Moulding machines

Metal casting (15Y503)

Presented by
Lakshmikruthiga (15Y208)
Mohammed Hameeth (15Y209)
Mohammed Hussain(15Y210)
Naveen Kumar(15Y211)
Padmapreetha(15Y212)
Pasupathi(15Y213)
1
 Moulding machine
A MOULDING MACHINE may e defined as a
device which have no. of correlated parts and
mechanisms, transmits and motions in
required direction to prepare sand mould
Types:
Hand operated
Machine operated
Hand operated Moulding machine
Operations done:
Ramming,
Pattern drawing,
mould rolling-over.
Operations done by hand lever or a pedal.
Theses machines may be of pattern-draw type
or pattern-draw and squeeze type.
 Pros and Cons
Hand moulding is economical when castings
are required in small number.

Requires skilled craftsmanship

Rate of production is less

Obtaining uniform size and shape is difficult.

Hand operated moulding machine
 Power operated Moulding machines.
They use
Hydraulic action,
Pneumatic action
Moulding machines classification:
Squeezers
Jolt machines
Jolt-squeeze machines
Slingers
High pressure moulders.
 Pros and cons
Use of external power
Manual labor and fatigue are reduced
Production rate is increased
Castings operated are more uniform in size
and shape
Semi skilled worker is enough.
 Squeezers
STEPS:

Flask is filled with moulding sand

The sand is squeezed against a pressure board
Pressure applied:
Pneumatically or
Hydraulically
Continued till required density is obtained.
 Limitation
Sand density decreases with the depth.
The density variation affects hardness
Restricted to moulds not more than 150 mm
in depth
Pressure used: 3000-20,000 kg
Not applied for mould with core as sand
remain loose near these cavities.
 Jolting machine
Steps:
The flask is filled with moulding sand
Table supporting flask raises and falls
Due to sudden change in inertia the sand gets
packed.
This action of raising and dropping the table is
called Jolting
The hardness of the sand is controlled by
varying height of stroke.
 Working principle
The table supporting the flask is mounted on
jolt cylinder
When the cylinder drops it presses a valve
which causes it to open.
This allows air beneath cylinder.
The high pressure air raises the cylinder
As pressure falls cylinder lowers.
 Limitations
The sand is rammed hardest at the parting
plane and around the plane

Less dense in top layers

Necessitates hand ramming at the back after

the jolting action.
 Jolt and Squeeze machines
To overcome drawbacks this machine is
employed.
Jolting action + squeezing
Jolting action to consolidate the sand on lower
surface
Squeezing done to impart desired density in
upper portion.
Eliminates hand ramming.
 Car type jolt squeeze strippers
The squeeze plate consists of a car mounted
on wheels and track
The car is rolled over mould and squeezed.
Stripping done by lowering the pattern.
Used only for standard sizes.
 Jolt rock-over pattern Draw
Used for moulding the drag.
The drag is jolted and finished off by
pneumatic ramming.
The drag is calmped and rocked over onto
leveling bars and the pattern is lifted away
from the moulds
Easy for patterns that have deep pockets on
them.
 Jolt rock-over pattern Draw
Slow drawing of mould assists in clean draw.
This tupe is used for heavy drags which can be
rocked over to conveyors
 Slingers
A sand slinger is a type of machine used for filling
and uniform ramming of sand in molds
Particularly adopted with advantage of large
molds.
This machine consists of a heavy base, a bin or
hopper to carry sand, a bucket elevator to which
a heavy number of buckets and a swinging arm
are attached, which carries a conveyor belt and
the sand impeller head.
 Sand slingers
Sand slinger fill the flask uniformly with sand
under high pressure stream throwing the sand
with high speed by impeller.
They can be used in conjunction with pattern
draw machines to eliminate more manual
operations
 The sand slingers are stationary or movable
The ejecting head can be moved all over the
moulding box.
Ramming capacity: 0.15 m3/min for small size
to 0.85 m3/min for large size.
Ramming range: 4500 mm 10000 mm
radius.
 High pressure moulding
Force of compaction is 5-10 times higher
The squeeze pressure ranges from 7-25
kg/cm2.
In practice the hardness increases at a steep
rate with pressure only upto 4.6 kg/cm2
Moisture content < 2.5%
Higher clay content with suitable additives are
used
 Processes:
Processes:
Blow squeeze
Impact Moulding
Shoot squeeze
Vacu-press
Blow squeeze: The sand is blown
pneumatically
Compaction obtained isnt uniform
 Processes:
Impact Moulding: It uses Gas injection in order
to use impact force to achieve compaction.
Gases used: Natural gas, methane or propane

Shoot squeeze: The sand is ejected from

shorter head.
Less noisy compared to Blow squeeze
 Processes:
Vacu-press: Here instead of gas, vacuum is
used.
This improves filling and compaction.
Highly effective to produce intricate castings
Rejection rate< 1%
 Pros and Cons
Highly flexible and
suitable for all types of
cast metals
Closer dimensional
tolerances
Initial cost is high
Can be used only for
mass production