Moulding Tools: Learn About Various Tools For Moulding and their Functions

Moulding tools are indispensable instruments utilised in various manufacturing industries to create complex and intricately designed products. These tools serve as the backbone of the moulding process, enabling the precise shaping and reproduction of a wide range of materials, such as plastic, metal, ceramics, and composites. With their ability to transform raw materials into finished components, moulding tools play a pivotal role in achieving consistent and high-quality output for mass production, prototyping, and custom manufacturing applications. From injection moulding machines to blow moulds, the evolution and innovation of these tools have revolutionised modern production techniques, making them an essential asset for countless industries worldwide.

The current discussion will elaborate on different types of moulding tools and their functions. This topic is important for your upcoming examinations like SSC JE ME and RRB JE Mechanical Engineering.

Moulding tools are important in foundry operations for preparing sand moulds. They are classified into hand tools and power tools. The commonly used moulding hand tools comprise riddle, rammer, trowel, and others. Draw spikes and rapping bars are used to remove patterns, while gate cutters shape the gating system. Bellows blow away loose particles. For industrial settings, pneumatic rammers and vibrators improve efficiency and uniformity. These tools ensure precision, smooth surfaces, and effective mould cavity preparation.

Shovel

One of the primary foundry tools, the shovel features a broad metal blade attached to a long wooden handle. It is instrumental in transporting moulding sand from the sand pit to the moulding box and is also used for mixing and tempering the sand by adding sufficient water.

Riddle

A metal sieve is utilised to eliminate foreign materials, such as stones and nails, from the moulding sand.

Rammer

This tool is employed to pack or ram the moulding sand into the moulding box firmly.

Trowels

Used for smoothing the surfaces of the mould and repairing any damaged portions.

Slick

This tool helps in repairing and finishing surfaces, as well as rounding corners of the mould.

Lifter

Used to remove loose sand from the mould and finish the bottom and sides of the mould.

Strike off bar

This tool is used to remove excessive sand from the mould after tempering.

Sprue pin

Employed to create a sprue hole, allowing the molten metal to be poured into the mould.

Vent rod

Used to create vent holes in the sand mould, allowing molten gases to escape during the casting process.

Bellows

This tool aids in blowing off loose sand particles from the mould and pattern.

Gate cutter

Used for cutting gates and runners in the mould, facilitating the casting process.

Swab

The swab serves the purpose of moistening the sand around the pattern's edge before its withdrawal, comprising a soft hairbrush at one end to retain water and a rubber bulb at the other end.

Draw Screw

A draw screw, a pointed steel rod with a loop at one end, is employed to extract the pattern from the moulding sand.

Mallet

A mallet is used to loosen the pattern in the mould so that it can be removed easily.

Gagger

Gaggers, iron rods or thick wires bent at one or both ends are used to reinforce the moulding sand in the cope part of the moulding box.

Rapping Plate

The rapping plate, a steel plate securely attached to the top of the pattern using bolts and screws, serves to lift the large and heavy pattern from the mould.

Spirit level

The spirit level is employed to maintain a horizontal position for the sand bed, moulding box, and table, comprising an air bubble inside a curved glass tube.

Other Components Required for Moulding

The various components required for Moulding include:

• Moulding Sand (Green Sand)
• Moulding Boxes
• Pattern

Moulding Sand: 

Moulding Sand, also known as Green Sand, is a vital aggregate comprising sand, bentonite clay, pulverised coal, and water. Primarily utilised in metal casting, it plays a crucial role in creating moulds for various components. The key ingredient in the aggregate is sand, which can be either silica or olivine. This type of sand is stored in flasks, essentially boxes without a bottom or lid, divided into two halves known as the top (cope) and bottom (drag) flask. Although it is called Green Sand, its name refers to its wet state, much like green wood.

Moulding Box:

Also called a Moulding Flask, this frame or box is crafted from wood or metal, with wood being the cheaper but less durable option, particularly in contact with hot metal. For mass production, metal boxes made of steel, cast iron, or aluminium alloys are commonly used. Moulding boxes serve the purpose of creating sand moulds for the casting process.

Pattern:

A Pattern in casting serves as a replica of the object to be cast, which is essential in preparing the cavity where the molten material will be poured during casting. These patterns, used in sand casting, can be crafted from various materials like wood, metal, or plastics. Pattern making is a skilled trade that shares similarities with tool and die making and mould making, often incorporating fine woodworking techniques.

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Moulding Tools Comparison

It is important to select the right moulding tool as per the requirements. There are various factors that need to be considered while selecting the moulding tool. A detailed comparison of moulding tools is provided in the table below. 

Tool Name	Cost	Durability	Ease of Use	Remarks
Shovel	Low	High	Easy	Ideal for lifting and mixing sand.
Riddle	Low	Moderate	Easy	Used for sieving sand; handle with care to avoid damage.
Rammer	Low	High	Moderate	Heavy tool used for compacting; requires manual effort.
Trowel	Low	High	Very Easy	Used for repairing and finishing surfaces.
Slick	Low	High	Easy	Finishing tool for corners and small surfaces.
Lifter	Low	Moderate	Easy	Removes loose sand; care needed to prevent breakage.
Draw Spike	Low	High	Moderate	Used for withdrawing patterns; may require force.
Vent Wire	Very Low	Moderate	Very Easy	Delicate; used for making vent holes.
Strike-Off Bar	Low	High	Easy	Strikes off excess sand for a level surface.
Gate Cutter	Very Low	Moderate	Very Easy	For cutting runners and gates in sand moulds.
Bellows	Medium	Moderate	Easy	Blows away loose sand from cavities.
Pneumatic Rammer	High	Very High	Easy	Expensive but efficient and ergonomic.
Rapping Bar	Low	High	Moderate	Loosens the pattern before withdrawal.

Moulding Tools Advantages

Candisaets can check the advantages of various moulding tools below. 

• They help to get accurate and detailed impressions in the mould cavities. 
• Hand tools like trowels and slicks ensure smooth internal mould surfaces.
• Moulding tools help to increase the production capacity. 
• A variety of tools are available for different patterns and casting requirements.
• Most basic tools are inexpensive and durable, with low maintenance needs.

Disadvantages of Moulding Tools

Applicants can check the disadvantages of moulding tools below. 

• Manual tools require physical effort and skilled labor.
• Variability in output can occur without proper technique and maintenance.
• Compared to automatic moulding systems, manual tooling takes longer.
• Frequent use may lead to damage or wear of certain tools (e.g., riddles, vent wires).
• Basic tools are less effective for complex geometries or mass production.
• Improper use of tools can result in defective moulds or casting failures.

Applications of Moulding Tools

There are many moulding tool applications in industry. It is important to use a specific type of tool as per the operation's purpose. For more information, candidates can refer to the table provided below. 

Application Area	Tools Commonly Used	Purpose
Pattern Making	Draw spike, Rapping bar, Riddle	Loosen and extract patterns cleanly from moulds
Mould Cavity Preparation	Rammer, Lifter, Trowel, Slick	Create and refine the mould cavity shape
Surface Finishing	Trowel, Slick, Lifters	Ensure a smooth finish for better casting quality
Ventilation	Vent wire	Prevent gas entrapment by creating air escape paths
Gating and Riser System	Gate cutter, Strike-off bar	Shape the flow channel for molten metal
Sand Blowing	Bellows	Clean cavities and remove loose sand particles
Industrial Use (High Volume)	Pneumatic rammer, Vibrators	Increase productivity and compaction uniformity

This blog highlighted the different Moulding tool used and their functions. We recommend our readers they should appear in the SSC JE Mechanical mock tests and SSC JE ME Previous Years Papers. Also, get enrolled in the AE/JE Mechanical coaching to get a firm grip on the subject.

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