GENERAL SAFETYRULES

AND
REGULATIONS IN THE WORKSHOP
1) Never work alone in the workshop, work at least in
pairs. This is so because in case of industrial/workshop
accident the other partner will be a helper
2) Know where the main switch is. This stops
processes immediately should anything go wrong in
the industry.
3) When work is being done which requires the
wearing of a safety belt, the supervisor in charge shall
determine whether or not stand-by personnel are
required, and if necessary, willprovide suitable
personnel.
area in
4) Any one working at or going to any plant shoes.
and safety
the complex must wear a safety cap
Always use a safety belt when working at height
5) danger of
such as on stacks or columnswhere the
falling exists.
tamper with or attempt to repair equipment
6) Do not do not understand.
or instruments which
you
Defective tools are dangerous, do not use them. In
07)
never use a tool except for its proper purpose.
fact used for electrical work
may not be
08) Metal ladders
and must not be used near electricalcireuits or
equipment.
Machines must be rendered inoperative by the
09) of moving parts.
removalof fuses or locking out
Replace guards before equipment is put back in
operation.
10) Provide a first Aid Box.
11) Protective valve caps must be placed on all
cylinders (oxygen, acetylene, ammonia, nitrogen,
carbon dioxide, butane or propane, chlorine, etc.) at
all times when not in use or in transit.
equipment
12) Guards may not be removed from
while it is in operation and equipment must never be
operated with guards removed.
13)Goggles or shield must be used when working on
or
emery wheels, using wire brushes, chipping, etc;
hazards exist.
any other circumstances where eye
Only authorized employees from the Electrical
14) from routine
section mayoperate switch gear., apart
stopping and starting of motors and lighting.
shut down
15) When electrically-driven equipment is
must isolated
be
for repairs, the electrical circuits
before commence.
immediately by
16)All injuries must be reported form". No
completing the official Accident report
suffering from after
employee who is feeling ill or
injuries or illness should be permitted to
effectsof permission.
report to work,without the doctor's
materials which will
17)Avoid carrying tools and
hands in going up
prevent reasonably free use of the
structures.
or coming downladders or
Employee must not be permitted to use any make
18)
apparatus of any type which involves the use of
shift gasoline or electricity
compressed air, steam, gas, oil,
without theapproval of his supervisor.
19) Before turning on electricity,steam, gas, or water
or setting in motion any machinery, equipmen
investigate to be sure that no one is in a position
injured.
20)Keep your hands off machinery that you are not
operating or repairing.
21) Pressuremust be released before repair work is
started on lines, vessels, pumps, etc.
22) The use of gasoline for cleaning purpose of any
nature is prohibited. A cleaning solvent should be used
in cleaning orifice meters, instruments, and electrical
motors.
23) Allstairways, platforms and walk ways must be
kept clear at all times.
24) Rubber gloves and eye protection material must be
used in the bandling of acids, caustic, and bactericides.
25) Wear nó loose hanging garments; wearsmart
fitting overalls if possible. No dangling ear-rings,
necklaces, chains, watches, etc. this is as things lie
long-ties may get into the machine and in the process
of trying to free it, theoperator may find him/herself
trapped in the machine.
Foundry Shop Syllabus for [Link] 1s year
" Introduction to

"molding materials;
" Moulds
" use of cores

"melting furnaces
" tools and equipment used in foundry
shops
" firing of acupola furnace
"exercises involving preparation of
small sand moulds and castings
 General Safety Precautions for
Foundry shop
[Link] methods and materials involved in a. yform
of metal castingoperation are very hazardous.
Educate yourself on the proper safety precautions
before attempting any metal casting.
[Link] put water on a metal fire. This can cause a
huge explosion!
[Link] a dry pile of sand and a shovel ready to put
out fires or to control metal spills.
[Link] asand bed under all areas. The sand bed
should be at least three inches thick. This will help
in containing metal spills and will help protect
flooring.
[Link] pour over wet ground. Remember, even
trace amount of moisture can cause explosions.
[Link] metal spilled on concrete will cause the
concrete to explode. Use a thick sand bed over
Concrete.
[Link] use clean metal as feedstock.
Combustion residues from some lubricants and
paints can be very toxic.
[Link] operate in awell-ventilated area. Fumes
and dusts from combustion and other foundry
chemicals, processes and metals can be toxic.
[Link] a niosh rated dusk mask. Dusts from s nd
parting dusts and chemicals can be hazardouo or
cancer causing. Protect your lungs!
[Link] use safety glasses. Even minor mishap
can cause blindness.
[Link] use a crucible that has been damaged or
dropped. It's just not worth the risk. Imagine what
would happen if a white-hot crucible of brass
crumbledas you were carrying it.
12 Always charge crucibles when cold. Adding
metal to a hot crucible is really dangerous. If there
is moisture on the metal, even just a
haze, the
metal can cause the entire contents of the
to explode. crucible
[Link] molten metal can travel for a great
distance. Operate in a clear work area.
[Link] about what you are doing at all times.
Focus on the job at hand and the next
all moves planned and reh step. Have
earsed prior to any operation.
[Link] yourself beforehand and always be
careful of your own and bystander safety
 Melting points of some Ferrous
and Non-Ferrous Metals
Melting may be defines as changing from solid state to
a liquid state by the application of het
Metal Melting Point in C
Carbon 3550
Chromium 1890
Iron 1535
Nickel 1455
Silicon 1420
Manganese 1260
Copper 1083
Gold 1063
Silver 960.8
Aluminium 659.7
Magnesium 651
Antimony 530.5
Zinc 419.47
Lead 327.43
Cadmium 320.9
Bismuth 271.3
Tin 231.89
Sulphur 112.8
phosphorus 44.1
 Foundry Shop

FOUNDRY SHOp
1.1 FOUNDRY SHOP melted in asuitable furnance.
it is a place where casting are prepared by 6: Pouring the metal into the mould:
melting. puring t:emolten metal into moulds Is When the molten metal attains pourng tempera
know1n as foundry. ture, it is taken Into ladles and poured into the
i. Makiag a pattern : Pattern is a model of mould_
the casti:g to be produced and is used many 6 Cooling 1.e. Solldlicatlon Aner pour
tines in casting production. ing the molten metal Into the rhould cavity it is
L. Preparation of Moulding Sand : Sand is allowedo cool down so that thÃmetal solidines.
the principal moulding material in a foundry Removing the solldided oasting from
shop. The quality of the selection and mixing of the înold: The solldifled castings areextracted
sand, which may be natural or synthetic and is by breaking the mould and cleaned by removing
used ff mould and core making. adhering sand.
3. Preparing a mould and core making :
Muulis are prepared with the help of patterns to
8. Fettling:The unwanted projcctions ln the
iorms of gates, risers etc, are cut off andthe en
produce a cavity of desired shape. Usually the tire surace is made clean and unlform.
nOud is male of sand and is used only once.
[Link] Treatment :lhe
But someiimes permaient. metal moulds are
castngs may need
heat treatment depending on the apeciflc proper
also used. For obtaining hollow portions, cores
arc pieprelseparately in core boxes. Moulds and
ties
requigcá.
corcs aré baked to impact furnance. 10/Testing and Inspeotion :Finally the
casting is inspected toen0ure that 1s free from
4Melting the Metal : The required quan- casting defects [Link] per,depired
Lity of thenetal with proper composition is tions. specifica

FOUNDRY TOOLS AND EQUIPMENT

These can be divided into following groups
(iii) Skimmers: ThesE Are M.S. rods used to
- iland tools like moulding tools core mak
ing tonls. paltern making tools. remove the slag from thà:molten metal.
(iv) Tapping Bart Tili la made of low carbon
2.1.2 CLASSIFICATION OF TOUNDRY steel rod with one alde otrcirand the other side
TOOS pointed. It is used to open he tap hoie of cupola.
Foundry tools can be classified s under: 3. Fetting Tool: Fetting /S the nethod os
1. Moulding Tools e.g. shovel, hand riddle, removing extra materlalo rom the cABting e.g.
burnt sand, runners, rdaers, auparfiuous metals,
raminer, strike off bar, vernt wire, trowels, slicks. ete. and the tools used are:
lifters, swab, draw spike, sprue pin, gate cutter.
bellow etc. Chisels. hamnmers, wlre bruah, hackSaw.
2. Melting Tools e.g. grinder_ and files cic.
(ü Boit Stick :It is used o bolt the tap l:ole Hand tools for hand mo:ilding:
of cupola by clay bat. Shovcl: It is u8cd for trunsfet 8lnd by
(ii) Raking Bar: It is a MS. steel :o :sed to hand Iroi one pl:ace l) oer.
rake the coke in the cupola.
 3

touniy Siop

() SHOVEL

(vii) FINSIHING TROWEL

(vü) HEART TROWEL

(i) RIDDLE

(ix) Mallet

(i) FLAT RAMMER

()BELLOW
Gv)PIN RAMMER

(vi)VENT WIRE (x) Swab

lumps and foriegn particles from the sand.

(Rammer:These are used for ramming sand
in themoulding box to pack it uniformly around
the pattermn. There are two types of [Link] (i) Pin
rammeránd (ii) Flat rammer.
[Link] off Bar: It is used to strike off the
excess sand from te top of the moulding box ()EUg SLICK

after rammíng.
([Link]: Gagger is a steel wire bent at one (a) aATE &
HEAdROEL, SON [Link],
or both ends and is used to reinforce the sand
and to support the hanging and unsupported
portion ofthesand.
([Link] Wire: After ramn1ing and striking off
the excess sand, vent wire is used to make small
holes in the sand iould to allow the exit of gases
and steam during casting.
Q) RINN RO D
(7jTrowels: Theseare used for finishing lat
Surlaces and joints in the nould after
withdrawh; the pattern.
(8. Slicks, When pattern is withdrawn slicks Fig. ! Foufidry Tonis
 Foundry Shop
4

used for repairing and finishing the mould -Hinge

are double ended tool
surfaces and edges. It is a
the other end.
having oheend lat and a spoon on
(Lifter_: Lifters are used for removing loose
'sandfrom inside the mould cavity.
1O Swab: Swab is used to flow a small
amount of water around the edge of the pattern
in the sand beiore the pattern is rapped for
Cope
removing it fromthe mould.
( . Draw Spik or Screw: It is used to
withdraw the patterm from the mould.
() Sprue Pin: Sprue pin is embedded in the
sand mould and later withdrawn to produce a Handles
hole called runner, through which the molten
metal,is»poured into tie mould. Trunnns
/3.) Gate Cutter:It is used to cut gates in the Fandles
Drag
moutd for eásv fiow of the nolten metal from g 3 Wooden snap Flask
runner hóle to the mould cavity. A snapfask is hnged at one cormer and is
14:) Below: It is used to blow out the loose rectangular in shape and made of wood.
or unwantd sand írom the suiface and cavity of 2.1.3 Ladles
the moul¥. Themolten meal is transported from melting
(15 Plane Smootber: It is used for furnace to mould cavity. Ladles are made of steel
smoothening the sarndsurface after striking off shell ined with suitable refractory material like
excess sand frop top of the moulding box. fire clay, to withstand temp of molten metal.
MOULDIEG BOXES/AND FLASKS (A)Cruolble:, Metal is melted in a furnace by
putting nto crucible. The crucible is packed into
These are used in sand moulding. These may the furnace,,These are made of refractory
be rmade of cost iron steel or wood. It is a container matertals nd smilar in shape to the ladles. These
in which noulding sand is filled, packed and are used u'pot for metal melting. The charge
rammed. Acavity in which a molten metal is which ls put into curcible is broken into small
poured is called mould. Moulding box consists of pieces. The umgce which use crucible are called
two parts. Lower part is drag where as upper part pit [Link] and ¢ructble furnace, which are cock
is cailed cope. Intermedicte parts are called fred. After meltung of metal the crucible taken out
"cheeks'. The cope and drag are provided with from furnace by holding it in handle and it is
suitable clamps to help in locating brought to the'mould cavities for pouring the
molten metal.

-Copo
Cug

Drug
-Dowol PinForAlignont)

rg. zMOuudung Box (rask;

u. 4 (rucible
Different mould are shown in fig.
 Foundry Sho

machine : Pattern whích

sand is done
(e) Stripping plate
plate of this machine
:
t)
nmoulding the strippirig by
I N ncompactionof head and it progres- attached to mould. Pattern is withdrawn
squcqe from the downward after the
attop neaest to the towards the pattern side. draw stripping plate
sivey gong to be sofier : It ts combinatlon moving
mould
the
being ready.
machine
(c)Jolt squeeze
operaions, Both the operations
of the above two this machine.
2.2 PATTERNS
are done smullaneouslv in
casting in the forn
-Low hardness Patterns is a model of the arround
suitlable mnaterials
of wood, metal other
Medium hardnoss produce the
-High hardness which moulding material is fited to
Pattem mould cavity.
(a) Jot ony (A) PATTERNS TOOLS
High
Medium Measuring And Markting tools-plarning tools.
Low sawing tools-Boring tools And Clamping tools.
Pattern
(B) PATTERN MATERIALS
o) Squeeze onty Wood-Metal cast-iron-Brass-Aluminium.
niyi
Medium White Metal-Plaster of Paris Wax or Mercury.
Low
(C) MACHINE USED
Medium
-HighPattern BANDSAW-Cifcular SAW Wood Turning
(c) Jot and Squeaze Lathe-Jointins-aberasive-disc Machine I drill
4High press-grinder-wood Trimoun wood Planner
Medium
Morters orand Fennoner.
High ( 2.3TYPES OF PATTERNS
Pattern
Following are commonly used pattern
(d) Smutaneous jot ard squenze
- Solld or single piece pattern
Fig. &
Distribution of hardness in the mould - Split (two plece) pattern.
(d) Sand slinger:In extremely large and deep -Multi piece pattern.
moulds sand slingers are used for quick compac - Gated pattern
ion process. The sand is thrown into the mould
- Match plate pattern
with high force by an impeller to which sand is
supplied by a conveyor belt. The spced of the im - Sweep pattern
peller controis the rmning of sand. - Follow board pattern
Opening - Segmental pattern
Blade -Skelton pattern
-Housing 2.3.1 (u) Solid or Single Plece Pattern
P'atlern withos jolnts, loose pieces, partings
in its construction ls called a single piece or solid
pattern.1These pattejns are used for [Link] castngs
Flask uf simple sha_e. Ticse patten are cheaper These
ire not atlached tola plate or b0ard.
The casting pr)ued fron these palteiis are
sluffing box and gland of stean euleS.
Fiq. 9 Sund Slnger
 7

2.3.4 (d) Gated Patterm

To obtaingood castins it is ensured that lu
supply of molten metal flows into every part of th
Hg. l0 Solid Pattern mould. Provi_iorn for easy flow of metal in th
mould is called gating and it is providcd in th
232Syit (Two Piece) Pattern gated pattern.
Falnn cn ot be made in sirrgcpiece some- In gated pattern a single mould carrles a
LIRNS due to difieuls f£ced in moulding and in huge number of cavities. Pattern for these cavi
withhirwi from the mould. Because of these dif- ties are connected to each other by means of gates.
cuittes ptlterns are ttade in two pieces called Use of this pattern is done when identical items
silpallens.
are to be castcd on large scale. A single runner
One pat ol the pattem will produce the up will supply the mollen to all the gates and uni
Yhalt oi the tould and other part will produce form feeding of liquld metal is assured.
the lower hall. of the mould. These twO pieces of
Pattern
pallenn r heldn their propor position by means
of dowel prs which are fastened in one piece and
thes t into corTesponding recesses provided on
the other piece. The line of separation of two parts
uSually at he centte line of pattem is called part IN Gates
ig line. Example : Cylinders, spindles, steam Rynngt
valves bodies, water stop cocks, and taps are ex
ample of spit patterns.
Lpgrart
Fg. 13 Gated Pattern
gie -Dowel pins 2.3.5 (e) Match Plate Pattern
When two parts of a split patterr are
mounted with one half on one sicde of the plate
Lmet cart
(match plate) and other half in opposite side of the
Fy. ll Split Pattern plate, them pattern is called plate pattern.
2.3.3. (c) Multi Piece Pattern For mass production, machine moulding.
Sorneties the pattem are made in more than dimesional accuraçy use of match plate patterm
has to be done. Although manufacturing cost of
two parts if the shape is cormplex or intricate.
These patterns may consists of 3,4 or even more
number of parts depending upon their design.

Cooe
Dowel pins

Paring lines

Fig. 12 Multipece Pattern Fig. 14 Match }late Patleem

 Drag
i'inacg Rilling Prepardilon
QPËR1TiON in:tial
D.
Aim
requirements:-moulding
Composition Pattern
: Pattern
Sand Sand
Water
Molasses Ciay Dust
Cozi Siicea
S3nd =
type
Drag Juller
[Link]
EQUPMENT
Shove [Link]&
REURED type
Material ant
Riidle 1..Shorei :-
Synthetic :- Solid eesig
One
:
.2 Aluminium
Piece Patern, of
0.1%
5to to a
8%
to6 3%
to1 to 15%12 to85% 79 or
Artificial solid
water
7-8%
Add 4 Pattern Green
iownwards
floer. theon Pluce the from'umpsand To 0o..
prepared moisture
it % JOB
given f material
iool. sand remOve with METHOD pattern
rertically tlie the or Sand.
the Sand
drag with sand, in Solid
the help sand of
e alre (Green
apper thridlle extra and adr Patern
aluminium.
help
efgiven
mix
Sand)
civmed.
lerelcd
nd
sltould
Floorbe before
[Link]
meshCheck
efwirethe proper
quantitynfAdd
PRECAUTIONS

water.
 12. hisin.
p0ur mahecudrod riser
Runtiing.
i . cleaning
thein filling,
Sanl10. runuer
riser
and arítny
s4nd
and
Separadin Plucungof
9, plucng.
.(upe Rening.
iSsd
filling. [Link]
Remosing tilting
Drag .
und ngin
th
ranner
of
! : [Link] [Link]
[Link] [Link]
Trovel [Link]
[Link] !.[Link] of Parting
Sand ope ( Jlunually [Link]
Trvel
[Link] Solid
[Link] [Link] paltern
analy

[Link]
nukeRenove
withbusin witl1
surface il,inlo direction. !
runner Plucepatter1nplace beween
!spr
Fillopposile On To top Place gently.
degree tilt Pick wisurface
th it, into tlhe
Plucing
Pice level top ead avoid level Fill
heut the the cope the it
lhe oftlhe at up the drag the cetre
up lhelp the lhelp ofprepared it i on
thie ofthe the
and and od
riser anthe help of it tlhe
rods tlhe in (irst tlhe cope the drag. cope
2"parting
angle tlhe and
undprepared of
Ahe of part drug stichness drag pattern
mould rauned
of cleun cope and and mould
of rammed the
given und given.
part. om clean
sand the 180 and given
lole the in ufand sand drag, sund lrag.
the in
Revolve
removing
during rodsthe properly. cornerSwulls
Rummed
und theslhouldDistunce
between
be
pattern
rods
und properly thequuntily
putern parting
|[Link]
copethe of proper. spread
Don't Fit tilting.
during pruperly. dra Runmedlpositlon
theof
corners
wulls
und the properPlace
Avoed jerhing
Avoid
hod both thr
part sanl lugs the
ofand of pattern
the
fit in
 [Link]
finishingand hole.
"ent (reu.
drag. in
PunchingI5. surrouding removing
softenung Putlern14.
the afier

[Link]
Sioother
[Link] Wire
Vent | Rammer Cutter
[Link]
Bellow [Link]
Spike
[Link] [Link]

naking
mouldandduring he hole.
ventihe [Link]
the gases Togiven the surrounding 1front
shake area Softthe runner
thefinish nouldlRepair (ut
help sand draW pattern
the from the of hole. of of
the by out then tlhe riser tle
of
mould breakage punching the extra with pattern
pattern wo
given draw
layer help
and gates
tool. with of out all
inand
of of in
holes.
quantity
excessof noisture.
properly. Use punch
Don'thet of
quantityexcess
Don'uset depth
[Link]
the of
tools the
proper
 SURFACE
PARTING
GATE
RISER
HOLE

POURING
BASIN

SKETCH
MAIN

RUNNER

HOLE
HOLE
WIRE
VENT
CAuITY
MeuLo

CeE

ORAG -LUGSKEoR
F

RAM