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Kingdom of Saudi Arabia Ministry of Higher Education Umm Al- Qura University College of Engineering and Islamic Architecture Mechanical Engineering Department Sand Molding Arrangement , Design and Production B.sc Project Prepared By :

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Kingdom of Saudi Arabia

Ministry of Higher Education

Umm Al-Qura University

College of Engineering and Islamic Architecture

Mechanical Engineering Department

Sand Molding Arrangement , Design and Production

B.sc Project

Prepared By :

1-Ahmad Mohammad Tarmom. 2-Naief Ali Al-Malki

3-Abdullah Abdurrahman Al-Faqasi 4-Meshari Eidhah Al-Juaid

5-Faisal Mohammad Bashaikh 6-Assaf Saleh Al-Khathami

7- Ali Ahmad Al-Omari

Supervised By :

Dr. Ahmed Hassan

H


ABSTRACT

Casting is a liquidus for process, includes melting the metal, pouring it in a pre-shaped mould and allowing it to solidify.

Sand casting process is a metal process in which natural sand, containing a proportion of clay to bind the grains of sand together and water, or a pure silica sand with an artificial binder added to it, is contained in a flask


(the name given to a pair of matching molding boxes) and compressed by hand, or mechanical ramming, around a pattern.

In this project a sand molding arrangement was designed and produced to simulate the automatic sand molding machine.


CHAPTER ONE


* Casting is a liquidus for process, includes : melting the metal, pouring it in a pre-shaped mould and allowing it to solidify.


* Sand casting process is a metal casting process in which a natural sand , containing a proportion of clay and water to bind the grains of sand together.


When two flasks are parted, the pattern and the dowels forming the sprue system are removed, a negative mould shape is left in the sand. The molten metal is poured into this cavity.


It can be used to produce complex and huge shapes, such as cast-iron engine blocks and very large propellers for ocean liners.

Sand casting can be economical for relatively small production runs, and equipments cost are generally low


1- The surface finish obtained is largely a function of the materials used in making the mold.

2- Dimensional accuracy is not so good as that of other casting processes.


CHAPTER Two


  • The objective of automatic molding is to produce accurate parts able to withstand lifting and handling .

  • Molding Machine enables moulds to be produced at high rates .

  • The principal feature of molding machine is the use of power operated mechanisms for mould compaction; this mechanization can extend in varying degrees to pattern withdrawal and mould part manipulation


  • 1- Eliminate labor cost.

  • 2-Offer high quality casting by improving the application and distribution of forces.

  • 3-Manipulate the mold in a carefully controlled fashion .

  • 4-Increase the rate of production


CHAPTER THREE


  • Sand molding process was a hand process. And it is developed to be an automatic process.

  • In this project a sand molding arrangement was designed and produced to simulate the automatic sand molding machine


We select pneumatic cylinder with bore

D = 10 cm

that is available Commercially and to be more efficient , while the stroke is taken L= 10 cm.

l


  • 1- All parts are assembled on the plates including the flasks for making cope and drag .

  • 2- The flasks were filled with sand

  • 3- The two assembled flasks then placed under the squeeze head of the arrangement one by one.

  • 4- The sand was compacted using the repeated impact of the squeeze head


  • 5- After squeezing, the plate with pattern, sprue and riser removed .

  • 6- The flasks (cope and drag ) were bolted together .

  • 7- The molten metal is poured through the sprue to fill the mold .

  • 8- The molten metal is left to cool, the casting extracted from the sand mold and cleaned


4.1 Conclusions :

1- The sand mold obtained have a good force distribution better than the manually rammed

2- The sand molding process take small time compared with the manually one.

3- This mean that the production rate is increased .

4- This arrangement will be good example for the sand molding machine for the students of the foundry course .


4.2 Recommendation :

1- The force that form the mold is assumed depending on experience and need several experiments to find the optimum force .

2- The operating valves is working manually and can be changed to operate automatically .

3- Use the compressor with higher pressure rate will help to reduce the molding time.


THANK You


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