FACULTY OF MECHANICAL ENGINEERING,

UNIVERSITI TEKNOLOGI MARA (UiTM)

VIDEO PRESENTATION ON SAFETY IN
LABORATORY/WORKSHOP

Program : Bachelor of Engineering (Hons) Mechanical (EM220)

Course : Engineering Workshop Practice
Course Code : MEM460
Lecturer/ Instructor
: Dr Azianti Ismail
Name
Group : EMD1M1A1
Title :
1.
2.
Student’s Name & ID : 3.
4.
5. Mastura Ain Bt Mohd Zamri ( 2021709253 )

General Guidelines:
LEVEL Weak Marginal Satisfactory Good Excellent
Scale 1-2 3-4 5-6 7-8 9-10

Scale Marks
Criteria Weight
Achieved Obtained
Qualifying requirements:
Cover - Acceptable? * Yes / No
Introduction 0.5
CLO3 Safety Rules 1.5
safety rules, Standard operation procedures or methods
standards 1.5
for using machines/equipment
and
regulations Personal Protective Equipment Required 1.0
Conclusion & Reference 0.5
Total Marks (50%)
CLO4 Peer Assessment (Google Form) 1.0
Group
Management Resource Planning 1.0
Total Marks (20%)

Introduction
A foundry is a kind of factory that produces metal castings and responsible for our current
standard of living and industrial development. Foundries also produce various metal product
such as engine, railroad and components. Most, if not all machine that makes essential
consumer goods requires metal components. 90 percent of all manufactured product uses
metal casting. Silica sand is always used as mold material. To cast metals into various
shapes, we need to melt it into a liquid, pour it into a mold, and remove the mold material
after the molten metal has solidified.
A melting furnace is “charged” with metal and is heated above the metal’s melting point. This
process is known as charging, and it is one of the most dangerous operations in the foundry.
Mistakes made during this process can be lethal. Once the molten metal has reached a
specific pouring temperature, it is tapped from the furnace through a spout into a refractory
lined steel pouring ladle. Before we pour out the Molten metal, there will be slag and
impurities at the top of the molten metal surface. We need to remove it by skimming it off
from the surface. The ladle is then tipped to pour molten metal into a mold cavity. We also
usually produce the metal castings in a workshop because we deal with high temperature,
heavy machinery and a lot of grease. Casting are divided into two types of process. First is
an expendable mold process. It uses an expendable mold which must be destroyed to
remove the casting. Expendable mold are made out of sand, plaster and etc. The second
type is a permanent mold process. It uses a permanent mold which can be used over and
over again to produce many castings. Permanent mold are usually made out of metal, or
less commonly made out of ceramic refractory material. Workshop is just like a room that is
used for manufacturing or other light industrial work. There are many tools and equipments
used in a workshop which allows various activities and works such as sand preparation,
molding, melting, pouring and casting. Workers who perform casting are called foundrymen.
Aluminum and cast iron are one of the most common metals used in the process. Foundries
melt and recast millions of scrap metal annually to create new product, which contribute to
the manufacturing recycling movement.
There are many common hand tools used in foundries;
1) Hand riddle. It is used to clean sand in order to remove foreign material and debris.
2) Shovel. It is used to mix, temper, condition the foundry sand and to move and transport
the molding sand to a container or molding box or a flask.
3) Rammers. It is used to strike the molding sand mass in the molding box to pack or
compact it uniformly all around the pattern. Usually there are hand rammer, peen rammer,
floor rammer and pneumatic rammers.

•Hand rammer. It is a small tool which at one end wedge construction, called peen and other
end possesses a solid cylindrical shape known as butt. It is used to ram the sand in the
bench molding work
•Peen rammer. It is a wedge shaped construction formed at the bottom of a metallic rod. It is
used in packing the molding sand in pockets and comers.
•Floor rammer. It is a heavier and larger in comparison to hand rammer. It is used is in floor
molding for ramming the sand for larger molds.
•Pneumatic rammers. It is used for making large molds and they also save time and labor.
4) Sprue pin. It is used to make a passage for pouring molten metal in mold through gating
system.
5) Strike off bar. It is used to strike off or remove the excess sand from the top of a molding
box after completion of ramming.
6) Mallet. It is used to drive the draw spike into the pattern and then rapping it for separation
from the mold surfaces
7) Draw spike. It is used for driven into pattern which is embedded in the molding sand and
raps the pattern to get separated from the pattern and finally draws out it from the mold
cavity.
8) Vent rod. It is used to pierce series of small holes in the molding sand in the cope portion.
9) Lifters. It is used for cleaning, repairing and finishing the bottom and sides of deep and
narrow openings in mold cavity after withdrawal of pattern
10) Trowels. It is used for smoothing or slicking the surfaces of molds. They may also be
used to cut in-gates and repair the mold surfaces.
11) Slicks. It is used for repairing and finishing the mold surfaces and their edges after
withdrawal of the pattern.
12) Smoothers. It is used for repairing and finishing flat and round surfaces, round or square
corners and edges of molds.
13) Swab. It is used for sweeping away the molding sand from the mold surface and pattern.
It is also used for coating the liquid blacking on the mold faces in dry sand molds.
14) Spirit level used to check whether the sand bed or molding box is horizontal or not.
15) Gate cutter. This tool is used to cut runners and feeding gates for connecting sprue hole
with the mold cavity.

Apparatus

1. Molding flasks
2. Rammer
3. Parting agent
4. Heart trowel
5. Trowel
6. Shovel
7. Lifter
8. Sprue pin
9. Bellows
10. Scriber
11. Strike rod
12. Bottom board
13. Silica sand
14. Coal dust
15. Bentonite
16. Water
17. Pattern

Industrial Apparatus

1. Sand miller
2. Jolt squeeze machine
3. Sand separator

Results
 FIGURE 1 FIGURE 2
The green sand in drag flask The green sand that has been used

FIGURE 3 FIGURE 4
The green sand in sand mill machine The final product with Formula One car pattern

FIGURE 5 AND FIGURE 6 : The Formula One car pattern that has come out with a little crash on it .
DISCUSSION
Green sand (casting) is a slightly moist sand used in metal sand casting.
Greensand, often known as green sand, is a greenish-coloured sand or sandstone. This
word refers to shallow marine sediment that contains rounded greenish grains in
significant quantities. Glauconies are a type of grain made up of a mixture of mixed-layer
clay minerals like smectite and glauconite mica. Any glauconitic silt is also referred to as
greensand. In the metal casting process, a casting fault is an unwanted abnormality. Some
flaws can be accepted, while others can be corrected; nevertheless, all flaws must be
removed. Gas porosity, shrinkage defects, mould material defects, pouring metal defects,
and metallurgical defects are the five primary categories. Permeability refers to a property
of foundry sand that determines how well it can vent. For example, consider how readily
gases travel through sand. In other words, permeability is a quality that determines a
material's ability to transport fluids or gases. It's typical to test the permeability to see if it's
appropriate for the casting conditions.
During the lab, we will be required to construct a sand casting mould. For the mould, we
utilised green sand. Green moulding sand is made up of a sand, clay, and water mixture.
In today's metal casting operations, green sand is by far the most versatile moulding
procedure. The green sand technique employed a mould formed of compressed or
compacted damp sand packed over a wood or metal pattern. The term "green" signifies
that moisture is present in the moulding sand and that the mould has not been baked or
dried. Green sand is the most well-known of all the sand casting procedures since the
moulds may be poured right away. This moulding is ideal for light bench moulding or
production moulding machines for medium-sized castings. A mould is a hollowed-out block
that holds a liquid such as plastic, glass, metal, or ceramic raw materials. The liquid within
the mould solidifies or settles, taking on the shape of the mould. The opposite of a cast is a
mould. The moniker "green sand" came about as a result of the sand's high moisture
content. Because of the moisture in the sand, it binds together and prevents the mould
from decomposing. Green sand moulding is a more advanced method than the others.As
sand control is applied, green sand moulding is replacing many of the more expensive
moulding technologies.
Green sand has a number of characteristics. To begin, the green sand for moulding must
fill and pack tightly around the pattern while under pressure. To put it another way, it must
be able to flow. Second, green sand for moulding should be able to be gently bent without
cracking, allowing the pattern to be removed. To put it another way, it needs to be plastic.
To achieve green strength, green sand must be able to strip from the patterns, maintain its
own weight without deforming, and endure the pressure of molten metal when the mould is
cast. Green sand should also be porous, allowing gases and steam to escape the mould
before pouring, preventing any flaws. To avoid corrosion by liquid metal while pouring,
green sand must increase dry strength as the mould surface dries. Finally, green sand
must have a high refractoriness so that it can endure the high temperatures without
melting or fusing with the metal. Green sand casting is a safe and cost-effective way to
pour aluminium and zinc metal into almost net shapes.
Green Sand Moulding has a number of advantages, including adaptability to small and
large quantities, low material and pattern costs, part flexibility in terms of shape, weight,
References
1. Jim Smith, J. (n.d.). Introduction to Greensand Casting. Retrieved April 16, 2021,
from https://blog.eaglegroupmanufacturers.com/introduction-to-greensand-casting
2. The 6-step process of sand casting. (2019, October 30). Retrieved April 16, 2021,
from https://monroeengineering.com/blog/the-6-step-process-of-sand-casting/
3. Report, A. (2019, January 22). Nine green SAND facts to KNOW: CASTING
SOURCE. Retrieved April 16, 2021, from
https://www.castingsource.com/articles/2019/01/22/nine-green-sand-facts-know
4. Report, A. (2019, January 22). Nine green SAND facts to KNOW: CASTING
SOURCE. Retrieved April 16, 2021, from
https://www.castingsource.com/articles/2019/01/22/nine-green-sand-facts-know
5. Sand casting process: Advantages and limitations. (2020, December 09). Retrieved
April 16, 2021, from https://www.metaltek.com/blog/sand-casting-process
advantages-and-limitations/