Improving the Performance of Foundry Industry through FNB Sand Mould System

Abstrakt

There are many new advanced technologies for casting of metal, furan no bake (FNB) sand casting remains one of the fastest spreading and used casting processes today due to the lower cost of raw materials, a wide variety of castings with respect to composition and size, and the possibility of reclaiming the moulding sand. The FNB sand casting process is one of the most versatile processes in manufacturing as it is used for most metals and alloys with high melting temperature such as copper, molten metal iron and nickel. The FNB sand casting process consists of preparation of furan no bake mould, pouring molten metal into a FNB sand mould, allowing the metal to solidify, and casting product can then be machined to remove a casting product. The casting product is then machined to remove surface defects or imperfections or to add new features by standardized methods of machining such as milling, grinding, turning and polishing. The sand used in the furan no-bake process is typically bonded with hardener and resin to mould the sand. The sand can be recycled multiple times but each recycling requires the addition of hardener and resin. If the proportions of hardener and resin are not appropriate, the bonding strength of the furan no-bake sand mould would be reduced. This leads to a substantial reduction in the properties of the sand mould and as a result increases the rate of rejection in terms of casting defects. Defects in casting can negatively affect the bottom line of a foundry. They manifest as casting scrap costs. In many cases, the defects in casting may be seen at the machining stage, during usage of the component. The resultant value added costs and may sometimes be passed on to the foundry by their customer. These charges may be significantly extra than the cost of the production of casting itself. Foundry personnel must have the time to conduct a detailed analysis of casting defects, determine root causes and implement those which are most effective to prevent re/occurrence of these defects. This paper mainly deals with the evaluation of quality of furan no-bake sand and its effect on major defects. This paper also covers causes and remedies of FNB (Furan No Bake) sand casting system; and increases in productivity of the plant by improving quality of sand and minimize defect of castingCite this Article Acharya Shailee G, Vadher Jeetendra A, Kartik Kothari. Improving the Performance of Foundry Industry through FNB Sand Mould System. Journal of Production Research and Management. 2016; 6(3): 26–30p.