Sand rammer

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A sand rammer is a piece of equipment used in foundry sand testing to make test specimen of molding sand by compacting bulk material by free fixed height drop of fixed weight for 3 times. It is also used to determine compactibility of sands by using special specimen tubes and a linear scale.

Foundry sand testing is a process used to determine if the foundry sand has the correct properties for a certain casting process. The sand is used to make moulds and cores via a pattern. In a sand casting foundry there are broadly two reasons for rejection of the casting — metal and sand — each of which has a large number of internal variables. The defects arising from the sand can be prevented by using sand testing equipment to measure the various properties of the sand.

Molding sand, also known as foundry sand, is a sand that when moistened and compressed or oiled or heated tends to pack well and hold its shape. It is used in the process of sand casting for preparing the mould cavity.

Contents

Sand Rammer Rammersand.jpg
Sand Rammer

Mechanism

Sand rammer consists of calibrated sliding weight actuated by cam, a shallow cup to accommodate specimen tube below ram head, a specimen stripper to strip compacted specimen out of specimen tube, a specimen tube to prepare the standard specimen of 50 mm diameter by 50 mm height [1] or 2 inch diameter by 2 inch height for an AFS standard specimen. [2]

The American Foundry Society (AFS) has a three-part mission of advocacy, education and innovation in the $33 billion metalcasting industry. It serves all metalcasting industry producers, suppliers, and end users, including all metals and all processes. The organization traces its roots to 1896 when the American Foundrymen's Association was formed. The Association was subsequently named The American Foundrymen's Society, and later the name was adjusted to the American Foundry Society, or AFS. The society is considered an international organization consisting of 7,500 members across 48 countries, organized into more than 40 regional chapters and 34 student chapters in the United States, Canada and Mexico. The AFS promotes the interests of the foundry industry to the federal government and consists of a professional staff and volunteer committee structure. The six major areas of focus are: 1) Member Success and Sustainability; 2) Industry Stewardship; 3) Policy Advocacy; 4) Promotion of Castings; 5) Workforce Development; and 6) Technical Innovation. AFS develops and funds research to address metalcasting technical needs. The organization also maintains a Washington DC office and advocates for public policies conducive to a strong metalcasting industry. The AFS Institute, formerly Cast Metals Institute, provides education on metalcasting processes, materials and disciplines, and launched an e-learning initiative on July 1, 2016. AFS is based in Schaumburg, Illinois. Doug Kurkul joined AFS as CEO in January, 2016.

Specimen preparation

The cam is actuated by a user by rotating the handle, causing a cam to lift the weight and let it fall freely on the frame attached to the ram head. This produces a standard compacting action to a pre-measured amount of sand.

Variety of standard specimen for Green Sand and Silicate based (CO2)sand are prepared using a sand rammer along with accessories

Specimen Type of sand
Compression (Cylindrical) Green Sand and Silicate based sand
Tensile Specimen Silicate based sand
Transverse Specimen Silicate based sand

The object for producing the standard cylindrical specimen is to have the specimen become 2 inches high (plus or minus 1/32 inch) with three rams of the machine. After the specimen has been prepared inside the specimen tube, the specimen can be used for various standard sand tests such as the permeability test, the green sand compression test, the shear test, or other standard foundry tests.

The sand rammer machine can be used to measure compactability of prepared sand by filling the specimen tube with prepared sand so that it is level with the top of the tube. The tube is then placed under the ram head in the shallow cup and rammed three times. Compactability in percentage is then calculated from the resultant height of the sand inside the specimen tube.

A rammer is mounted on a base block on a solid foundation, which provides vibration damping to ensure consistent ramming.

Used for sand types

Prerequisites

Prerequisite equipments for sand rammer may vary from case to case basis or testing scenario:
Case 1: If the prepared sand is ready


Case 2: Experiment by preparing new sand sample If sand needs to be prepared before making specimen following equipments may be needed


Case 3: For low compressive strength sands and mixtures:

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References

  1. Indian standards for Physical testing of foundry sands
  2. AFS Mould & core test hand book