is kept ready for pouring.



Diagram

SQUARE CAVITY

z

Results:

Skill for preparation of square cavity mould will be acquired.



Applications:

Used in Foundry for manufacture of casting

Remarks :

Signature of Staff Incharge with date




Preparation of hexagonal mould cavity using two mould boxes

Aim:Cutting a hexagonal cavity using two mould boxes.

Tools required:

moulding flask, hand rammer, trowel, leveller, strike off bar, cleaner, vent rod, scale, divider

Operations:


Procedure:

Keep the drag on the table and fill it with moulding sand. First ram the sand with

flat head rammer, put more sand and rammed with round head rammer. Remove

the excess sand and finish the top surface of the mould using leveller and

trowels.

Sprinkle sand on the top of the finished drag mould. Draw circle of required

diameter on the top surface of the mould and inside the circle draw the hexagon

to the required dimension.

Now keep the open box on top of the drag box and keep the wooden sprue and

riser at appropriate location on the drag and fill the cope box with the moulding

sand and finish the cope box in the same manner as that of the drag box.

Lift the cope box and keep it inverted position on the table. Now using the sand

lifter remove the sand from the mould to get the desired shape that is round

finish of the mould after outing the gate in this position.



Diagram

CASTING



Results:

Skill for preparation of hexagonal cavity mould will be acquired.

Applications:


Remarks :





Mould Preparation using Split Pattren

Aim: To prepare a mold using split Pattern

Tools required:

Shovel, moulding box, hand rammer, strike off bar, trowel, lifter, sprue pin, split

pattern.

Operations:


Procedure:

Prepare the moulding sand by separating the foreign materials by riddle.

Transfer the green sand to the working place

Keep the drag on the table and place the lower part of the split pattern at

the centre of the drag. Fill it with green sand and ram the sand with round

head rammer and remove excess sand using strike off bar and finish the top

surface using trowel.

Spray parting sand on the top of the drag and fix the other half split pattern

to the drag.

Put the cope, riser and runner and fill up the sand and ram with hand

rammer. Remove excess sand, make vent hole to remove air.



Separate the mould boxes and remove the pattern by using vent wire, cut

the cavity using cleaner. Prepare pouring basin gate

Assemble cope and drag which is kept ready for pouring.

Diagram:

Results:

Skill for preparation of mould cavity using split mould pattern will be acquired.

Applications:




Remarks :





Mould preparation using Solid PatternAim:

To prepare a mould using solid pattern (Pelton Cup).

Tools required:

Shovel, moulding box, hand rammer, strike off bar, trowel, lifter, sprue pin,

pelton cup pattern.

Operations:

Filling up the sand, ramming the sand, leveling the sand, marking, cutting,

finishing.

Procedure:

Keep the drag box on the table and place the given pattern (pelton cup) in

the drag. Fill up sand and ram it properly.

Using straight leveller, sand is levelled.

Tilt the drag box and sprinkle parting sand.

Place the other half of the pelton cup and place the runner and riser. Fill the

sand in cope and ram it properly.

Remove the runner and riser. Prepare vent holes.

Remove the cope and place it on the table and ram it to obtain the pattern

(pelton cup).

Cut the ingate in the drag. Assemble the two mould boxes which is ready to

pour the molten metal.



Diagram:

PELTON CUP CASTING

Results:

Skill for preparation of mould cavity using solid mould pattern will be acquired.

Applications:




Remarks :

Signature of Staff Incharge with date:



Introduction to Forging (Smithy)

A blacksmith’s work involves heating of metal stock to a desire temperature (above

recrystalisation temperature), enable it acquire sufficient plasticity, followed by operations

like hammering, bending, Pressing etc. to give desire shape. This work is known as Forging.

The above operations either carried out by hand hammering or by power hammering or by

forging machine.

Smithy is the term used for process when it is done by means of hand tools.

Power hammers are used in large quantity of production

Advantages of Forging:

Forging refines structure of metal

It renders metal stronger by setting the direction of the grains.

It saves material, Labor and time of production as compare to other production process.

Forging furnace:

LPG Fired Furnace: LPG fired furnace used for forging/ hand smithy consists of a

refractory lined furnace. The furnace has a hinged door which can be opened for loading

the raw material pieces. It is equipped with a burner in which LPG is supplied & it burns

inside the refractory lined chamber. A thermocouple inserted in the chamber which is

connected to a temperature indicator with temperature controller and temperature display

unit for precise temperature measurement. Temperature can be set to a desired level( 850-

880c) for forging. The furnace is having gas sensors to detect gas supply. The safety of

operator is taken care of.



Forging tools:

Smiths Forge or Hearth: It has a robust steel structure consisting four leg supports, iron

bottom known as hearth. A hood /Chimney at the top and tuyers openings in to the hearth

either from the rear or from the bottom. The hearth carries the coal which is used for

heating the metal by combustion of coal. The hearth is lined with fire bricks withstand high

temperature. Air under pressure is supplied by the blower is suitably placed near the

hearth. This blower can either be hand operated or power driven . Metal pipes are used to

connect the tuyers and blower. Chimney is provided at the top to enable easy escape of

smoke and fumes.

Anvil:

It is equipment used as a support to the job. It is generally made of mild steel provided

with hardened top, about 22 – 25 mm thick. The horn or beak is used in bending the metal

or forming curved shapes. It carries square hole to accommodate this square shank of the

bottom part of various hand tools like swages,fullers. It is called hard die hole. the circular

hole provided near the hard die hole is known as pritchel hole.

Swage Block:

It is a block of cast steel carrying a number of slots of different shapes and sizes and

through holes from its top to bottom. This is used as a support in punching holes and

forming different shapes.



FULLERS SWAGES

FLATTER

Swages:

They are made of High carbon steel. Their working faces carry circular groups to suit the

size of the work. Top swage carries a handle and bottom swage has a square to be fitted in

to the hardy hole during forging operation.

Sledge hammer:

Hammer is a principal striking tool made of forge steel.

Classification of hammers is largely according to the size and weight of the hammers is

used in forging. All the hammers are mainly divided in to four parts; namely Peen, eye,

cheeks and face. The face is hardened and polished



Sludge hammers are comparatively 3 – 4 times heavier than the hand hammer. They are

available in varying sizes and weights from 3 kg – 8 kg. They are employed when heavy

blows are needed in forging.

Tongs:

They are used to hold the job in position and turning over during forging. They are made of

mild steel. Tongs are usually made in two pieces, riveted und together to form a hinge.

Tongs are usually name after the inside shapes of the jaws. Flat Tongs are used for gripping

small flat pieces. Round hollow tongs are used for holding round work.

Hollow tongs with square jaws are used to hold square or hexagonal work.

Chisels:

Chisels are used to cut metals in hot or cold state. Those which are used for cutting the

metal in hot state are termed as hot chisels and others used for cutting in cold state are

known as cold chisels.

Punches: punches are tapered tools made in various shapes and sizes. They are used for

producing holes in red hot jobs.

Drifts: Drifts is a large sized punch used to expand the hole to the desired shape and size,

after the punching is over.

Fullers:

These tools are made of high carbon steels in different sizes to suit the various types of

jobs. They are usually used in pairs, consisting of top and bottom fuller. Their working

edges are normally rounded. They are employed for making necks by reducing the cross

section of job and also in drawing out.

Flatters:

They are also known as smoothers. They are made of high carbon steel and consist of a

square body fitted with handle and flat square bottom. They are used for leveling and

finishing a flat surface after drawing out or any other forging operations.




To obtain a Square Bar from Round Rod by ForgingAim:

To obtain a square bar from round rod by forging

Tools required:

Anvil, sledge rammer, round & square tong, swage, flatter, steel scale.

Operations:

Heating(using LPG fired furnace), hammering, drawing

Precautions:

Hold the tong outside the anvil while hammering.

Take care about hammer slipping from handle.

Procedure:

Switch on the LPG fired furnace and set the forging temperature to 800-8500C.

Keep the given work piece in the hearth and heat it to red hot condition.

Flatten the opposite face with the help of flatter by placing it on the anvil

Obtain the required model and then dip it in water for quick cooling.

The required model is thus obtained.



Diagram:

ROUND MILD STEEL

*length can vary from 70-75mm/ diameter can vary from 18-20mm

*length can vary from 90-105mm

Calculation of raw material length in forging

1. To find the length of raw material required for forging to square



Let a=side of the finished squarei.e a=15mmh=length of the finished squarei.e h=105mm

Volume of the finished square=a2 x h =152 x 105 = 23625mm3

Volume of the raw material [MS round dia=20mm] = Assuming no scaling lossesVolume of the finished square = volume of the raw material a2 x h = rπ 2 l (Taking r = 10mm) l= a2 x h / rπ 2

l= 152 x 105 / 3.142 x 102 l=75mmLength of raw material will vary depending on raw material diameter/ radius

Results:

Skill for getting square bar by forging is acquired.

Applications:

Used in industry for making simple components by forging.

Remarks :





To obtain a Hexagonal Bar from Round Rod by Forging

Aim:To obtain a hexagonal bar from round rod by forging

Tools required:

Anvil, sledge rammer, round tong, swage, flatter, steel scale.

Operations:

Heating(using LPG fired furnace), hammering, drawing

Precautions:



Procedure:



Flatten the opposite face with the help of flatter by placing it on the anvil


The required model is thus obtained.



Diagram:

ROUND MILD STEEL *length can vary from 70-75mm/ diameter can vary from 18-20mm

HEXAGONAL BAR

*the length can vary from 90-110 mm

Calculations:

To find the length of raw material required for forging to hexagon

Consider the right angle triangle Area of triangle= ½ x base x height By Pythagoras theorem : a2=h2 + (a/2)2


*

*


h2=3 x a2/4 h= (3)1/2 x a /2Therefore area of triangle= ½ x a x (3)1/2 x a /2 = (3)1/2 x a2 / 4This is for one side but hexagon consists of 6 sides i.e 6 x (3)1/2 x a2 / 4

Let a= side of the finished hexagon = 10mm h= length of the finished hexagon = 90 mm

Volume of the finished hexagon = 6 x (3)1/2 x a2 / 4 x h = 23382 mm3

Volume of the raw material [ MS round dia=20mm]= Assuming no scaling lossesVolume of the finished hexagon = volume of the raw material

23382= rπ 2 l (Taking r = 10mm)Therefore l = 23382 / rπ 2

l = 75 mmLength of raw material will vary depending on raw material diameter/ radius.

Results:

Skill for getting hexagonal bar by forging is acquired

Applications:


Remarks :





To obtain Gib Head Key from a given Round Rod by Forging

Aim:

To obtain a Gib head key from round rod by forging

Tools required:

Anvil, sledge hammer, flat tong, chipping tool, flatter, steel scale.

Operations:

Heating(using LPG fired furnace), neck forming, hammering, drawing

Precautions:



Procedure:



Flatten the all face with the help of flatter as per drawng by placing it on the anvil.

Finish sides as per dimensions.




Diagram:

ROUND MILD STEEL *length can vary from 70-75mm/ diameter can vary from 18-20mm

*length can vary from 95-100mm.other dimensions are approximate

Results:

Skill for getting Gib head key from round by forging is acquired

Applications:


Remarks :



*

*

*


SAND TESTING

Importance of sand test:

Important property of mould sand is that it should produce a sound casting. To achieve

this, sand should posses following desired properties.

Property of moulding sand:

1. Refractoriness: it is that property of moulding sand which enables it to withstand

high temperature of molten metal without fusing.

2. Permeability: It is that property of sand which allows the gases and steam to escape

through, heater.

3. Flowabilty: It is that property of sand due to which it flows during ramming to all

portions of the moulding flask, packs properly around the pattern to acquire the

desired shape

4. Adhesiveness: It is that property of sand due to which capable of adhering to surface

of the other materials

5. Cohesiveness: It is that property of sand due to which its rammed particles bind

together firmly show that when the pattern is withdrawn from the mould ,with out

damaging the mould surfaces and edges.

6. Collapsibility: It is that property of sand due to which sand mould automatically

collapses after solidification of castings.

7. Other Requirements:

7.1 It should be cheap and easily available

7.2 It should be reusable

7.3 It’s coefficient of expansion should be low.

7.4 It should not stick the surface of the castings.

Sand test:

Various sand tests are conducted on moulding sands to as certain its working qualities.

The Sand tests helps in controlling the sand properties during mould preparation.




Sieve Analysis of Base Sand Aim: To find the distribution of sand grains, using a set of sieves and to find average grain

fineness number (G.F.N).

Materials required:

Base sand/Silica sand

Apparatus Used:

Weighing Balance (Digital), Stop watch, sieve set, motor run sieve shaker.

Procedure:

1. Take 50/100 gm of dry sand and place it in the top sieve of series of sieves and tightened

the lid and clamp it tightly

2. Switch on the sieve shaker and start the stopwatch. After shaking the sand for 15 min

stop the sieve shaker.

3. The sand particles retained in each sieve are collected separately and weighed. These

weights are entered in the tabular column.

4. The percentage of weight retained in each sieve is calculated and entered in the tabular

column (A).

5. Multiply this weight by multiplication factor (B) of each sieve and find the total of the

product (AB).

1. Find the average grain fineness number using the formula

G.F.N= A.B/A=

Where,

AB= Sum of he percentage sand retained in the sieves and corresponding multiplier

A=Sum of the percentage of the sand retained in the sieves.



2. Plot graph of cumulative percentage of sand retain (X-Axis) V/S Sieve No (Y-Axis).

Diagram:

SEIVE SHAKER SETUP

Tabular Column:

Sl.No Sieve

No

Sieve

Size in

Micron

Weight of

sand

retained

in gm

Percentage

of sand

retained

‘A’

Multiplier

‘B’

Product

AXB

Cumulative

percentage

of sand

retained

1 16 850 10

2 22 600 20

3 30 425 30

4 44 300 40

5 60 210 50

6 100 150 70

7 160 100 100

8 200 75 140

9 300 53 200

10 PAN PAN 300

∑A = ∑AB =



Results:

The average grain fineness number (G.F.N) =

Applications:

GFN is used in foundry for preparing moulding sand.

Remarks :





To find the Amount of Clay Aim:

To determine the amount of CLAY in the given base sand (Silica sand).

Apparatus/Components required:

A Clay washer measuring jar, Mechanical stirrer, siphon tube, weighing balancening sand

from the jar to a PAN.

Procedure :

1. The sample under test (dry silica sand containing clay) is dried and then 50 gm

(W1) is poured into the jar.

2. 475 cc of distilled water and 25 cc of standard sodium hydroxide solution is poured

into the jar.

3. The jar is covered with mechanical stirrer and rotate the stirrer at about 60 rpm for

about one minute.

4. Lift the stirrer and water to the jar so that the height from the bottom of the jar is

150mm with water. Again stir for about one minute at slow speed.

5. Lift the stirrer allowed the mixture to settle for about five minutes so that silica

particle settled in the bottom and clay particles float on top of water.

6. Siphon the water about 125mm from the top.

7. Repeat the steps 4,5 and 6 about 3 to 4 times to remove all the clay particles from

the sand.

8. Take out the remaining sand



Observations & Calculation

Initial Weight of sand (W1)= 50gm

Amount of NaoH taken= 25 cc

Amount of distilled water = 475 cc

Final weight of sand = W2 gm

Percentage of clay = W1-W2/W1*100

Diagram:

CLAY CONTENT APPARATUS

Results:

The percentage of clay in the given sand =

Applications:

The clay content in the sand is used for preparing moulding sands.

Remarks :



Signature of Staff Incharge with date:Experiment No: __________ Date: ____________

To find the Compression Strength

Aim: To determine the compression strength of the given green sand containing different

amount of clay and water


Weighing Balance, Measuring Jar ,A.F.S sand rammer, Specimen tube, Universal sand tester, compression shackles.

Procedure:

The experiment may be conducted in two ways.

(a) Vary clay content in sand and keep water content constant

(b) Vary water content in sand and keep clay content constant

Weighed quantities of sand, clay& water mixed thoroughly for 3 min, this sand mixture

is transferred to the specimen tube and rammed thrice in standard A.F.S. sand rammer

so as to obtain a correct size of specimen ( 50 mm length and 50 mm diameter) remove

the specimen from the tube using strippers post. Place the specimen between

compression shackles of the universal sand tester. Rotate the hand wheel for applying

the load on the specimen. After breaking the specimen note down the reading from the

dial gauge of the universal sand tester. This gives the compression strength of the sand

mix. Repeat the above procedure for specimens containing various percentage of clay

and water.



Diagram

UNIVERSAL SAND TESTER

SAND RAMMER

COMPRESSION TEST



Graph to be plotted/ Nature of Graph

1. Compression strength Vs Percentage of clay content when moisture is constant

2. Compression Strength Vs Percentage of moisture when the clay content constant

Tabular Column:

Sl.No Sand Moisture Clay Compression

Strength

( gm / cm2 )

% of

Weight

Weight

in

grams

% of

weight

Weight

in

grams

% of

weight

Weight

in

grams

Results:

The compression strength of given sand =

Applications:

The value of compression strength of sand mixture is useful in preparing sand green moulds.

Remarks :





To find the Shear Strength Aim:To determine the shear strength of the given green sand containing different amount of

clay and moisture.


Weighing Balance, Measuring Jar, A.F.S sand rammer, Specimen tube, Universal sand tester,

shear shackles

Procedure :


a. Vary clay content in sand and keep water content constant

b. Vary water content in sand and keep clay content constant

Weighed quantities of sand, clay& water mixed thoroughly for 3 min, this sand mixture

is transferred to the specimen tube and rammed thrice in standard A.F.S. sand rammer

so as to obtain a correct size of specimen ( 50 mm length and 50 mm diameter) remove

the specimen from the tube using strippers post. Place the specimen between shear

shackles of the universal sand tester. Rotate the hand wheel for applying the load on the

specimen. After breaking the specimen note down the reading from the dial gauge of

the universal sand tester. This gives the shear strength of the sand mix. Repeat the

above procedure for specimens containing various percentage of clay and water.



Diagram:

SHEAR TEST

Graph to be plotted/Nature of Graph

Shear strength Vs Percentage of clay content when moisture is constant

Shear Strength Vs Percentage of moisture when the clay content constant

Tabular Column:

Sl.No Sand Moisture Clay Shear

Strength

( gm /

cm2 )

% of

Weight

Weight

in

grams

% of

weight

Weight

in

grams

% of

weight

Weight

in

grams



Results:

The shear strength of given sand =

Applications:

The value of shear strength of sand mixture is useful in preparing sand green moulds.

Remarks :





To find the effect of water and clay on the permeability of green sand

Aim:To determine the effect of water and clay on the permeability of green sand

Apparatus required:

Weighing balance, A.F.S sand rammer, Specimen Tube, permeability tester, stop watch.

Procedure:


(a). Vary clay content in sand and keep water content constant

(b). Vary water content in sand and keep clay content constant

Weighed quantities of sand, clay& water mixed thoroughly for 3 min, this sand mixture is

transferred to the specimen tube and rammed thrice in standard A.F.S. sand rammer so as

to obtain a correct size of specimen ( 50 mm length and 50 mm diameter). Place the

specimen with the tube by inverting on the rubber pad of the permeability tester. Collect

2000 CC air in bell jar. By keeping valve in close position note down the monometer

reading and pass the air through the specimen. Soon after air passing, start the stop clock

and once again take the monometer reading. Note down the time to pass 2000 CC of air

completely through the specimen and the air pressure. Substitute the values in the

following formula and find the permeability.

Permeability No. PN = VH PATV = Volume of the air passing through specimen = 2000 ccH = Height of the specimen in cm = 5.08 cmP = Pressure ( Final-Initial) reading from monometer in grams per square cmA = Cross sectional Area of the specimen = Pd2/4

T = Time taken to pass 2000 CC of air through the specimen in minutes.



Compare the values with standard values graduated on the permeability meter.

Diagram:

PERMEABILITY TESTER

Graph to be plotted/Nature of Graph

Plot the following GraphsPermeability number v/s % of clayPermeability number v/s moisture content

Tabular Column:

Si.

No

Sand Moisture Clay Pressure

in gm / cm2

Time

T

in min

Permeability

% Weight

in gms

%

of

Wt

Wt

in

gms

% of

Wt

Wt in

gms

Initial

Read

ing

Final

Read

ing

Fin

Iin

Indi-

-cated

Calcu-

-lated



Results:

The permeability number of sand mixture=

Applications:

Permeability number is useful in preparing green sand moulds

Remarks :





To find the parentage of moisture in green sandAim:

To determine the percentage of moisture in the green sand

Apparatus required:

Rapid Moisture Teller

Procedure:

Weigh 16 gms of sand using the balance and keep it in the sand chamber of the moisture

teller. Take one spoon of calcium carbide crystals and transfer it to carbide chamber in the

moisture teller. Close the gap and tighten the cap with locking screw. Mix the carbide and

sand by shaking the moisture teller. The following chemical reaction take place in the

moisture teller

CaC2 + H2O = C2 H2 + CaO

The acetylene (C2 H2 ) gas generated creates the pressure which is directly calibrated to

percentage of moisture in the green sand. The pressure indicated in the pressure gauge

gives directly moisture content in the green sand.



Diagram:

MOISTURE TELLER

Results:

The percentage of moisture in sand=

Applications:

Percentage of moisture value is useful in preparing green sand moulds

Remarks :






To find the tensile strength of the core sandAim:

To determine the tensile strength of the core sand.

Apparatus required:

Universal Sand Testing Machine, Tensile test shackles, Sand Rammer, Specimen Tube, and

Heating Oven.

Procedure:

Mix silica sand ( 80 %) , Core Oil ( 15 % ), Clay ( 5 % ) thoroughly. Transfer this sand

mixer to specimen tube and ram with A.F.S sand rammer ( Give 8 to 10 strokes). Keep the

specimen in the oven along with the specimen tube and bake it for about 30 minutes at

150 C and take this specimen out from the oven and cool it. Fix the tensile test shackles to

universal sand tester and fix the sand specimen to shackles. Apply load by rotating the

hand wheel till the specimen breaks. Note down the core sand tensile strength in the gauge

provided in the universe sand tester.

Diagram:

TENSILE TEST PIECE

Results:

The tensile strength of core sand =



Applications:

The value of tensile strength is useful in preparing core sand.

Remarks :





To find the bending strength of the Moulding sandAim:

To determine the bending strength of the moulding sand

Apparatus required:Specimen tube, oven, AFS sand rammer universal sand tester,weighing balance.

Procedure: Prepare sand using 80% of silica sand 15% of core oil and 5% of clay fill up this

mixture to the specimen tube and ram it for about 8 to 10 times using AFS sand rammer.

Keep the specimen tube inside the heating oven and bake the specimen from the oven 30

min at temp of 150 deg C after baking take out the specimen from the oven and cool it. Fix

the bending shackles to universal sand tester and fix the specimen. Apply load by rotating

hand wheel till the specimen brakes. Note down the bending strength from the dial gauge.

Diagram:

TRANSVERSE STRENGTH TEST PIECE

Results:

The bending strength of core sand =



Applications:

The bending strength value is used in dry sand moulds.

Remarks :





To find the sand mould hardness

Aim:To determine the sand mould hardness

Apparatus required:Specimen tube, oven, AFS sand rammer universal sand tester,weighing balance.

Procedure: The mould harness test performs the indentation test on moulds ,the tester resembles a

dial indicator. It has a spring loaded plunger with a ball end. The tester is pressed against

the mould at the ball end. Due to opposition of the penetration the dial indicator shows the

hardness valve of the mould.

Diagram:

Results:

Mould hardness =



Applications:

Mould hardness number is useful in preparing sand moulds.

Remarks :





To find the sand core hardness

Aim:To determine the sand core hardness of the given core.

Apparatus required:core and core hardness tester

Procedure: The core hardness test performs the scratch test on cores.

The resembles a dial indicator it has a spring loaded plunger with a sharp

wheel end by pressing and scratching on core at the wheel end the dial gauge

works with resistance of the core and dial gauge shows the hardness valve of the core.

Diagram:

CORE HARDNESS TESTER

Results:

Core hardness=



Applications:

The hardness of core is useful in preparing cores.

Remarks :




Probable viva questions:

Sand Testing:

1. Define grain fineness number (GFN)

2. What is the importance of GFN in respect of sand properties?

3. What is the effect of moisture in sand?

4. What is the effect of clay on properties of sand?

5. What is clay ? How it is defined?

6. Describe the parts of Universal sand Testing Machine

7. What is the effect of moisture and clay content on sand properties (Compression

and Shear Strength?)

8. What is permeability and how it affects the mould and casting?

9. What are the different types of shackles used in sand testing?

Moulding:

1. What are the constituents of moulding sand?

2. What is the difference between reverse sand and sea sand?

3. What are the tools used in moulding work and its function?

4. Name the type of patterns used in moulding work?

5. What is cope and what is drag?

6. Why Clamps are used in moulding?

7. What machines are used in machine moulding?

8. What are the differences in moulds made by hand and made by moulding machines?

9. What is runner and riser and its function?

10. What is meant by Gating System?

Forging:

1. What is hot working and cold working?

2. What are the tools are used in forging and its application

3. What is the forging temperature of mild steel?

4. What is die forging and upsetting?

5. What are the difference between hand forging and Machine forging?



General:

1. Name of the few casting used in Machine tools and automobiles

2. What are the furnaces used in melting cast iron and steel.

3. What are defects in castings and how do overcome them

4. Draw the layout of foundry

5. What the safety equipments used in Foundry?

References:

1. Foundry technology by O.P. Khanna.2. “Principles of metal casting”, Rechard W. Heine, Carl R. LoperJr.,Philip C. Rosenthal,

Tata McGraw Hill Education Private Limited Ed.1976.

Dayananda Sagar College of EngineeringMechanical Engineering Department

Bengaluru-560078

FOUNDRY AND FORGINGLABORATORY (MEL68)

PROBABLE/SUGGESTED QUESTION BANK

(Please include Question Bank of respective Lab here)

Appendix (If any)



DAYANANDA SAGAR COLLEGE OF ENGINEERINGDEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING, BENGALURU-560078

CONTINUAL EVALUATION FORMAT

CONTROL SYSTEMS LABORATORY (10EEL48)

(Academic Year)

Semester /Section : Batch :SNo.

USN student Name Expt. No: 1 Expt. No:2 Expt. No:3 Expt. No:4Date: Date: Date: Date:Viva(05)

Record(10)

Total(15)

viva(05)

Record(10)

Total(15)

Viva(05)

Record(10)

Total(15)

Viva(05)

Record(10)

Total(15)

Faculty Signature With Date

Name of the Faculty Incharge (1)

(2)

(3)Note: (1) Viva questions to be asked w.r.t the current experiment of the particular week. (2) The above same page format is used for next set of experiments i.e. 5, 6,….expts.



(3) Separate sheets must be used for different batches.DAYANANDA SAGAR COLLEGE OF ENGINEERING

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING, BENGALURU-560078

FINAL IA MARKS FORMAT

CONTROL SYSTEMS LABORATORY (10EEL68)

Year:

Semester /Section : Batch :

SN USN Name Of The Student

Continual Evaluation

Marks (15)

IA Test Marks (10)

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