Process and Rejection control in Green Sand
Molding Line
By
P. Periannan
GM production
Magna Electro castings Ltd.,
1 17 August 2017
Classification of Green Sand Molding
1. Naturally bonded green sand Molding:
If green molding sand is prepared from clay containing sands, it is called naturally bonded
green sand.
2. Synthetic green sand Molding:
If a green sand mixture is prepared from relatively clean silica sand by the addition of clay, it is
called synthetic green sand
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Why was it called Green Sand Molding
The term GREEN SAND comes from the fact that the sand is bonded with a mixture of clay and
water and the water is not driven out or fired prior to its use – (D.F.Hoyt, AFS Transactions).
This is very similar to the green ware in ceramics where the term “green” means that the
ceramic has not been fired or dried in a kiln.
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Characteristics of Green Sand Molding
Flowability:
The mixture should be weak enough to flow and be packed around the pattern.
Plastic deformation:
Strong enough to retain its shape during the withdrawal of the pattern and pouring of
the metal.
Green strength:
It must have sufficient strength to strip from the pattern and support its own weight
without deforming and withstand the pressure of the molten metal when the mould is cast.
Dry Strength:
It should prevent the erosion by liquid metal during pouring as the surface of the
mould cavity dries out-dries strength
.
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Characteristics of Green Sand Molding
Refractoriness:
It must withstand the high temperature involved without melting and fusing to the
casting
Collapsibility:
Heated sand which becomes hard and rock like is difficult to remove from the casting
and may cause the contracting metal to tear or crack.
It Should be reusable
Remove heat from the cooling casting
It must be permeable.
.
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Source of sand mines
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Characteristics of Sand
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Types of Molding sand
There are many types of sand used in foundry, most prevalent sand is Silica, others
are Chromites, Olivine and Zircon sand.
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Size and distribution of Molding sand
As per ISO standard sand size are classified as coarse, medium and fine sand
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Shape of Molding sand
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Shape of Molding sand
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Shape of Molding sand
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Shape of Molding sand
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Shape of Molding sand
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Refractoriness of sand
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Thermal Expansion of sand
Thermal expansion is the property of a substance that determines its change in volume with change in
temperature. The coefficient of thermal expansion of the materials is a number value that indicates the
change in volume for one degree change in temperature.
Silica sand has the highest %age of linear expansion of 1° increase in temperature compare to other
sand. Above 600°C silica sand have contraction, this contraction create crack in core and mold, and
leads to scab, rat tails and buckles casting defects.
Even though Silica sand has more suitable for molding because of low cost compare to other sand.
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Thermal Expansion of sand
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Green Sand Molding System
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Green Sand Molding System
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Green Sand Molding System Ingredients
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Green Sand Molding System Ingredients - Silica
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Green Sand Molding System Ingredients - Clay
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Green Sand Molding System Ingredients - Water
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Green Sand Molding System Ingredients - Additives
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Properties and Testing of Green Sand Molding
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Properties of Green Sand Molding – Total clay
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Properties of Green Sand Molding – Active Clay
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Properties of Green Sand Molding – Compactability
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Properties of Green Sand Molding – Compactability
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Properties of Green Sand Molding – Green Compression Strength
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Properties of Green Sand Molding – Loss On Ignition
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Properties of Green Sand Molding – Hot Compression Strength
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Properties of Green Sand Molding – Permeability
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Properties of Green Sand Molding – Permeability
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Properties of Green Sand Molding – Wet Tensile Strength
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Properties of Green Sand Molding – Friability
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Properties of Green Sand Molding – Specimen Density
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Equipments and process of Green Sand Molding
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Equipments and process of Green Sand Molding
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Process control in Green sand System
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Process control in Green sand System
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Process control in Green sand System
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Process control in Green sand System
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Process control in Green sand System
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Process control in Green sand System
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Casting Defects in Green Sand Molding
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Casting Defects - Molding Related
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Casting Defects - Molding Related -Cracked Mold
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Casting Defects - Molding Related – Mold Crush
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Casting Defects - Molding Related – Mold Drops
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Casting Defects - Molding Related – Soft Mold
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Casting Defects - Gas (Porosity) Related
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Casting Defects - Gas (Porosity) Related - Blisters
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Casting Defects - Gas (Porosity) Related - Blows
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Casting Defects - Gas (Porosity) Related – Pin Holes
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Casting Defects - Gas (Porosity) Related – Shrinkage
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Casting Defects - Gas (Porosity) Related – Surface Pitting
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Casting Defects – Surface Related
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Casting Defects – Surface Related - Buckles
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Casting Defects – Surface Related – Rat Tails
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Casting Defects – Surface Related – Expansion Scabs
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Casting Defects – Surface Related - Veins
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Casting Defects – Surface Related – Burn On
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Casting Defects – Surface Related – Burn In
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Casting Defects – Surface Related – Explosive Penetration
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Casting Defects – Surface Related – Metal Penetration
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Casting Defects – Surface Related – Casting Swells
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Casting Defects – Surface Related – Erosion Scabs
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Discussion
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