Mechanical World

Parts of Cupola Furnace:   Parts of Cupola Furnace 5. Air Blower: An air blower is connected to the wind box by means of blast pipe. It supplies the air to the wind box. A valve is provided within the blast pipe to regulate the flow of air. The blast pressure varies from 250 kg/m 2 to 1050 kg/m 2 . 6. Volume Meter: The volume meter is installed during a cupola furnace to understand the quantity of air passing. The amount of air needed to melt one tone of iron depends upon the standard and quantity of coke and coke iron ratio. 7. Tuyeres: Air, which is required for the combustion is blown through the tuyeres located about 36 inches (0.9 m) above rock bottom of the furnace. Total area of the tuyeres should be 1/5 to 1/6 of the cross-section area of the cupola inside the liner at tuyere level. 8. Tap Hole: Slightly above rock bottom and within the front there are a faucet hole to permit molten forged iron to be collected. 9. Slag Hole: There is also a sl...

Cupola Furnace: The cupola may be a most generally used foundry furnace for melting ferrous metals and alloys. Sometimes, it's also used for melting non-ferrous metals and alloys. Cupola furnace is that the cheapest means for converting iron or rubbish into gray forged iron. The fuel used may be a good quality low sulphur coke. Anthracite coal or carbon briquettes can also be used. Parts of Cupola Furnace: Following are the main Parts of Cupola Furnace: 1. Foundation 2. Shell 3. Charging Door 4. Charging Platform 5. Air Blower 6. Volume Meter 7. Tuyeres 8. Tap Hole 9. Slag Hole 10. Chimney     Parts of Cupola Furnace 1. Foundation: The whole structure is erected on legs or steel columns. A drop door, which is formed of 1 piece, is hinged to a supporting leg. When the cupola is filled with charge, a prop support at rock bottom door is provided in order that door remains close and don't collapse thanks to the heavy weight of the charge. ...

Cupola Furnace: Cast Iron is manufactured during a furnace referred to as cupola furnace. Cupola furnace is cylindrical in shape with an almost uniform diameter (about 1 meter) and a height of about 5 to six meters. The cylinder has an inner lining of Refractory Bricks which is given tuyers near rock bottom for injecting the availability of air blast. The outer shell is made of Steel. The top of the furnace remains open. The cupola furnace contains a charging door, a platform and tapping holes for the purpose of blasting the air. Manufacturing of Cast Iron:  Cupola Furnace The mixture of Pig Iron, coke, and limestone, known as a charge, is prepared in correct proportions. Coke is used as fuel and limestone as a fluxing material. Flux is the material which easily fuses and mixes with impurities to form a slag, which can be taken through the top of the furnace. The molten metal in almost pure form is collected at the bottom of the furnace along with the floating sl...

Properties of Moulding Sand:  Moulding Sand 5. Cohesiveness or Strength: The ability of the sand particles to stay with one another is named cohesiveness. The strength of the sand depends upon how cohesive the sand particles are. The sand should have sufficient strength in order that it can easily capable to retain its shape during conveying, turning or closing and pouring. If it's not of appropriate strength than it'll not be ready to hold its shape and therefore the mould may damage during pouring of molten metal. Low strength sand results in pouring casting defects in metals. To avoid pouring defects, the sand should be of sufficient strength to supply mold of desired shape and also retain this shaped even when the molten metal is poured in the moulding cavity. 6. Green Strength: The strength of sand possessed by it in its green or moist state is named green strength. The mould with adequate green strength retains its shape and don't collapse even when th...

Properties of Moulding Sand:   Moulding Sand During casting of metals within the foundry shop we uses sand for the preparation of mould. It is the moulding sand properties which improves the standard of the casting metal. If a sand of suitable property is chosen, than it greatly minimises the casting defects that may be produced during the mould preparation and casting. Following are the properties of moulding sand: 1. Porosity 2. Flowability 3. Collapsibility 4. Adhesiveness 5. Cohesiveness or strength 6. Green strength 7. Dry strength 8. Refractoriness 1. Porosity or Permeability: It is the power of sand by which it allows the gases to undergo it easily. Some gases gets dissolved in molten metal and when this molten metal starts to solidify, these dissolved gases comes out of the molten metal and check out to flee out of the moulding sand. If the sand isn't enough porous than these gases won't be ready to leave of the mould and gets trapped...

Types of Moulding Sand: 5. Facing Sand:  Facing Sand The face of the mould is made by facing sand. Facing sand is employed directly next to the surface of the pattern and it comes in direct contact with the molten metal, when the molten metal is poured into the mould. It possesses high strength and refractoriness because it comes in touch with the molten metal. It’s made from clay and silica sand without addition of any used sand. 6. Backing Sand:  Backing Sand Backing sand or flour sand is employed to copy facing sand. Old and repeatedly used moulding sand is employed for the backing purpose. It’s also sometimes called black sand due to the addition of coal dust and burning when it comes in touch with the molten metal. 7. System Sand:  System Sand In mechanical sand preparation and handling units, facing sand isn't used. The sand which is employed is cleaned and reactivated by adding of water, binder and special additives. And theref...

Moulding Sand: The principal staple utilized in moulding is that the moulding sand because it provides several major characteristics which will not be obtained from other materials. Moulding sand is defined as granular particles resulting from the breakdown of rocks, thanks to the action of natural forces, like frost, wind, rain, heat and water currents. Rocks have a posh composition and sand contains most of the weather of the rocks. Due to this reason, moulding sand differs considerably in several parts of the planet. In nature, it's found on rock bottom and banks of rivers and lakes. Moulding sand is classified into different categories according to the nature of its origin. Types of Moulding Sand: Following are the various types of moulding sand: 1. Green sand 2. Dry sand 3. Loam sand 4. Parting sand 5. Facing sand 6. Backing sand 7. System sand 8. Core sand 1. Green Sand:   Green Sand Green sand may be a mixture of silica sand and clay. ...

10. Follow Board Pattern:  Follow Board Pattern Follow board pattern consists of tool that's an easy wooden board which is employed for several reasons. The wooden board is employed as a base in follow board pattern for molding process. This pattern is employed in processes where casting structures are weak and that they may break after the appliance of force. 11. Segmental Pattern:  Segmental Pattern It is just an identical thereto of sweep pattern. The working structure of segmental pattern and sweep pattern is nearly similar. For designing require shape or structure of mold they both employ a neighborhood of pattern. As the name suggest segmental pattern is in the form of segments and used for molding circular or round structures. In sweep pattern there's complete rotation but in segmental pattern there's no complete rotation. For creating mold, we will rotate partly to urge required output. 12. Shell Pattern:  Shell Pattern ...

7. Sweep Pattern:   Sweep Pattern In sweep pattern we use of wooden board. The wooden board of proper size is to be rotated about one edge to shape the cavity as circular symmetry. Sweep pattern is usually used once we need to create casting in very short interval of your time. Molds of in depth symmetrical casting are often made easily with the assistance of sweep pattern. There are three parts in sweep pattern spindle, base and sweep which is wooden board. The spindle is directed in vertical direction and the base is attached with sand. 8. Loose Piece Pattern:  Loose Piece Pattern It is very difficult to get rid of one piece of solid pattern which is above or below the parting plane having projections from the mold. With the assistance of loose piece sorts of patterns projections are often made by loose pieces. It requires skilled labor work also because it is extremely expensive. There is one disadvantage of this loose piece pattern is that their sh...

4. Match Plate Pattern:  Match Plate Pattern Basically Match plate pattern may be a split pattern. Cope and drag areas are on the other faces of metallic plate. This metallic plate is termed as Match Plate. This sort of pattern requires very less diligence and provides very high output. Because the gates and runners also are on the match plate. this is often utilized in various manufacturing industries. This is often very expensive and provides accuracy also as high yield. This pattern is widely used for casting metals like aluminium. 5. Gated Pattern:   Gated Pattern Gated sorts of patterns are wont to make multiple components inside the only mold. Gated pattern is nothing but the pattern consisting one or more patterns. For joining different patterns gates are used. These are loose patterns where gates and runners have already attached. These patterns are very expensive. Thanks to their high cost they're used for creating small castings. These small ca...

1.    Solid or Single Piece Pattern:   Single Piece Pattern Single piece pattern is that the cheapest pattern among all other sorts of pattern. This pattern generally utilized in simple processes. It’s applied in small scale production. It’s often used for the generation of huge castings like packing box of external-combustion engine and for creating simple shapes, flat surfaces like simple rectangular blocks. The important characteristic of this pattern is that there's no need of joint within the mold area. During this pattern one surface is taken into account as flat portion. This flat surface is employed for parting plane. Sand tools are wont to cut the sand which ultimately makes gating system. The molding becomes a difficult task if there's absence of this flat surface. It’s expected to dwell cope or drag. 2.    Split Pattern:  Split Pattern Split piece pattern is additionally called as Two- piece pattern. It’s the popularly used ...

  Pattern: Pattern is that the replica of the device which is that the output of casting process. This when molded in sand forms mold. After filling mold with the molten metal there's a formation of casting. Patterns play a really important role in casting as they decide the standard also as perfection during a particular casting process. Gates and runners are the foremost important components in several sorts of pattern. Pattern is that the basic requirement for creation of mold and it's always bigger than the dimensions of casting. There should be a correct selection of pattern so it must be ready to sustain rough handling. It forms mold cavity for casting processes. The patterns could also be made from metals like aluminum, brass, plaster and wax.   Sorts of Patterns:  Types of Pattern Following are the common sorts of patters: 1. Single piece pattern 2.   Split pattern 3. Gated pattern 4. Multi piece pattern 5. Match plate pattern...

Types of Precious Metals: This kinds of metals are divided into three subgroups: gold and gold alloys, silver and silver alloys, platinum group metals (consists of six metals extracted from nickel ores: platinum, palladium, rhodium, iridium, ruthenium, and osmium). These metals are nearly completely corrosion resistant. Platinum metals withstand up to 1760 °C without any evidence of erosion and corrosion. Following are the types of Precious Metals: Gold (Au):  Gold Very soft, ductile material that undergoes very little work hardening. Gold is often alloyed with other metals (such as copper) for greater strength. It has many kinds of occasional uses as a reflecting surface, attachments to transistors and jewelry. Silver (Ag):  Silver The least costly metal of this group. Very corrosion resistant. Plated onto low-voltage electrical contacts to stop oxidation of surfaces when arcing occurs. Used in photographic emulsions due to photosensitivity of silve...