MF3302 Foundry Technology Syllabus:
MF3302 Foundry Technology Syllabus – Anna University Regulation 2021
COURSE OBJECTIVES:
The main learning objective of this course is to prepare students for:
• To impart the basics of casting and foundry practice.
• To introduce various casting processes
• To be acquainted with design of gating system and to obtain defect free castings
• An overview of the designing of molds, casting defects, inspection and testing of castings and modernization of foundries.
• Casting of ferrous and non-ferrous materials.
UNIT I INTRODUCTION:
Introduction to moulding and casting processes – steps involved advantages, limitations, application of casting process. Patterns – types, applications, pattern allowances-pattern materials, colour coding as per BIS, pattern making, core and core making, core boxes, core prints, core blowers, core shooters. Sand mould making: Moulding and core sands, ingredients, properties, types of sands, sand selection – machine moulding, types of machines, applications.
UNIT II CASTING PROCESSES:
Sand preparation and sand reclamation-sand control tests. Sand casting process, types of moulding processes – plaster mould casting, die casting process – die casting methods. Centrifugal casting, continuous casting, shell moulding, CO2 moulding – investment casting, full mould process.
UNIT III MELTING, POURING AND TESTING:
Foundry remelting furnaces – selection of furnaces – crucible furnaces -oil fired furnace, electric furnaces – resistance, arc, induction furnaces –cupola steel melting, non-ferrous melting practices – pouring equipments – cleaning and inspection of casting –destructive and nondestructive testing – defects in sand casting and remedies.
UNIT IV GATING, FEEDING AND MECHANIZATION:
Elements of gating system, functions, types and design of gating systems, gating ratio, risers, functions, types and designs, methods controlling solidification, solidification time calculations, foundry mechanization
UNIT V FERROUS AND NON-FERROUS METALS:
Production of iron castings – Steel foundry practice – Copper alloy foundry practice – Aluminium alloy foundry practice – Magnesium alloy foundry practice – Zinc alloy foundry practice. Foundry metallurgy: Heat treatment of castings, inspection, testing and quality control in foundries, salvage in defective castings, foundry mechanization. Foundry environment, health and safety: Dust problems in foundries, preventive maintenance in foundries, returning a sick foundry to profitability.
TOTAL: 45 PERIODS
COURSE OUTCOMES:
Upon the completion of this course the students will be able to
• Gain basic knowledge in casting.
• Select suitable casting process for application requirement.
• Apply gating design and mould design knowledge to overcome defects in casting.
• Selecting the type of sand, for molds and cores as well as the molding process.
• Know about the special molding processes and when their use is warranted.
• Have a broad knowledge of casting of ferrous and non-ferrous alloys and of the inspection techniques to detect casting defects.
TEXT BOOKS:
1. O.P. Khanna, “A Text Book of Foundry Technology”, Dhanpat Rai & Sons, 15th Edition, 2011.
2. P.N. Rao, “Manufacturing Technology”, TMH, 5th Edition, 2013.
REFERENCES:
1. Campbell J., “Castings Practice: The Ten Rules of Castings”, Butterworth-Heinemann., United Kingdom, 2004, ISBN (13): 978 0750647915, (10) 9780750647915.
2. R.K. Jain, “Production Technology”, Khanna Publishers, 17th Edition, 2011.
3. Peter Beeley “foundry technogy”, Butterworth Heinemann 2nd Edition, 2001
4. P.L.Jain, ”Principle of foundry Technology “ Tata McGraw hill 4th Edition, 2006
5. T.R.Banga,”Foundry Engineering” Khanna Publishers, 5th Edition, 2014