Complete Lab Sand Casting
Complete Lab Sand Casting
Complete Lab Sand Casting
0 TITLE
2.0 OBJECTIVE
BACKGROUND
Clay content test is responsible for bonding of sand particle together because
it will affect the strength, permeability and moulding properties. Otherwise,
moisture content test is to defined amount of water present in the mould. Low
moisture content show sand mould does not develop strength properties and
high moisture content decreases permeability.
For this sand testing preparation, we run only 2 tests that are the green
compression strength and permeability.
THEORY
Green sand is is not green in color, but "green" in the sense that it is used
in a wet state (same as green wood). According to the Cast Metals Federation
website, an alternative casting method is to heat-dry the molded sand before
pouring the molten metal. This dry sand casting process results in a more rigid
mold better suited to heavier castings. As examples, the engine parts,
components and casings in automotives sector, and also electronics housings.
This test determines the strength and natural bonding of the sand grains
and also required the sand specimen to ruptured under compressive loading.
Usually, there are 4 types of test for sand strength: (1) compression,(2) shear,
(3) tensile, and (4) over-hang bar test. Of these tests, the compression test is
most widely used and is very convenient for routine testing of all types of
national bonded and synthetic moulding sand. Also for this experiment, we have
to get the exact height of specimen to make sure it is suit for the compression
test.
For green compression strength test, the test is performed on the sand
specimen by using Universal Sand Strength Testing Machine. While, preparing
the sand specimen, the sample are required to be taken out quickly from the
specimen tube to avoid the sample from drying which will cause increase in the
strength of the sample. The machine consists of a pusher arm and weight arm,
both hanging from a pivot bearing at the top of the machine. The weight arm
applies load on the specimen while pusher arm pushes thespecimen against the
weight until the specimen breaks. Then the compression strength psi may be
read from the magnetic marker. The green strength of sand is generallyin the
range of 0.03 to 0.16 MPa.
Here are some of advantages and disadvantages of Green Sand Mould Casting:
Advantages :
1. Less expensive Method. (Very economical)
2. Sand can be reused many times after reconditioning with clay and
moisture.
3. Preferred and suitable for simple, small and medium size castings.
4. Suitable for mass production.
Disadvantages :
1. Moulds prepared by this process lack in permeability, strength and
stability.
2. They give rise to many defects like porosity, blow holes etc. because of
low permeability and lot of steam formation due to their moisture
content.
3. Moulds cannot be stored for appreciable length of time.
4. Not suitable for very large size casting. It is for a simple design of mold.
5. Surface finish and dimensional accuracy of castings are not
satisfactory.
6. Mould erosion is common in Green Sand Mould Casting.
7. Difficult to cast thin and complicated shapes.
Permeability
P= VxH
AxT
Where;
Volume of air, V = 2000 cm3
Pressure, P = 10 gm/cm2
Apart from that, this formula also can be used to calculate the permeability of
the specimen.
This equation also can be reduced to AFS permeability:
P= 3000.7
T (sec) for old machine with Hg
P= 30557
air pressure in cm of water x time in sec
P = 30557
pxt
5.0 EXPERIMENTAL PROCEDURE
By observing the Table 1, it shows 6 trials in which it shows the weight of the green
sand, permeability and the height. In the laboratory work, reproducing ramming condition are
achieved by the use of a standard sand rammer and specimen tube accessories. The sand is
placed in the specimen tube and rammed by impact with three blows of a standard weight. The
required height for the specimen is 50.8 with tolerance of ±0.125mm.
From the experiment that has been conducted, our group managed to obtain 50.82mm.
On the sixth trials, we are managed to obtain the required sample of height
which is 50.8 mm. The value that we have obtain are 50.82 based on Table 2. From the results
that we have obtain in table 2, it produced a strength of 11.8 psi which is equivalent to
0.081MPa in SI unit which is also still in the ideal range of (0.03Mpa to 0.16MPa) .
P= 30557
PxT
Parameters Value
Volume of air, V ( cm³) 2000
Height of sand specimen,H (cm) 5.08
Pressure,P (gm/cm²) 10
Cross section area of the sand specimen, A (cm²) 6.4516
Time , T (minute) 1
P = 30557
10 x 60
= 50.93
From the experiment conducted, data was obtained. 6 times of testing at last
satisfied the criteria needed to get specific height of 50.8mm(±0.125mm). The 6th
testing shown 50.82 of height with 11.8 Psi of strength and 152.45gram of mass.
Permeability obtained is 62 cc/m. The experiment shown increasing of
permeability value when the mass of green sand increases, except for the 6 th
sample, where the permeability value supposedly lower than it was.
The height of each specimen was varies even though the mass of some
specimen almost the same. This is due to the surrounding effect. Green sand
contains of 4% of silica sand, 2% of bentonite, 2% of coal dust and 1% of water
acting as bonding agent. Water may vary due to surrounding. The longer the
sand was leaved to the surrounding, the lower water contain. Water will dissolve
with clay and provide strength to the molding sand enable to retain it shape as
molding cavity. The strength of the molding product is greater when the sand is
drier.
In order to get the required height, we had made six samples. The
interpolation method is used to determine the accurate value of weight in order to
get the required height, 50.80 mm. During conduct the experiments; there are
some errors that have occurred. Parallax error is occurred during take the
measurement height of samples by using Vernier calliper. It caused by the
improper technique is applied during take the readings. In order to overcome this
error, eye level must be perpendicular to the scale during taking the readings.
Another error is occurred during prepared the sample is systematic error. It is
very difficult to get the accurate weight of sand in order to have required height
because the mass measurement machine that used is very sensitive.
The best result is should be below than 20% of percentage error .The
percentage error that is determined from the calculation for this experiment is
21.70%. This error occurs because of the some errors during conduct the
experiment. The improper skill of measurement is applied during read the scale
reading on Vernier Calliper, permeability machine and strength testing machine
can be one of the errors. For overcome this problem, the eye level must be
perpendicular to the scale reading during do the measurements and take
average readings in order to get accurate result. The next error that is occurred is
systematic error. This error is happen during using some of instrument such as
Digital Weighing Device. This instrument has very sensitive scale reading and it
make so difficult to adjust the weight of green sand before sand is being tested.
The value of green compression strength that was determined from the experiment is
11.8 psi or 82 kPa. That value of strength is determined from the test for sample number six. The
suitable types of material that can be used in pouring moulding sand is depend on value of green
compression strength. So, the suitable type of material is non-ferrous metal. These moulding
sand samples are capable to withstand with low melting point of material such as Aluminium.
The green compression strength can also be defined as the capacity of the
rammed sand during pouring process. Permeability is a property by which we can
know the ability of material to transmit fluid or gases. This permeability is usually
tested whether the material is suitable for the use of casting conditions. Green
compression strength and permeability are important factor to be considered as
an important aspect in the sand casting mold preparation.
The trials to get the complete result ends with 6 trials. The experiment had
been repeated just to obtain the suitable height which is 50.8mm. On the sixth
trial, we managed to obtain suitable height, 50.82mm. From the height that we
obtained, the value of green compression test also had been obtain which is
11.8psi equivalent to 0.08MPa. The suitable pressure for green compression test
is between 0.03MPa to 0.16MPa where that value obtained are considered as a
success. The permeability for the sixth trial is 62cc/min.
After obtaining the required result, the value of the permeability of the
experiment has is 50.93cc/min. In the term of percentage error, the percentage
should be under 20%. The percentage error that we have obtained is 21.7%. One
of the errors that causes this percentage error that the experiment that had been
conducted is at the evening where the green sand is slightly dry due to humidity
loss towards the environment. Each time that the experiment had been
conducted, the reading for permeability increase each and every time. This
shows the loss humidity due to time and environment factors.Next, there might
be an error while pouring process. The sand might stick at the funnel while we
were pouring it to specimen tube. This decrease the mass that is measured
before.
(Done By: WAN KAMARUL ARIFF BIN WAN KAMARUDDIN 2014421604)
Based from this experiment, the sand testing preparation (green sand) is
about the preparation that we had to measure the properties of permeability,
green compression strength clay content and moisture of the clay. The value for
permeability is depends to the rate of air to pass through the standard
compression specimen. If the value of permeability is high, the mould maybe
excessive with water and will create mold defect when do the casting. The
permeability of specimen must be in optimum condition between this value (60-
150). While for green compression strength value is depend on the type of metal.
For non-ferrous metal must be high value than ferrous metal value in green
compression strength and vice versa. Bentonite and coal dust is the important
material for strengthen the sand.
That have a different in the actual and the experimental value of permeability
and green compression strength in this experiment. These different are cause by
several factor such as moisture contain in the sand specimen could be has dried
up by time and temperature surrounding. The experiment was done with six
dissimilar value of mass and for each value of mass the time taken are depend
on us to take measurement of the size of specimen. As a result, the water contain
in specimen box are considered to the atmosphere because we not lock up the
box after take some sand from specimen box. there also has other error that
influenced by the loss of sand due to the handling the experiment. Since the
moisture was condensed and the loss of sand will effect to the dimension of the
specimen that our desired height is 50.8mm with tolerance 0.125mm were hard
to achieved it in 1st test.
For the green compression strength test, the specimen may be not being
accurate and will be fails at inappropriate force because of the specimen keeps
drying by time. It is because of the cold dust, Bentonite and water mixture are not
optimum ratio.
(Done By: NUR NABILA BINTI MOHD NAZALI 2014659124)
The experiment conducted is sand testing that is then divided into two which are
green compression strength and the permeability of the compressed sand. The
percentage error after conducting the experiment is 21.7%, whereas the desired
percentage error should be less than 20%. After testing 6 specimens, the 6 TH trial is
success as the suitable height achieved is 50.82mm, making it within the range of
50.8mm ± 0.125mm as this is the requirement of the machine. To achieve this suitable
specimen, the mass tested was 152.45g. Using this specimen, the strength of it was
11.8psi which is equivalent to 0.081MPa in SI unit. The ideal range for the strength
should be between 0.03 to 0.16 MPa.
The properties of the sand that is vital in preparing the sand for casting is the green
compression strength, permeability, clay content and the moisture content of the sand.
These factors are important as to avoid the defects that may happen during the metal
forming process. Some of the defects examples are pin holes, shrinkage cavity and
penetration of the molten metal through the sand.
The permeability of the sand is the ability for gases to pass through the standard
compression specimen. The amount of water in the sand mixture is vital as the water
acts as the bonding factor of the sand particles thus effecting the permeability. The range
of the permeability should be around 80 - 150 for it to be optimum for the pouring of the
molten metal. The bentonite affects the hardness of the sand, where this factor is
calculated for in the green compression strength. If the sand is not strong enough, it
might no withstand the molten metal that is poured into the mold. As for the types of
molten metal, non-ferrous metals should have a higher value of green compression
strength compared to ferrous metals.
The errors that occur affects the outcome of this experiment. One of the errors might
be caused by the sand itself as the sand may have lose moisture due to the surrounding
atmosphere. Due to this factor, the experiment has to be repeated 6 times before the
desired values are achieved. Besides that, the method of reading the vernier caliper may
not be correct due to parallel and human error, making the calibrations of the specimen
incorrent and not accurate. The electric permeability meter may also contribute to the
error happened as an incompetent person that handles the machine may stopped the
machine a little bit too early or too late.
8.0 CONCLUSION
In the end of this experiment, we can conclude that the permeability, the
green compression strength and the properties of the specimen are important to
do preparation appropriately. This is important because in this experiment, we
found a lot of factor that could affect the results. The main error that could
produce is the loss of sand. Some of little sand maybe stick at the funnel or head
of rammer while do the processing of the specimen. Even the loss of sand is very
little, it is still affected to the whole processed especially to the sand volume.
Since the sand volume drops, the dimension of the specimen required will not be
accurate to the desired height of 50.8 ± 0.125mm.
For the permeability test, the first trials we get the value of permeability is 55 cc/min
while at the last trials we get 62 cc/min. This will conclude that’s specimen has been condensing
to the surrounding while we do the processes of the experiment. The first trial is too low and
second trial took the lowest and highest value of permeability more than others. The value for
the second trials is 68 cc/min.
For the green sand compression strength, a machine is being used to test the specimen’s
strength. The specimen that undergoes this test was the 152.45 g specimen which states the
reading of 50.82mm in height. The specimen is tested until it fails at 81.358kn/m^2.
Lastly, to obtain good quality of product, the material for the green sands must be
mixed with the correct amount of bentonite, coal dust and water. Excessive amount of water
would make the sand harder in uniformly condensed even in a short while. Besides that, we
must do research for what type of material for that product because the green compression
strength between non-ferrous and ferrous is difference and will affect to the amount of ratio of
material to do preparing.
The value of the properties that are achieved as follow; green compression
strength: 11.8 psi @ 0.081MPa and permeability: 62 cc/min. The strength is
within optimum range which is between 0.03 to 0.16MPa while the the optimum
range for the permeability is between 60-150. Although the percentage error still
exists, this can be fixed through proper handling of the specimen and
equipments.
9.0 RECOMMENDATIONS
To further enhance the accuracy of the experimental values, one of the ways
is to keep the sand in a vacuum container if possible to avoid further loss of
moisture. The equipments should also be checked and maintained regularly to
avoid systemic errors. For the accuracy of the calibration, the traditional vernier
calipers can be replaced with a modern, digital vernier calipers. Lastly, the sand
should be changed into new ones more often to avoid the loss in the strength of
the sand. The values of the bentonite and the clay content should be supervised
at all times to maintain the proper ratio of the sand.
10.0 REFERENCES
2.http://www.instructables.com/id/General-Steps-to-Sand-Casting/step9/Safety-Concerns-and-
Precautions/ , 28 sept 2015. SAFETY CONCERNS AND PRECAUTIONS.
6.https://www.scribd.com/doc/173809435/GREEN-SAND-PREPARATION-Manufacturing-Lab-
Foundry , 28 Sept 2015. Foundry Lab
7.http://engineeringhut.blogspot.my/2010/11/moulding-sand-properties-and-its-types.html 28
Sept 2015 , Moulding Sand Properties
8.http://www.simpsongroup.com/tech/rpt-sales-Fundamentals%20of%20Sand%20Control.pdf ,
28 Sept 2015 .AFS Permeability