Amazone Castings & Engineering Private Limited

Here Silica sand, which is prepared in a separate mixer using sand, and Sodium Silicate is added 5 to 6 % of sand quantity 100 kg, with a Dry core break down agent added in it. While sand and break down agent are mixed first then Sodium Silicate in added and mixed for 2 minutes or so ensuring proper mixing. Than CO2 gas is passed through the holes made in pattern or cores. And gas is passed at a uniform pressure tight, the sand mould is hardened. And then core is stripped out of the pattern by ramming smoothly.

This is done in moulding machines using sand prepared in intensive sand mixers with coal dust, Dextrine (if required), Bentonite and water. In this type of Moulding, Facing sand is used for covering the Pettern and then backing sand is used for moulding in regular way.

After proper inspection of the Pettern and the match plate, if is mounted on the moulding machine and set for leveling tightness and listing of the moulding box from the match plate after making the moulds.

Once this is made ready moulding box is placed on the machine into match plate fix going inside the Lug Holes with buses. After covering the Pettern with facing sand backing sand is added and jointing of the machine is started. Once the sand sets in the moulding box, squeeze board is pleased that above the box and in squeezed into simultaneous jolting for a minute or so. Then the squeeze board is moved out and box relieved from the Pettern. The mould is checked for proper condition and placed on them for pouring. The Cope and drag boxes are made separately with cope box having down spare and air vents. During the process of moulding, the sand prepare is also checked in the laboratory for moisture, Permeability, Green Compression strength, Computability etc. So mat quality of the sand is maintained. 

Though there are a number of practices involved, Kamani Foundry follows the following systems: -

 

3 Part A-B-C- system: Where’s’ part is Resin, while part ‘C’ is a catalyst (or Activator) and part ‘B’ is a Hardner. The quantities Mixed very depending on the type of Pettern/Mould and the bench life needed for the same. General proper GMS followed are: 

Part ‘A’: - 2% of the sand quantity.
Part‘B’: - 8% of Part ‘A’ and
Part ‘C’: - 15% to 20% of Part ‘A’: 

First part ‘A’ and Part ‘C’ are mixed along with sand in the sand mixer for about 90 second to 2 minutes and then Part ‘B’ is added and further mixed for one minute. Immediately after this, sand a discharged from the mixer and put in the core box. The sand mix is rammed by way of hand rammers and leveled on the core box. After allowing the sand to harden slightly, the core is stripped from the Pettern and allowed for ageing further.

 

2 – Part System: In this systems Resin and activator are made in a single from and after mixing it with sand for an initial period of about 2 minutes, Hardner is added and mixed for another one minute. Then the sand mix is put in the core after allowing the sand to harden slightly, the core is stripped from the Pettern and allowed for ageing further. box.

 

Single Part System: Here, it is an air setting chemical is mixed with sand for a minute to 90 seconds and then mould made as a for with further procedure.

These cores are made through shell core shooters using resin-coated sand.

Here the core box, which is known as “Die” is, heated upto 200 ‘c ranging from 400 ‘c depending on the size of die. Then the resin-coated sand is introduced into the die by air pressure. The sand inside the die takes the shape of the core cavities and gets heated up. Then onwards the time is taken for baking the core, after the core is baked at the time decided, the core as ejected from the die. And the shell core is prepared.