Recommended Process:

1

Most recommended process to make anchor is sand casting. Most companies uses sand casting process especially to make anchor.

Molds used:The type of mold used is green sand mold.

Green sand mold:

A green sand mold is very typical in sand casting manufacture, it is simple and easy to make, a mixture of sand, clay and water. The term green refers to the fact that the mold will contain moisture during the pouring the casting.

Binders

Clay, water and additives are used in the process.

Reason to Use:

Because of its high collapsibility, permeability, reusability, low cost and sufficient strength.

MOLD ACCESSORIES:

Green sand Flask Cope and drag Aluminum Pattern Core Core print Sprue with pouring cup Riser Runner Gate Chaplets Well

Sequence of Manufacturing Process:

2

MATERIAL SELECTION:

Carbon steel is used for the manufacturing of an anchor.

CASTING:

As Carbon steel is ferrous related high melting point material, hence we prefer sand casting for its manufacturing.

PATTERN

The patterns are made of metal because of mass production.

We have used one pattern in mold in our process.

CORE MAKING:

In the anchor we have selected; core is not always required as there is no inner part to be formed.

MOLD MAKING:

The most suitable type of mold for this process is green sand mold as the requirements is to have high collapsibility , permeability, less cost and the strength of material. Here we also incorporate the addition of riser sprue runner and gating system.

MELTING OF RAW MATERIAL:

The raw material is collected in a furnace and then heated till the temperature reaches 2000°C above the melting point of the carbon steel which is 1426-1523°C.

POURING:

The molten metal is then poured in the mold with the help of ladle.

SOLIDIFICATION AND COOLING:

After pouring the total system should be kept for cooling.

REMOVAL OF MOLD:

Mold is removed by shaking it with machine.

Finishing Operation:

3

Machining operation:

REMOVAL:

After the predetermined solidification time has passed, the sand mold can simply be broken, and the casting removed. This step, sometimes called shakeout, is typically performed by a vibrating machine that shakes the sand and casting out of the flask.

TRIMMING:

During cooling, the material from the channels in the mold solidifies attached to the part. This excess material must be trimmed from the casting either manually via cutting or sawing, or using a trimming press.Apart from that there is a hole in the object which isnot part of the pattern or core that is made by mahinning.

Some sort of mechanical finishing would be required to remove that parting line.

INSPECTION & TESTING:

Inspection follows, to check for defects in the casting as well as to ensure that the casting has the dimensions specified on the drawing.

VISUAL INSPECTION:

It consists of inspecting the surface of the casting with naked eye or sometimes with a magnifying glass or microscope. It can only indicate surface defects such as blow holes, fusion, swells, external cracks, and mismatch.

DIMENSIONAL INSPECTION:

Dimensional inspection is carried out to make sure that the castings produced have the required overall dimensions including allowances for machining.

ULTRASONIC TESTING:

Ultrasonic rays are passed to check defects like cracks and voids within the interior of the casting.

Pattern:4

Final product:

Mold:

5

1)Cope

2)Drag:

2D Sketch of Anchor:

6

7