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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

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


Kingdom of saudi arabia ministry of higher education umm al qura university

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


Kingdom of saudi arabia ministry of higher education umm al qura university

(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.


Kingdom of saudi arabia ministry of higher education umm al qura university

CHAPTER ONE


Kingdom of saudi arabia ministry of higher education umm al qura university

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


Kingdom of saudi arabia ministry of higher education umm al qura university

* 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.


Kingdom of saudi arabia ministry of higher education umm al qura university

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.


Kingdom of saudi arabia ministry of higher education umm al qura university

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


Kingdom of saudi arabia ministry of higher education umm al qura university

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.


Kingdom of saudi arabia ministry of higher education umm al qura university

CHAPTER Two


Kingdom of saudi arabia ministry of higher education umm al qura university

  • 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


Kingdom of saudi arabia ministry of higher education umm al qura university

  • 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


Kingdom of saudi arabia ministry of higher education umm al qura university

CHAPTER THREE


Kingdom of saudi arabia ministry of higher education umm al qura university

  • 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


Kingdom of saudi arabia ministry of higher education umm al qura university

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


Kingdom of saudi arabia ministry of higher education umm al qura university

  • 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


Kingdom of saudi arabia ministry of higher education umm al qura university

  • 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


Kingdom of saudi arabia ministry of higher education umm al qura university

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 .


Kingdom of saudi arabia ministry of higher education umm al qura university

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.


Kingdom of saudi arabia ministry of higher education umm al qura university

THANK You


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