No Bake Versus foamcast Lost Foam Metal Casting Technology
| Process Steps involved in foamcast | |||
| Pre-formed EPS bead fead in Pattern Mold. | = | EPS bead Rate Rs.95.0/kg Density of EPS Pattern, 45Kg/cu.mt. 1.0kg of Molded EPS equivalent to 185kgs of cast steel EPS rate per kg of casting Rs.0.515 EPS Feeding Cycle Time approx. 1.5 - 2 mins | |
| I | I | ||
| Assembly of EPS Patterns | = | Approx. time 15 minutes per pattern cluster | |
| I | I | ||
| a. Slurry Prime Coat followed by stucco & then Dried b. Slurry back-up Coat followed by stucco & then Dried | = | Ceramic Coatings Rs. 50.0/kg Shell to metal Ratio 0.08:1 with a 65% yield Shell cost Rs. 7.15/kg of finished casting Approximate Cycle Time - 4 Hours | |
| I | I | ||
| Drying of Coated Pattern/Cluster | = | 3 Hours | |
| I | I | ||
| Burn-Off of EPS Pattern & Shell Sintering | = | 40 Minutes | |
| I | I | ||
| Ash removal & quality check of Shell | = | 15 Minutes | |
| I | I | ||
| Placing Ceramic Shell at Room Temp. in Molding Box | = | 5 Minutes | |
| I | I | ||
| Metal Pouring | = | 1.0 Ton in 20 Minutes with assistance of 4nos. Workers | |
| I | I | ||
| Knock-out & Shell Removal | = | Thin shell requires short vibratory knockout & shot-blasting | |
| Process Steps involved in No Bake Process: | |||
| Mix moulding sand Mould cope and drag Mix core sand Mould cores | = | Mixed sand = Rs. 1.5 / kg 4.5kg sand = 1.0 kg cast metal Sand cost = Rs.18.0/kg finished casting | |
| I | I | ||
| Hardening of cores and molds | = | Approx. 25 Minutes | |
| I | I | ||
| Painting of Cores & Mold Cavity | = | Paint cost Rs.3.0/kg cast metal | |
| I | I | ||
| Clean mould Set cores Close mould Clamp mould | = | 8 molds per hour 6 man team for moulding, painting and closing 1 mold per man hour | |
| I | I | ||
| Metal Pouring | = | 1.0 Ton in 25 Minutes with assistance of 5nos. Workers | |
| I | I | ||
| Knock-out & finishing | = | Grinding wheels Rs.6.0/kg finished casting Welding rod Rs.5.0/kg finished casting Plus labour content to remove risers & flash | |