BANNARI AMMAN INSTITUTE OF TECHNOLOGY

SATHYAMANGALAM
Department of aeronautical engineering
Class
Subject Code
Subject
Prepared By
Unit No
Lesson No
Time
1.
2.

S4/ Aero
11A404
Manufacturing Technology
U.Sivasathya
1
1/5
75 mins
Content List: Introduction to manufacturing - Casting process Green sand
mould preparation
Skills Addressed: Reading, Questioning, Drawing mind map, Summarizing,
Discussion, Expressing orally and in writing.

3.

Objectives:
To understand classification of manufacturing processes, basics of
casting process.
To learn about sand mould preparation.

4.

Lesson Links:
Different types of casting process
Relative merits and demerits
Alpha Breathing : (2 Mins)
The three steps for alpha breathing are
Breathe in
Breathe out
Hold
(Repeat the three steps for 8 times)
Evocation : (5 mins )
Evocation needed for the present class requires:

5.

6.

PPT about casting process (Annexure 1).

7.

videos (Annexure 2)
Introduction:( 20-25 mins)
There are many different metal casting processes used in the
manufacture of parts. Two main branches of methods can be distinguished by
the basic nature of the mold they employ. There is expendable mold casting
and permanent mold casting. As the name implies, expendable molds are
used for only one metal casting while permanent molds are used for many.

When considering manufacturing processes, there are advantages and

disadvantages to both.
Expendable Mold
Can produce one metal
casting only
Made of sand, plaster, or
other similar material
Binders used to help
material hold its form
Mold that metal solidifies
in must be destroyed to
remove casting
More intricate geometries
are possible for casting

Permanent Mold
Can manufacture many metal
castings
Usually made of metal or
sometimes a refractory
ceramic
Mold has sections that can
open or close, permitting
removal of the casting
Need to open mold limits part
shapes

Green sand is an aggregate of sand, bentonite clay, pulverized

coal and water. Its principal use is in making molds for metal casting. The
largest portion of the aggregate is always sand, which can be either silica.
There are many recipes for the proportion of clay, but they all strike different
balances between moldability, surface finish, and ability of the hot molten
metal to degas. The coal, typically referred to in foundries as sea-coal, which
is present at a ratio of less than 5%, partially combusts in the surface of the
molten metal leading to off gassing of organic vapors.
Sand casting is one of the earliest forms of casting practiced due to the
simplicity of materials involved. It still remains one of the cheapest ways to
cast metals because of that same simplicity. Other methods of casting, such
as those using shell molds, boast higher quality of surface finish, but higher
cost.
Green sand (like other casting sands) is usually housed in what casters
refer to as flasks, which are nothing other than boxes without a bottom or lid.
The box is split into two halves which are stacked together in use. The halves
are referred to as the top (cope) and bottom (drag) flask respectively.
Green sand is not green in color, but "green" in the sense that it is used
in a wet state (akin to green wood). According to the Cast Metals Federation
website, an alternative casting method is to heat-dry the molded sand before
pouring the molten metal. This dry sand casting process results in a more
rigid mold better suited to heavier castings.

8.

Brain Activation: (2 mins)

9.

Any one of the following activities like

Right brain activities
Solving puzzles
Brain GYM
Optical Illusions
Perpetual calendar recalling
Survey and Reading by students: (15-18 mins)
Phillip F. Ostwald and Jairo Munoz, Manufacturing Processes and Systems,
9th Edition, Wiley India, 2008, Pages 1 5
Pages 77-79

Headings to be covered:
Manufacturing process:
The manufacturing Process mainly encompasses

1) Product design - Market expectation & As per standards

2) Selection of raw material - Low cost and easily available

3) Deciding the sequence of operation

Metal casting process:

Metal casting is the old manufacturing process used for converting molten
raw materials in to finished products.
The process of producing castings may be classified into

1) Pattern making

2) Mould and core making

3) Melting and casting

4) Fettling

5) Testing

The process of producing castings may be classified into

1) Pattern making

2) Mould and core making

3) Melting and casting

4) Fettling
5) Testing

10.

Discussion: ( 9 mins)
The students will be asked to discuss the relevant topic among their
team/other team/Faculty. The students those who have not taken part will be
noted and kindle them to do.

11.

Mind Map: (5-7 mins)

12.

Summary: (5 mins)

1. Manufacturing is the application of application of physical and chemical

processes to alter the geometry, properties or appearance of a given starting
material to make parts or products.
2. Casting is a process in which molten metal flows by gravity or other force
into a mould where it solidifies in the shape of mould cavity.
3. Mould contains a cavity whose geometry determines the shape of the cast
part. The actual size and shape of the cavity may be slightly oversized to
allow for shrinkage that occurs in the metal during solidification and cooling
4. Green sand is uncured sand that uses clay and water for bonding. The term
green means that the mould, which is tempered with water, is not dried or
baked

13.

14.

Green sand mould consists of silica sands bonded with a bentonite-water

mixture
Gazing/Rote memory: (2 mins)
A long and fixed look at the Mind map by the students
before doing the presentation.
Assessment:
MCQ Questions:
1) Sand casting uses a
(a) metal mould
(c) ceramic mould

(b) sand mould

(d) plaster mould

2) A solid pattern
a) It is made of one piece
b) It is the simplest type of pattern
c) It is useful for low production run.
3) Gated pattern is suitable for
a) small pattern
c) a & b

b) large pattern
d) none of the above

4) Moulds are prepared by using

a) Solid patters

b) Split pattern

c) Sweep pattern

d) None of the above

5) Patterns are used to make

a) mould

b) core

c) a & b

d) none of the above

Higher order Questions:

1. What do you mean by manufacturing?
2. How manufacturing processes are classified?
3. Define casting process
4. Mention the sand casting production sequence
5. How moulding processes are classified?
15.

Learning outcomes:
Classification of manufacturing processes
Introduction to casting process
Green sand mould preparation.