Deen Dayal Upadhyaya Gorakhpur Univesity
Gorakhpur(273010)
FOUNDRY
SHOP
Presented by: Aastha Mishra
Department : Computer
Science and Engineering(CSE)
01 02 03
Introduction Process Pattern making
overview
OVERVIEW 04 05 06 07
Mold making Melting and pouring Cooling and Removal from
solidifcation mold
08 09 10 11
Finishing and
Applications Challenges Conclusion
inspection
01 INTRODUCTION TO FOUNDRY
A FOUNDRY IS A FACTORY WHERE METAL
CASTINGS ARE PRODUCED BY MELTING
METAL AND POURING IT INTO MOLDS.
Definition: Metal casting is a manufacturing process in which
liquid metal is poured into a mold to create a specific shape.
History: Metal casting dates back to ancient civilizations
(Egypt, Greece, Rome).
Importance: Foundries produce castings for various
industries (automotive, aerospace, medical, art).
02 FOUNDRY PROCESS OVERVIEW
The foundry process involves several stages to
produce high-quality castings.
Pattern making:
01 Creating a replica of the desired part.
Mold making: Creating a mold to shape the
02 molten metal.
Melting and pouring: Heating metal to its
03 melting point and pouring into molds.
Cooling and solidification: Allowing the metal to
04 cool and solidify.
05 Removal from mold: Extracting the casting
from the mold.
Finishing and inspection: Cleaning, machining,
06 and inspecting the casting.
03
Patterns are replicas of the desired part,
used to create molds.
Materials: wood, plastic, metal, wax.
Techniques: carving, 3D printing, CNC machining.
Considerations: size, shape, material, and
dimensional accuracy.
04
Molds shape the molten metal into the
desired form.
Materials: sand, clay, graphite,
ceramic.
Techniques: hand molding,
machine molding, investment
casting.
Considerations: mold strength,
permeability, and surface
finish.
05
Heating metal to its melting point and
pouring into molds.
Furnace types: electric, gas,
induction.
Safety precautions: heat protection,
ventilation.
Pouring techniques: gravity pouring,
pressure pouring.
06
Allowing the metal to cool and
solidify.
Cooling methods: air, water, oil.
Factors affecting solidification:
temperature, time, mold material.
Considerations: shrinkage, porosity,
and defects.
07
Extracting the casting from the
mold.
Methods: vibration, chemical release
agents.
Safety precautions: protective gear,
proper lifting.
Considerations: mold damage,
casting damage.
08
Cleaning, machining, and
inspecting the casting.
Finishing techniques: grinding, sanding,
machining.
Inspection methods: visual,
radiography, testing.
Considerations: surface finish,
dimensional accuracy.
09
Foundries produce castings for
various industries.
Automotive parts (engine blocks,
cylinder heads).
Aerospace components (turbine blades,
rocket parts).
Medical equipment (implants, surgical
instruments).
Artistic sculptures and decorations.
SHORT-TERM
10 CHALLENGES
LONG-TERM
CHALLENGES
L
ENVIRONMENTAL REGULATIONS :
STRICTER EMISSIONS CONTROLS AND WASTE
MANAGEMENT REQUIREMENTS.
RAW MATERIAL PRICE VOLATILITY:
FLUCTUATIONS IN METAL AND ENERGY COSTS.
LABOR SHORTAGES:
AGING WORKFORCE AND DIFFICULTY ATTRACTING NEW
TALENT.
GLOBAL COMPETITION:
INCREASING COMPETITION FROM LOW-COST PRODUCERS.
QUALITY CONTROL :
MAINTAINING HIGH-QUALITY STANDARDS AMIDST
PRODUCTION PRESSURE.
SUSTAINABILITY AND CLIMATE CHANGE:
REDUCING CARBON FOOTPRINT AND ADAPTING TO
CLIMATE CHANGE.
DIGITAL TRANSFORMATION:
INTEGRATING NEW TECHNOLOGIES (INDUSTRY 4.0, IOT, AI).
CHANGING MARKET DEMANDS:
SHIFTS IN INDUSTRY TRENDS (E.G., ELECTRIC VEHICLES).
SKILLS GAP:
ADDRESSING THE NEED FOR SPECIALIZED SKILLS IN
EMERGING TECHNOLOGIES.
CYBERSECURITY:
PROTECTING FOUNDRY OPERATIONS FROM CYBER
THREATS.
The foundry industry plays a vital role in
manufacturing, producing metal castings for
various sectors. The process involves pattern
making, mold making, melting, pouring, cooling,
11 removal, and finishing. Applications include
automotive, aerospace, medical, and art. Despite
challenges, the industry is driven by growing
demand from electric vehicles, renewable energy,
and aerospace. To address challenges,
collaboration and investment in technology and
workforceL
development are crucial. Embracing
sustainability and innovation will ensure future
growth. By understanding the foundry process and
its applications, we can unlock opportunities for
advancement and economic development. The
future of foundry looks promising with emerging
trends.
