F & F Lab Manual

FOUNDRY AND FORGING LAB MANUAL
Department of Mechanical Engineering
M.S Engineering College
Bengaluru-562110
NAAC ACCREDITED INSTITUTE
FOUNDRY AND FORGING LAB
SUBJECT CODE: 18MEL38
Compiled By : Mr. Bhaktavatsala H R
MSEC. Bangalore Page 1

Syllabus
Foundry and Forging lab

[AS PER CHOICE BASED CREDIT SYSTEM (CBCS) SCHEME]
(Common to ME/IP/IM/AU/MA/AE)
Subject
Code 15MEL57
Teaching Hours / Week IA Marks 20
Lecture Tutorial Practical Exam Marks 80
01 00 02 Exam Hours 03
CREDITS – 02
COURSE OBJECTIVES:
1. To provide an insight into different sand preparation and foundry equipment’s.

2. To provide an insight into different forging tools and equipment’s.
3. To provide training to students to enhance their practical skills.
4. To practically demonstrate precautions to be taken during casting and hot working.
5. To develop team qualities and ethical principles.
COURSE OUTCOMES
Students will be able to
1. Demonstrate various skills of sand preparation, molding.

2. Demonstrate various skills of forging operations.
3. Work as a team keeping up ethical principles.
Part-A
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. Sieve Analysis to find Grain Fineness Number (GFN) of Base Sand
4. Clay content determination in Base Sand.

PART B
Foundry Practice
1. Use of foundry tools and other equipment’s.

2. Preparation of molding sand mixture.
3. Preparation of green sand moulds using two molding boxes kept ready for pouring.
 Using patterns (Single piece pattern and Split pattern)
 Without patterns.
 Incorporating core in the mould. (Core boxes).
 Preparation of one casting (Aluminium or cast iron-Demonstration only)
PART C
Forging Operations
1. Use of forging tools and other equipment’s

 Calculation of length of the raw material required to prepare the model considering
scale loss.
 Preparing minimum three forged models involving upsetting, drawing and bending
operations.
 Demonstration of forging model using Power Hammer.
Scheme of Examination:
One question is to be set from Part-A : 15 marks
One question is to be set from either Part-B or Part –C : 35 marks
Calculation of length of the raw material required for forging model is compulsory irrespective
of the student preparing part-B or part-C model
Calculation of length for Forging :10 Marks
Viva-Voce : 20marks.
Total : 80 marks.

Sl.No. CONTENTS
Part-A
I Testing of Moulding sand and Core sand
1 Compression strength test

2 Shear strength test
3 Tensile strength test
4 Bending strength test
5 Permeability test
6 Mould hardness test
7 Grain fineness number test
8 Clay content test
9 Moisture content test
Part-B
II Foundry Practice
10 Foundry tools and equipments

11 Foundry model-I
12 Foundry model-II
13 Foundry model-III
14 Foundry model-IV
Part –C
III Forging Operations
15 Forging tools and equipments

16 Forging model-I
17 Forging model-II
18 Forging model-III
19 Forging model-IV

Experiment No. 1
MOISTURE CONTENT TEST
Fig: 1 Infrared light source.
Calculations:
Initial weight of sand + Water (Before drying) = W1 = ------------------(gms)
Weight of mixture after 5 minutes drying = W2 = ------------------(gms)
Weight of dry sand (constant weight) = W3 = ------------------(gms)
Moisture present in the sample = W1-W3 = ------------------ (gms)
Percentage of water content = (W1-W3)/W1 * 100 = ------------------%

Aim: To determine the moisture content present in the prepared sand mixture of given
base sand.
Apparatus: Physical balance with weights, infra red heating lamp with pan
Materials Required: Base sand, Water.
Theory: Dry sand as such will not have bonding strength. Binders give strength to the
moulding sand so that it can shape in the mould cavity. Clay binders are most commonly
used for bonding moulding sands. Addition of clay alone to the base sand will not give the
binding property of the sand. Hence to get the binding actions water is added to the sand. The
water added to the sand and the clay-sand mixture develops strength and plasticity. The
amount of water may vary from 1.50-8%.
Water added to the sand mixture partly gets absorbed by the clay and the remaining will stay
free in the spaces available between the grains. The absorbed water is responsible for
developing proper binding and green strength. Too little quantity of water will not develop
proper strength and plasticity; if excess water is present then it increases plasticity. The
addition of water has great influence on different properties of sand such as permeability,
strength and moulding characteristics. Hence control should exercise in deciding the quantity
of water that is added. So, it is very important to know the level of water present in the sand
mixture.
Procedure:
1. Add unknown quantity of water to the base sand and thoroughly mix it.
2. Weigh 50 grams of the sand sample and transfer the same on to a pan.
3. Place the pan under infrared light source as shown in the Fig.1.
4. Switch on the infrared light source and heat the mixture for a period of 5 minutes.
5. Switch off the lam-p and cool the mixture to room temperature.
6. Weigh the dry sand and note down the readings.
7. Repeat the above procedure till a constant weight of sand is obtained after complete
evaporation of water.
8. The percentage of water is calculated from the difference in the weights of the original
moist sand and the final dried sample.
Result: The percentage of moisture in the given sand is=…………….

Experiment No. 2
GRAIN FINENESS NUMBER TEST
Sl. Sieve no. Weight of sand Percentage of Multiplier Product

No. (P) retained (Q) in sand retained ® (S) (R*S)
gms in each sieve
X= ∑ R Y=∑(R*S)
Grain Fineness Number (GFN) = Y/R
Graph:
1. Percentage of sand retained on Y-axis v/s sieve number on X-axis.
2. Percentage of cumulative sand retained in each sieve on Y-axis v/s sieve number on
X-axis.

Aim: To determine the average Grain Fineness Number (GFN) of the given moulding sand.
Apparatus: Digital balance Sieve shaker equipment with a set of sieves, stop watch.
Material required: Silica Sand
Theory: The sand is a mixture of grains having different shapes such as round, angular,
subangaular etc. Base sand is relatively free from any additives or binders. The shape and
size of the grains play an important role in the foundry practice. Generally fine (smooth)
grain sand is preferred for smooth surface finish, but in addition the permeability will be
poor. Coarse grain sands are employed in applications where the surface of the casting is
rough. So the shape size of the sand grains affects the permeability property of the foundry
sand. So, selection of the particular grade of foundry sand is important in foundries.
The size of the sand grains is designated by the Grain Fineness Number (GFN). This number
indicates the average size of the grains of sand present in the given sample. The test for the
fineness is conducted by screening sand grains by means of a set of standard sieves that are
graded and numbered according to the fineness of their mesh as shown in the Fig. 2.
The number embossed on each sieve gives the bore size through which sand grains pass or
retained in it. For e.g. sieve no. 16 means that in a 1 inch square area of a sieve, there are 16
X 16 holes in each row and column.
Procedure:
1. The sieve set is stacked or arranged with the top sieve being the coarsest and the bottom
most being the finest of all the sieves. The sieves between the top and the bottom are
placed in the order of fineness.
2. 50 gms of dry sand whose fineness is to be found out is placed on the top sieve and is
covered with a lid and secured to the vibrator with a rubber band.
3. The sieves are then vibrated for 15 min and then the motor is switched off.
4. The sand particles retained in each of the sieves is collected separately and then weighed
precisely using a digital balance.
5. The corresponding weight of each individual sieves are then entered in the tabular
column.
6. The percentage weight retained in each of the sieve is calculated.
7. This quantity is multiplied by the multiplier for each sieve.
8. The results are entered in the tabular column and the GFN is found by using the
appropriate formula.
Result: The Grain Fineness Number (GFN) for the given silica sand is=…………………

Experiment No. 3
CLAY CONTENT TEST
Fig: 3. Clay contest test apparatus
Calculations:
Initial weight of sand = W1 = ------------------(gms)

Weight of dry sand = W2 = ------------------(gms)
Clay content present in the sample =W1-W2 = ------------------(gms)
Percentage of clay = (W1-W2)/W1 * 100 = ------------------%

Aim: To determine the percentage of clay in the given base sand sample
Apparatus: Wash bottle, Mechanical stirrer, Siphon tube, stop watch, drying oven
Material required: Base Sand, Sodium hydroxide pallets, Distilled water
Theory: Clay is a mineral which is used as a binder in the moulding sand. The amount of
clay present in the moulding sand varies from 4 to 8%. Higher clay contents give better
strength to the mould, but it decreases the permeability. Clay consists of two ingredients.
a. Fine silt
b. True clay
Fine silt has no binding power whereas true clay imparts the necessary bonding strength to
the moulding sand, thereby the mould does not loose its shape after ramming.
The base sand used should preferably be free from clay. However, sometimes in the base
sand available from river and sea bed will contain small quantities of clay. In such cases, if it
is essential to determine the amount of clay present in such sand samples. This will help us to
decide the amount of clay to be added while mixing the moulding sand.
Procedure:
a. Preparation of Alkaline Solutions:
1. Weigh 30 gms of sodium hydroxide.
2. Dissolve it in 50 cc of distilled water and make the volume to 1000 cc by adding distilled
water.
b. Test Procedure:
1. Take dried sample of 50 gms in a glass jar and fill way with water
2. Add 10 cc of alkaline solution of sodium hydroxide to the above mentioned solution of
sand and water.
3. Fill up the glass jar up to 250 cc mark as shown in Fig. 3.
4. Keep the glass jar under a mechanical stirrer and switch on the power.
5. The contents in the mechanical stirrer are mixed thoroughly for 10 minutes in the stirrer.
6. The stirrer is switched off after 10 minutes and the glass bottle is placed stationery on a
table.
7. The sand particles are allowed to settle down at the bottom of the glass bottle.
8. By using a siphon, remove about 200 cc of water from the glass bottle.
9. Add 10 cc of sodium hydroxide again and repeat the same procedure as in steps 5-8.
10. Transfer the washed sand with water into the sieve and dry completely under infrared
source or in an oven
11. Allow it to cool and weigh the same
12. The reading of the final weight is tabulated and the percentage of clay in the given
sample of base sand is found out.
Result: The percentage of clay in the given sample of sand is=……………….

Experiment No. 4
COMPRESSION STRENGTH TEST
Tabular Column:
a. Water percentage constant =
Sl. Percentage of Percentage of Percentage of Compression

No. sand clay water strength
gms/cm2

Aim: To determine the green compression strength of the give foundry sand sample
containing different amounts of clay and moisture.
Apparatus: Measuring jar, AFS Rammer, Specimen tube, Universal Sand Testing Machine,
Digital balance.
Material required: Base sand, Clay, Water
Theory: Periodic tests are necessary to check the quality of foundry sand; compression
strength test is one of them. Silica sand, clay, water and additives are the basic constituents of
the foundry sand. Clay imparts the necessary strength to the moulding sand when mixed with
water.
The green compression strength of foundry sand is the maximum compressive strength a
mixture is capable of developing when it is moist (wet).
Procedure:
2. The experiment is carried out in two stages.
a. In the first stage vary the clay percentage and keep the water percentage
constant.
b. In the second stage vary the water percentage and keep the clay percentage
constant.
3. Weighed quantity of sand and clay is mixed thoroughly.
4. To this mixture calculated quantity of water is added and again mixed thoroughly to get a
homogeneous mixture.
5. The weight of this sand mixture is taken to be between 160-200 grams.
6. This sand mixture is transferred to the specimen tube and is rammed thrice in the rammer
as shown in the Fig. 4.
7. Observe the position of the sand rammer by using the tolerance limit provided in the
frame of the rammer.
a. If the top end of the rammer is above the limit, reduce the weight of the sand
mixture and prepare the new specimen.
b. If the top end of the rammer lies below the limit, increase the weight of the sand
c. If the top end of the rammer lies within the tolerance limit
8. The specimen as per the standards should be of the dimensions confirming to a diameter
and height of 5.08 cms.
9. The prepared standard sample removed by using a stripper.
10. This sample is placed between the compression shackles in the Universal Sand Testing
Machine.
11. The handle of the sand testing machine is rotated slowly.
12. The hydraulic pressure is applied continuously till the specimen breaks.
13. On the universal sand testing machine (Fig 5,1) the dial for indicating the compression
strength is read and the readings are recorded.
14. The same procedure is followed for the second case (Part. B) of the experiment.

b.Clay content constant=
Sl. No. Percentage Percentage Percentage Compression

of sand of clay of water strength
gms/cm2
Graphs:
1. Plot the graph of compression strength (Y-axis) v/s Percentage of moisture on X-axis.
2. Plot the graph of compression strength (Y-axis) v/s Percentage of clay on X-axis.
Result: The compression strength of the given sand mixture is =………………

Experiment No. 5
SHEAR STRENGTH TEST

Aim: To determine the green shear strength of the given foundry sand sample containing
different amounts of clay and moisture.
Apparatus: Measuring jar, AFS Rammer, Specimen tube, Universal Sand Testing Machine,
Digital balance, shear shackles.
Material required: Base sand, Clay, Water
Theory: Shear strength is the ability of the sand particles to resist the shear forces and retain
the shape. It is necessary for the moulding sand to possess adequate strength to enable the
preparation of the mould. In addition it should retain the strength during pouring of the
molten metal and also during solidification. Under the action of the shear stress rupture
usually occurs parallel to the axis of the specimen.
Procedure:
a. In the first stage vary the clay percentage and keep the water percentage constant.
b. In the second stage vary the water percentage and keep the clay percentage
constant.
5. This sand mixture is transferred to the specimen tube and is rammed thrice in the rammer
as shown in the Fig. 5.
9. This sample is placed between the shear shackles (Fig.5.2) in the Universal Sand Testing
Machine.
10. The handle of the sand testing machine is rotated slowly.
11. The hydraulic pressure is applied continuously till the specimen breaks.
12. On the universal sand testing machine (Fig 5,1), the dial for indicating the shear strength
is read and the readings are recorded.
13. The same procedure is followed for the second case (Part. B) of the experiment.

Tabular column:
a. Water percentage constant =
Sl. No. Percentage Percentage Percentage Shear

of sand of clay water strength
b. Clay content constant=
Sl. No. Percentage Percentage Percentage Shear

of sand of clay water strength
Graph:
1. Plot the graph of shear strength (Y-axis) v/s Percentage of moisture on X-axis.
2. Plot the graph of shear strength (Y-axis) v/s Percentage of clay on X-axis.
Result: The Shear strength of the given sand mixture is =…………….

Experiment No. 6
TENSILE STRENGTH TEST FOR CORE SAND
Tabular column:
Sl. Percentage of Percentage of Tensile

No. sand binder strength in
gms/cm2

Aim: To determine the tensile strength of the given foundry core bonded with core oil
binder.
Apparatus: Split core box, Sand rammer, Oven, Tensile shackles, Universal Sand Testing
Machine.
Material required: Base sand, Core oils
Theory: Cores are made of usually sand, which are placed into a mould cavity to form the
interior surface of the castings. Thus the void space between the core and the mould cavity is
what eventually the casting becomes.
A core is made using core sand which is a mixture of silica and core oil. Core oil is used as
the binder, which hardens with the addition of heat.
The cores are made in core boxes and are made either in one or two parts. Split core box is
commonly used and is made in two parts which can be joined together by means of pins.
After making the core it is baked in the ovens at a temperature of 250 C. During baking, the
core oil undergoes polymerization reaction which enables the cores to become hard and
strong.
The cores are placed in the mould cavity and the molten metal is poured in the cavity. When
molten metal begins to cool, it contracts near the inside and the outside radius. Because of the
contraction in the inner radius, the core sand will be pulled outwards which results in a
tensile load around the core. Thus measurement of the tensile strength of the core sand is
very important.
Procedure:
1. Weigh the calculated quantity of sand and binder and mix them thoroughly (sand
percentage is kept constant and the percentage of binder is varied)
2. The mixed sand is then transferred to the core box assembly.
3. The core box is kept under the sand rammer and then rammed.
4. After cleaning the top surface of the specimen, the core box is slowly removed such that
specimen remains on the flat plate.
5. The specimen along with the plate is kept in the oven for about 30 minutes at a
temperature of 250 C.
6. The specimen is then taken out of the furnace and then cooled to room temperature.
7. The tensile testing shackles are shown in figure 6 are fitted on to the universal sand
testing machine.
8. The hardened specimen is then [placed in between the shackles.
9. Load is applied gradually by turning the hand wheel of the testing machine till the
specimen breaks.
10. The strength is noted down from the appropriate scale on the testing machine.
11. The experiment is repeated for different percentages of the binder and the results are
tabulated.
Graph:
1. Plot the graph of tensile strength (Y-axis) v/s Percentage binder on X-axis.
Result: The tensile strength of the given core sand sample is -------- gm/cm2.

Experiment No. 7
BENDING STRENGTH TEST FOR CORE SAND
Tabular column:
Sl. No. Percentage Percentage Bending

sand binder strength in
gms/cm2

Aim: To determine the bending strength of the given foundry core sand bonded with core oil
binder.
Apparatus: Split core box, Sand rammer, Oven, bending shackles, Universal Sand Testing
Machine.
Material required: Base sand, Core oil.
Theory: Cores are made of usually sand, which are placed into a mould cavity to form the
interior surface of the castings. Thus the void space between the core and the mould cavity is
what eventually the casting becomes.
A core is made using core sand which is a mixture of silica and core oil. Core oil is used as
the binder, which hardens with the addition of heat.
The cores are made in core boxes and are made either in one or two parts. Split core box is
commonly used and is made in two parts which can be joined together by means of pins.
After making the core it is baked in the ovens at a temperature of 250 C. During baking, the
core oil undergoes polymerization reaction which enables the cores to become hard and
strong.
The cores are placed in the mould cavity and the molten metal is poured in the cavity. When
molten metal begins to cool, it induces bending forces on the core due to buoyancy effect.
Thus the knowledge of bending strength is very much essential.
Procedure:
1. Weigh the calculated quantity of sand and binder and mix them thoroughly (sand
percentage is kept constant and the percentage of binder is varied)
2. The mixed sand is then transferred to the core box assembly.
3. The core box is kept under the sand rammer and then rammed.
4. After cleaning the top surface of the specimen, the core box is slowly removed such that
specimen remains on the flat plate.
5. The specimen along with the plate is kept in the oven for about 30 minutes at a
temperature of 250 C.
6. The specimen is then taken out of the furnace and then cooled to room temperature.
7. The bending tests shackles are shown in figure 7 are fitted on to the universal sand testing
machine.
8. The hardened specimen is then [placed in between the shackles.
9. Load is applied gradually by turning the hand wheel of the testing machine till the
specimen breaks.
10. The bending strength is noted down from the appropriate scale on the testing machine.
11. The experiment is repeated for different percentages of the binder and the results are
tabulated.
Graph:
Plot the graph of bending strength (Y-axis) v/s Percentage binder on X-axis.
Result: The bending strength of the given core sand sample is ----------- gm/cm2.

Experiment No. 8
PERMEABILITY TEST
Aim: To determine the permeability number of the given specimen for different percentages
of sand, clay and moisture.
Apparatus: Permeability Apparatus, Sand rammer, Weighing Balance, Specimen tube, Stop
match, 2000 cc measuring jar.
Material required: Base sand, Clay, Water.
Theory: The molten metal always contains dissolved gasses, which are evolved when the
metal starts solidifying. In addition to this, when the molten metal comes into contact with
the green sand (wet sand), the water present in the sand starts evaporating in the form of
vapour. Thus gases and water vapour are liberated and are released by the molten metal and
sand.
If these do not escape completely through the mould they get entrapped and form gas holes
or blow holes in the casting. The sand must be sufficiently porous to allow the gases and
water vapour to release to the surroundings. This property of sand is called permeability.
Permeability is one of the most important properties affecting the characteristic of moulds

which depends upon the grain size, grain shape, grain distribution, binder content, moisture
content and the degree of ramming.
American Foundry Society defines “Permeability is a number obtained by passing 2000 cc
of air through a standard 2” X 2” specimen under a pressure of 10 gm/cm2 for a given time in
minutes.
Procedure:
c. In the first stage vary the clay percentage and keep the water percentage constant.
d. In the second stage vary the water percentage and keep the clay percentage
constant.
5. This sand mixture is transferred to the specimen tube and is rammed thrice in the rammer.
9. Adjust the permeability set up shown in the figure 8, valve to D position and lift the air
tank and bring it to the O position.
10. Set the tank level mark to coincide with the edge of the water tank by operating to P or D
position.
11. Screw in the orifice.
12. 2000 cc of air is held in the bell jar.
13. Adjust the valve to valve to P position
14. The valve is opened and the air in the jar is forced to pass through the sand specimen and
the time taken for 2000 cc of air to pass is noted down (by using a stop watch).
15. When the specimen is impermeable no air passes through the specimen and the pressure
of air below the specimen is equal to the pressure of air coming through the orifice and
this pressure is shown in the manometer.
16. When the specimen is highly porous, the orifice discharge pressure will equal to the
atmospheric pressure or zero on the manometer.
17. A situation arises when the pressure of the air entering the specimen is equal to the
pressure of air escaping through the specimen. Thus a stabilized reading is obtained on
the manometer.
18. The time taken for 2000 cc of air to escape is noted down using the stop watch.
19. The permeability number is then calculated by using the appropriate formula

The same procedure is carried out for the part b of the experiment also.
Tabular Column:
a. Clay content is constant and Water content varying
Sl. Water % Pressure Time in Permeability no, Pn

No. minutes Calculated Indicated
b. Water content is constant and Clay content varying
Sl. Water % Pressure Time in Permeability no, Pn

No. minutes Calculated Indicated
Permeability Number Pn = VH/PAT

Where V = Volume of air passing through the specimen = 2000 cc
H = Height of the specimen
A = Area of the specimen
T = Time taken to pass 2000 cc in the specimen in minutes
P = Air pressure recorded by the manometer in gm/cm2
Result: The permeability number of the given sand sample is:

a. When the clay content is constant and Water content varying
b. When the water content is constant and clay content varying

Experiment No.9
MOULD HARDNESS TEST
Aim: To determine the mould hardness of the rammed mould.

Apparatus: Moulding sand, Rammer, Cope/Drag box, Mould hardness tester.
Theory: The degree of ramming also plays a very important role in determining various
factors like permeability, collapsibility etc. If the degree of ramming is more, then the
permeability of the sand decreases, thereby leading to variety of casting defects the most
important being blow holes.
If the degree of ramming is less, there are always chances of the mould cavity crumbling
when the molten metal is being poured. Another major defect occurring is the moulding sand
collapsing when the cope is placed over the drag.
Thus the hardness achieved by ramming the sand can be measured by a mould hardness
tester as shown in the Fig.9. This is an indentation type test.
Procedure:
1. The moulding sand is first placed in the flask and is then rammed by using a hand
rammer.
2. A mould hardness tester as shown in the figure has a spring loaded steel ball attached at
the bottom end.
3. The spring loaded steel ball is pressed on the surface of the mould.
4. The dial indicator in the meter reads the value of the hardness when the ball is pressed
against the sample.
5. Generally hand moulded moulds exhibits a hardness of 60-75 on the scale.
Result: The mould hardness given mould sample is=…………

MOULDING TOOLS AND EQUIPMENTS
Slick
Lifter
Strike off bar

FOUNDRY: SAND MOULDING
SLICK:
It is a small double-ended tool having a flat on one end and a spoon shape on the
other end as shown in the figure. This tool is also made ode of a variety of shapes. The
type most commonly obtained is the oval spoon. Slicks are commonly used for repairing
and finishing small surfaces of the mould.
LIFTER:
Lifter are made of thin sections of steel of various widths and lengths with one
end bent at right angles as shown in the adjacent fig. They are used to clean and finish the
bottom and sides of deep, narrow openings in moulds.

STRIKE OFF BAR:

The strike off bar is a piece of metal or wood with a straight edge as shown in the
fig. It is used to stickle or strike off excess sand from the mould after ramming to provide
a level surface
SHOVEL:
A shovel is used for mixing and tempering the moulding sand and for moving the
moulding sand from the pit to the flask.
Sprue pin
Mallet

Riddle
SPRUE PIN:
A sprue pin is a tapered peg pushed through the cope the joint of the mould. As
the peg is withdrawn it removes the sand, leaving an opening for the metal. This opening
is called the sprue through which the metal is poured. The sprue pin forms the riser pin as
shown in the fig.
MALLET:
A mallet is used to loosen the pattern in the mould so that it can be withdrawn
without damaging the mould.
HAND RAMMER:
A hand rammer is a wooden tool for packing or ramming the sand into the mould.
One end is called the peen, is wedge shaped and the opposite side is called as the butt,
and has a flat surface as shown in the figure. Floor rammers are similar in construction
but have long handles.
Pneumatic rammers are used in large moulds saving considerable time and labour.

Gaggers
Vent rod Draw Spike

TROWEL:
A trowel consists of a metal blade fitted with a wooden handle as shown in figure.
Trowels are employed in order to smooth or sleek over the surfaces of the moulds. A
moulder also uses them in repairing the damaged portions of the mould. The usual trowel
is rectangular in shape and has either a round or square end.
STRIKE OFF BAR:

The strike off bar is a piece of metal or wood with a straight edge as shown in the
fig. It is used to stickle or strike off excess sand from the mould after ramming to provide
a level surface.
VENT ROD:
A vent rod or wire used makes a series of small holes to permit the gases to
escape while the molten metal is being poured.
DRAW SPIKE:
The draw spike is a pointed steel rod, with a loop and end as shown in fig 11.1. It
is used to rap and draw patterns from the sand. The draw spike is used to thread on end to
engage metal parts.
GAGGERS:
Gaggers sometimes know as lifters are iron rods bent at one end or both the ends
as shown in fig 11.2. They are used for reinforcement of sand in the top part of a
moulding box, and to support the hanging bodies of sand.

SOLID PIECE PATTERN
Step by step procedure of preparing mould cavity

Model – I
PREPARATION OF A SAND MOULD USING SOLID PATTERN
Aim: To prepare a mould cavity by using a solid / single piece pattern.
Apparatus Used: Moulding Flasks, Solid / Single piece pattern, Sand Rammers, Trowel,
Leveler, Vent Road, and Moulding Sand Mixture.
Procedure (Refer Figure 11)

1. Prepare the moulding sand mixture by adding adequate amounts of clay and water to it.
2. Keep the drag on the bottom board in the inverted position.
3. Locate the centre of the drag half by drawing two diagonals.
4. Place the pattern in the center.
5. Fill the drag half of the mould flask by green sand prepared as in step 1.
6. Ram the sand by using a sand rammer to form a hard mass.
7. Strike off the excess sand a level with a leveler (Strike off bar).
8. Sprinkle parting sand on the top surface of the drag half of the mould.
9. Place the cope on the drag half of the mould.
10. Place the riser pin on the pattern centre and place the sprue pin on the drag at a
convenient distance from the pattern.
11. Now by holding the sprue and the sprue and the riser pins fill the cope with the moulding
sand and ram it properly.
12. By using a vent rod pierce the holes on the top surface of the cope half.
13. Loosen the sprue pins and remove them from the rammed portion carefully.
14. Remove the cope and place it inverted.
15. By using sand lifters remove the drag and cut in – gates and sprue base.
16. Shake the pattern by using a mallet without disturbing the mould cavity.
17. Remove the pattern carefully.
18. Clean the pattern carefully.
19. Place the cope on the drag and close the mould cavity.
Result: The mould cavity similar to the drawing specifications shown is obtained.

MODEL –II
PREPARATION OF A SAND MOULD USING SPLIT PIECE PATTERN
SPLIT PIECE PATTERN
Aim: To prepare a mould cavity by using a Split piece pattern as shown in the fig.
Apparatus Used: Moulding Flasks, Solid/ Split piece pattern, Sand Rammers, Trowel, Leveler,
Vent Rod, and Moulding Sand Mixture, bottom board.
Procedure:
1. Prepare the moulding sand mixture by adding adequate amount of clay and water to it.
2. Keep the drag on the bottom board in the inverted position.
3. Locate the centre of the drag half by drawing two diagonals.
4. Place one half of the split pattern in the centre.
5. Fill the drag half of the mould flask by green sand prepared as in step 1.
6. Ram the sand by using a sand rammer to from a hard mass.
7. Strike of the excess sand a level with a leveler (Strike off bar)
8. Sprinkle parting sand on the top surface of the drag half of the mould.
9. Place the cope on the drag half of the mould.
10. Place the cope half of the pattern on the drag half in proper alignment of the dowel pins.

11. Place the riser pin the pattern centre and place the sprue pin on the drag at a convenient
distance from the pattern.
12. Now by holding the sprue and the sprue and the riser pins fill the cope with the moulding
sand and ram it properly.
13. By using a vent rod pierce the holes on the top surface of the cope half.
14. Loosen the sprue pins and remove them from the rammed portion carefully.
15. Remove the cope and place it inverted.
16. By using sand lifters remove the drag and cut in – gates and sprue base.
17. Shake the patterns in both the halves by using a mallet without disturbing the mould
cavity.
18. Remove the patterns carefully.
19. Clean the cavities for any loose sand.
20. Place the cope on the drag and close the mould cavity.
Result: The mould cavity similar to the drawing specifications shown is obtained.

MODEL –III
PREPARATION OF A SAND MOULD WITHOUT USING PATTERNS
REGULAR HEXAGON PATTERN WITH SQUARE
Aim: To prepare a mould cavity of a regular Hexagon of side 80mm and a square of sides 50mm
to a depth of 25mm.
Apparatus Used: Moulding Flasks, Sand Rammers, Trowel, Leveler, Sand Lifters, Vent Rod,
and Moulding Sand Mixture.
Procedure:
1. Moulding sand with adequate amount of binder and moisture is added to the sand.
2. This sand is thoroughly mixed with the help of a muller or by hand.
3. The sand is then filled in the drag half of the moulding box.
4. Sand is then rammed with the help of a hand rammer.

5. Strike off the excess sand with the help of a strike rod.
6. Apply parting sand on top of the drag half of the mould.
7. By using a vent rod, draw two diagonals on the top half of the mould.
8. Draw the hexagon as per the dimensions as shown in fig.
9. Inside the hexagon draw two square of side 50mm.
10. The cope is now kept on the drag half of the mould.
11. The wooden sprue rod and riser are kept in position in the drag half of the moulding box.
12. The cope half is then filled with sand and is kept in the rammed thoroughly.
13. The cope box is then lifted and kept in the inverted position.
14. Now, by using the sand lifter remove the sand from the mould to get the desired shape i.e.
square in the cope half and hexagon in the drag half.
15. The mould is finished after cutting the gate in the drag portion.
Result: A mould cavity similar to the drawing specifications give is prepared.

Part – C
SMITHY & FORGING
Fig.12 Bending

Smithy is understood to handle relativity small jobs only such as can be heated in an open fire or
hearth.
Forging refers to the production of those parts which must be heated in a closed furnace. The
portion of the work in which in which the forging is done is termed as forge and the work is
heavily formed by means of the heavy hammers, forging machines and presses.
Forging processes are among the most important manufacturing techniques since forged
components are used in small tools, rail road equipment, automobiles and truck components,
aeroplane industries etc.
Almost all commonly used metals and alloys satisfy these minimum requirements and can be
used for forging. The law and medium carbon steels are readily forged without rectangular cross
sections.
Forging Operations:
A number of operations are used to change the shape of the raw materials to the finished form.
The typical forging operations are:
1. Upsetting
2. Drawing
3. Bending
All these operations are carried out the metal in a heated condition, which must be maintained by
taking a ‘fresh’ hat when the work shows sign of getting cold.
1. Upsetting
Upsetting or heading is the process of increasing the thickness of a bar at the expense of its
length and is brought about by end pressure. The pressure may be obtained by driving the end of
the bar against the anvil, by supporting on the anvil and hitting with the hammer, by placing in
swage block hole and hitting with the hammer or by clamping in a vice and then hammering.
The fig 12.a shows the effect of heavy hammer blows on a uniformly heated bar, the fig 12.a
shows the effect of comparatively light hammer blows. Local upsets may be

WIRE DRAWING
Obtained as shown in fig 12.c 12. D shows the heating only at one end or the middle of the bar.
2. Drawing
It is the process of increasing the length of a bar at the expense of its width or thickness or both.
In fig 13 a,b,c a represents the original stock of materials, b shows the stock after hammering
with a straight peen hammer and C shows the finished forging after the flatter has been used.
3. Bending
Bending is an important operation forging and is very frequently used. This may be classified as
angular or curvilinear. Bending may be done over the edge of the anvil face, over the anvil horn,
in special forms such as the swage block edges.
When a metal is bent the layer of metal on the inside are shortened and on the outside are
stretched. This causes a bulging of the sides at the inside and a radius on the outside of the bend.
If a perfect square bend is required, additional metal must be worked to the place where the bend
occurs. The fig 12 shows the stages in bending a bar over the horn of an anvil using a hammer.
Forging Temperatures:
For forging a metal must be heated to a temperature at which it will possess high plastic
properties both at the beginning and at the end of the forging process. For instance, the
temperature to begin the forging for sift, low carbon steels is 1250° to 1300° C and the
temperature for finishing is 800 to 850° C . It forging operations are finished at lower
temperature, this leads to cold hardening and cracks. With excessive heating, the forgings suffer

oxidation and much metal is wasted. The blanks should be heated uniformly all over and at a
definite rate. The temperature of heating steels for hand forging can be estimated by the heat
color which is the color of the light emitted by the heated steel. The heat color disappears when
the steel cools down.
Finishing temperature of Forging

The temperature at which the hammering of a forging is left off has an important influence on
the properties of the forging. When steel is heated well above the upper critical temperature, the
grain begins to grow in size and they will continue to grow as the temperature is increased.
During, forging however the grains are broken and become finer. It the final forging temperature
is high, the grains during the process of cooling in the air, the cold forging will then have a
coarse grain during structure and low mechanical properties. It forging is finished at lower
temperature; the grains will not grow when the steel is cooled owing to lower temperature. The
cold forging will then process a fine grained structure and high mechanical properties.
If steel is hammered when it is below the lower critical temperature it will be cold worked and
give small hair line cracks. Thus, if forging of a piece of steel is finished within a temperature
interval of 910° C to 723° C, depending on its grade, the forging will possess a fine grain
structure. In other words, forging must be completed at a temperature at which further growth of
the grain will not take place.

Hand Tools and Accessories
SWAGE BLOCK
ANVIL
Ball peen hammer cross peen hammer straight peen hammer

The tools and the equipments used their applications in numerous forging operation are as given
below.
1. Anvil:
The anvil forms the support for blacksmith’s work when hammering. The body of the anvil is
made of mild steel face welded on the body. The beak is used for bending as shown in Fig.13.
There is a square hole at the end which is used for holding the shank of the lower member of pair
of tools.
Anvils vary up to about 100-150kg and should stand with about 0.75 m from the floor. This
height may be attained by resting the anvil on a cast iron or wooden base.
2. Swage Block:
This forge shop tool is used for many squaring, sizing, heading, bending and forming operations.
It is 0.25m or more wide may be used either flat or edgewise in the stand as shown in Fig.13.
3. Hand Hammers:
Two kinds of hammers are used in hand forging:
a. The hand hammer used by the smith himself.
b. The sledge hammer used by the striker.
Hand Hammers may further be classified as:
a. Ball peen hammer
b. Straight peen hammer
c. Cross peen hammer
a. Ball peen Hummer: This is the most common form of the hammer and is sometimes called as
engineer’s hammer or chipping hammer. The peen has a shape of a ball which is hardened and
polished as shown in Fig.14. This hammer is chiefly used for chipping and riveting. The size of
the hammer varies from 0.11 to 091 kg.
b. Cross peen hammer: This is similar to a ball hammer in shape and size except the peen which
is across the shaft or eye as shown in Fig.14. This is mainly used for bending, stretching,
hammering into shoulders, inside curves etc. The size varies from 0.22 – 0.91kg.
c. Straight peen hammer: Where it is necessary to strike metal a blow with the minimum damage
to the surface, a soft hammer, called mallet is used as shown in Fig.14. Mallet heads go by the
numbers or by the diameter is the head. They are made of raw hide, hard rubber, copper, brass,
lead etc.
Hammers are made of cast steel and the ends are hardened and tempered. The striking face is
slightly convex. The weight of a hand hammer varies from about 0.5 kg to 2 kg while the
weight of a sledge hammer varies from 4 to 10 kgs.

Sledge hammer
Open mouth tong
Hollow bit tong
Band saw tong

Sledge Hammer:
The sledge hammer is heavy and has a long handle as shown in Fig.14. Its weight ranges from 4
to 10 kgs. It is used for heavy work.
Tongs:
The work to be forged is generally held in tong. The tongs generally used for holding work are :(
Fig. 15)
a. The Gad tong is used for general pick up work, either straight or tapered.
b. The straight lip fluted tong used for square, circular and hexagonal bar stock.
c. The ring tong used for bolts, rivets and other work of circular section.
d. The flat tong used for holding for holding work rectangular section.

Swages
Fullers

Furnace or Hearth:
The furnace is used for heating the metal pieces. The main components of a furnace are cast iron
body with four legs, hood, chimney and a blower as shown in Fig. 16 Coal is the fuel used in the
hearth and the required of air is supplied by the blower. The hearth is providing with a fire brick
lining. Exhaust gases from the furnace goes to the atmosphere through the chimney. A small
water tank is also attached with the furnace for cooling / dipping the job.
Swages
Swages are used for work which has to be reduced and finished to round, square or hexagonal
from. These are made with half grooves of dimensions to suit the work being reduced. Swages
consists of two parts – the top part having a handle and the bottom part having a square shank
which fits the handle and the bottom part having a square shank which fits into the haedie hole in
the face as shown in figur
Fullers
Fullers are used for necking down a piece of work. They are made in top and bottom tools as in
case of swages. Fullers are made in various shapes and sizes according to the needs, the size
denoting the width of the fuller edge as shown in the

Model – I
Making of Square Rod from a Round Rod.
Square rod from a round rod
Aim: To forge a square rod from a given round rod.
Tools Required: Anvil, Sledge Hammer, Tongs, Fatter, Furnace.
Procedure:
1. Cut the raw material to the required length using a hacksaw frame.
2. Dip a piece of cotton waste in Kerosene oil and place it on the furnace.
3. Place small dry wooden pieces on the cotton waste.
4. Ignite the furnace
5. After few minutes of burning, add coal to the furnace.
6. Switch on the blower to supply necessary air for burning
7. After the flame is stabilized, place the specimen to be forged on the hot coal pieces.
8. The specimen is heated till it red hot. (Temperature around 1000 – 1300° C).
9. When the material is in the red hot state, it is said to be in the plastic state.
10. The red hot specimen is then placed on the anvil and held by tongs.

11. Hit the job hard by using the sledge hammer by holding one end with the help of tongs.
12. Change the position of the job and repeat hammering to change the rod from round to
square.
13. Repeat heating and hammering until the required shape is obtained.
14. A flatter is used to obtain a fine finish on the job.
15. Finally, the job is cooled by dipping in water.
Result: Thus the round rod is transferred to a square rod for the given dimensions as shown in
the figure.

Model No II
Preparation of Hexagonal Headed Bolt
Hexagonal headed bolt
Aim: To forge a Hexagonal Headed Bolt from a round rod of dia 16mm
Tools Used: Anvil, Hand Hammer, Tongs, Flatter, Furnace.
Procedure:
2. Calculate the final length of the hexagonal bolt by performing the volume calculations as
shown.
3. Dip a piece of cotton waste in kerosene oil and place it on the furnace.
4. Place small dry wooden pieces on the furnace.
6. After few minutes of burning add to the furnace.

7. Switch on the blower to supply necessary air for burning.

9. The specimen is heated till turns red hot, (Temperature around 1000 – 1300° C).
10. When the Specimen turns red hot, remove the specimen with the help of tongs.
13. One end of the bar is heated in the furnace to the plastic state.
14. When the job is red hot hammer it from the top end of the rod, holding the job carefully
while hammering.
15. Repeat Hammering until a round head is formed.
16. Turn the job for 60° and repeat hammering to change the round rod to hexagon.
17. Repeat Heating and Hammering until the required head is obtained.
18. The job is then consequently heated to get the required head is obtained.
19. The job is then consequently heated to get the required shape of the bolt as shown in the
figure .
Volume Calculations:
To find the final length of the forged component (1):
Volume of the raw material =  d2 / 4 *L ------------------------------(1)

Diameter of the raw material = d = 16 mm
Length of the raw material = L = 100 mm
Therefore substituting in the equation 1 we have:
Volume of the raw material =20109 mm2

Volume of the raw material = Volume of the forged component
20109 mm2=  d2 / 4 *1 ----------(2)
Where
D = Diameter of the forged component = 12 mm
Therefore Substituting the value of D in Equation 2 we have:
1 = 140mm
The final length of the forged component is 140 mm.
The flatter then used to get a fine job on the surface.
Finally, the job is then cooled by dipping it in water.
Result: Thus the hexagonal bolt is obtained for the given dimensions as shown in the figure.

Model III
Preparation of a Hook
Hook
Aim: To prepare a J component from a round rod of dia 16 mm
Tools Used: Anvil, hand Hammer, Tongs, flatter, Furnace, Swage, and Block
Procedure:
2. Dip a piece of cotton waste in kerosene oil and place it on the furnace.
3. Place small dry wooden pieces on the cotton waste.
5. After few minutes of burning, add coal to the furnace.
6. Switch on the blower to supply necessary air for burning.
8. The specimen is heated till turns red hot, (Temperature around 1000 – 13000 C).
9. When the Specimen turns red hot, remove the specimen with the help of tongs.
12. Hit the job hard by using the sledge hammer by holding one end with the help of tongs.
13. Change the position of the job and repeat hammering to change the rod from round help
to square.
14. Repeat heating and hammering until the required shape is obtained.
15. After the required diameter of the job is obtained (dia 10mm) then the job is again heated
to the plastic state.
16. The job is then placed on the swage block and then hammered to get the final shape.
17. Heating and Hammering is repeated to get the required shape of the J Bolt.
Result: Thus the hook is obtained for the given dimensions as shown in the figur.

List of Viva Questions
1. What are the different types of manufacturing processes?

2. Define the term Casing?
3. Define the term Foundry?
4. What are the basic steps involved in manufacturing process?
5. Why is testing of Foundry Sands necessary?
6. What are the common tests performed on foundry sand?
7. Discuss how the grain size and shape affects the performance of foundry sand.
8. Name different tools and equipments used in foundries.
9. What is a pattern?
10. Name the different types of patterns used in the laboratory
11. Distinguish between split pattern and solid pattern.
12. What are the different additives used in moulding sand?
13. Differentiate between moulding sand and core sand.
14. What is base sand?
15. What are the functions of clay and water in moulding sand?
16. Define Permeability or porosity
17. Discuss the function of dowel pins in moulding
18. What is a core and state its function?
19. What are the purpose of runner and riser in castings?
20. What is a gating system?
21. Name the different materials used for pattern making?
22. How does green strength of moulding sand vary grain size, shape, clay content etc?
23. Why is NaOH added during clay content test?
24. Define Compression strength and shear strength.
25. What is the aim of Sieve Analysis?
26. Define Grain Fineness Number.
27. How does the permeability of sand affect the casting?
28. Draw a diagram of a moulding box and label cope, drag and cheek.
29. When is a cheek used?
30. What are additives?
31. Name the additives used for base sand and core sand.
32. What are the basic ingredients of moulding sand?
33. Why are vent holes provided?
34. What are the different types of defects in castings?
35. What is core? Name types of cores
36. Why cores are required
37. What are the ingradients of the core
38. What are chaplets
39. What are chills
40. How do you obtain directional solidification?
41. What are gating elements
42. What is the function of sprue
43. What is the function of riser

44. What is the function of runners and in gates

45. Why tapered sprue are recommended
46. Explain different types of gating systems
47. Differentiate between open and closed riser.
48. Differentiate between pressurized and non pressurized gating system and their influence?
49. How the slag is removed in the mould cavity while pouring the molten metal.
50. What is fettling?
51. What are various casting defects? Explain.
52. What is NDT and why it is required?
53. What is forging?
54. Name the steps involved in forging
55. Define upsetting and drawing
56. List the different methods of forging
57. What is forging loss
58. Explain sequence3 of operation in forging
59. What are the various tools used in forging and their uses.

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FOUNDRY AND FORGING LAB MANUAL

Department of Mechanical Engineering

M.S Engineering College

FOUNDRY AND FORGING LAB

SUBJECT CODE: 18MEL38

Compiled By : Mr. Bhaktavatsala H R

MSEC. Bangalore Page 1

Foundry and Forging lab

1. To provide an insight into different sand preparation and foundry equipment’s.

Students will be able to

1. Demonstrate various skills of sand preparation, molding.

Preparation of sand specimens and conduction of the following tests:

MSEC. Bangalore Page 2

1. Use of foundry tools and other equipment’s.

1. Use of forging tools and other equipment’s

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1 Compression strength test

10 Foundry tools and equipments

15 Forging tools and equipments

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MOISTURE CONTENT TEST

Fig: 1 Infrared light source.

Weight of mixture after 5 minutes drying = W2 = ------------------(gms)

Weight of dry sand (constant weight) = W3 = ------------------(gms)

Moisture present in the sample = W1-W3 = ------------------ (gms)

Percentage of water content = (W1-W3)/W1 * 100 = ------------------%

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Result: The percentage of moisture in the given sand is=…………….

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GRAIN FINENESS NUMBER TEST

Sl. Sieve no. Weight of sand Percentage of Multiplier Product

Grain Fineness Number (GFN) = Y/R

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CLAY CONTENT TEST

Fig: 3. Clay contest test apparatus

Initial weight of sand = W1 = ------------------(gms)

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Result: The percentage of clay in the given sample of sand is=……………….

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COMPRESSION STRENGTH TEST

Sl. Percentage of Percentage of Percentage of Compression

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b.Clay content constant=

Sl. No. Percentage Percentage Percentage Compression

Result: The compression strength of the given sand mixture is =………………

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SHEAR STRENGTH TEST

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a. Water percentage constant =

Sl. No. Percentage Percentage Percentage Shear

b. Clay content constant=

Sl. No. Percentage Percentage Percentage Shear

Result: The Shear strength of the given sand mixture is =…………….

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TENSILE STRENGTH TEST FOR CORE SAND

Sl. Percentage of Percentage of Tensile

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BENDING STRENGTH TEST FOR CORE SAND

Sl. No. Percentage Percentage Bending