DESIGN AND FABRICATION OF

SAND MULLER
Submitted in the partial fulfillment of the requirement for the award

DIPLOMA

IN MECHANICAL ENGINEERING (FOUNDRY)

SUBMITTED BY:

1. P.JAYACHANDRU
2. C.VIGNESH
5.R.PRITHIVIRAJAN
3. K.SURENDHAR

4. S.HARI

Under guidance of
Mr V.K.RAJENDRAN, M.E.
OCTOBER 2015
DEPARTMENT OF MECHANICAL ENGINEERING (FOUNDRY).
A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGE
CHENNAI 600123

A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHENNAI- BANGALORE ROAD
SEMBARAMBAKKAM
CHENNAI 600123

BONAFIDE CERTIFICATE
This is to certify that this Project work on
DESIGN AND FABRICATION OF SAND MULLER

submitted by . Reg. No.

in partial fulfillment for the award of
DIPLOMA IN MECHANICAL ENGINEERING (FOUNDRY)
This is the bonafide record of work carried out by him under our supervision
during the year 2015

Submitted for the Viva-voce exam held on ..

H.O.D

INTERNAL EXAMINER

PROJECT GUIDE

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the

Principal Mr. A.VIJAY KISHORE,M.TECH for encouragement and
valuable advice.

We thank our Esquired Head of Department Mr. S.N. SUNDAR, M..E.

for presenting his filiations on us.
We are grateful on our Entourages Mr. V.K.RAJENDRAN, M.E.
For guiding in various aspects of the project making it a grand success.
We also owe our sincere thanks to all staff members of the Mechanical
Department and Foundry Department.

Ultimately, we extend our thanks to all who had rendered their cooperation for the success of the project.

CONTENTS

CONTENTS

SYNOPSIS
INTRODUCTION
NECESSITY
CONSTRUCTION
WORKING PRINCIPLE
COMPARISON
SPECIFICATION
PAINTING & FINISHING
DRAWINGS
FEATURES OF SAND MULLER
COST ESTIMATION
CONCLUSION
BIBLIOGRAPHY

SYNOPSIS

SYNOPSIS

In our project fabrication of sand mixing Muller. The mixing and

conditioning of sand is done automatically by the sand Muller. In early days
in industries are using manual method so to reduce the time and money.
We have to make the sand Muller. In this Muller, metal wheels rotating at
slow speed over the tempered moulding sand mixture.
The sand, moisture, additives, binded is mixed thoroughly and
uniformly. The cost of preparing the moulding sand by using Muller is
economically cheap. The time taken for conditioning of sand is less than
that when we use manual or old method. Ater mixing the sand it may be
taken out from a drop door at the bottom of the Muller.

INTRODUCTION

INTRODUCTION

The recent innovation in the development of the foundry industry compels

the use of sand mixing muller in the place of manual equipment such as
shovel etc. If significantly reduces the man power and mixing time.
The sand mixing muller eliminates any use of manual equipment for Co 2Silicate and mixing. The sand mixing muller does not read only manual
sacrifice for mixing the sand.
Now-a-days almost all the foundries in our country are involved in mass
production and they have achieved that with the aid of sand mixing muller
as part of their plant mechanization.

NECESSITY

NECESSITY

SAND MIXING MULLER

"The Foundry Sand Muller is a specialized production machine and a
foundry men judges the muller by sand its produce". Many million of varied
particles must be uniformly intermingled and surface coated with viscous
bond consisting of bentonite plus water.
"Water and bond must be kneaded into a dough-like consistency with
development of adhesive glue properties. So that the glue can readily
encompass the sand grains".
As mulling produces, the mixture becomes more uniform with the respect
to physical and mechanical properties. In most foundries extent of mulling
is established on an arbitrary time or mulling energy basis, as a function of
sand capacity demand.
The mulling process "should loose complete disorder so that mulled
product is uniform throughout when it sampled and tested".
Probability Laws tells that some sand grains will not be moved at all in the
mulling action, while a like number be moved continuously. In other word,
"movement is strictly random".

CONSTRUCTION

CONSTRUCTION

The equipment is made up of 3 mm thick mild steel sheet metal.

The equipment is consists of stationary cylindrical steel shell of small
capacity. The mouth is provided at the side of the cylindrical steel shell.
The opening and closing of mouth is done with provision of shutter door.
The mouth controls the uniform flow of sand, after the mixing.
The cylindrical steel shell is mounted from the base with the help of four
legs provided on the four corner of cylindrical shell.
An electric motor is provided at the base of the equipment. The motor shaft
is connecting with the plunge. The bearing plates are supported by 4
number of welded pillars.

WORKING PRINCIPLE

WORKING PRINCIPLE

The principle of working of sand mixing muller is that the two rotating
wheel, rotates above the mounted axis for uniform mixing of sand particles
present inside the steel shell. The principle of mulling is performed for both
Co2 and green sand molding process.
The primitive ingredients namely,
1. Molding Sand.
2. Saw Dust.
3. Bentonite Powder
4. Required Moisture.
are filled inside the steel shell.
The muller is switched on so that the rotatary motion is transferred from
the motor to the motor shaft through the reduction gear box. As a result the
two rotating whell starts rotation in the clock-wise direction of the speed of
900 rpm due to this rotating effect, the sand particles runs through the steel
shell freely. As the particles run through the added ingredients mixes with
one another finely.
Due to the speed rotating of wheel there is a chance for the molding sand
to stack over the centre of the assembly to prevent this two sharp edged
blade are provided.
This is performed for about 15 minutes or up to the uniform mixing of sand
which is earlier. Finally the shutter door provided is opened and the sand is
collected through the mouth in the sand collector.

COMPARISION OF SAND
MULLER BETWEEN
HAND MULLING

COMPARISION OF SAND MULLER BETWEEN HAND

MULLING

SL.NO.
1.
2.
3.

SAND MULLER
Higher Production Rate
Continuous Production
Requirement Manual Power is

HAND MULLING
Low Production Rate
Not as Sand Muller
Requirement of Manual

4.
5.

less
Cost of Production is less
Uniformly
sand
mixing

6.

guaranteed
as sand muller.
Quality of sand produced remain Quality depends upon the

1.
2.

same for ever process.

worker
LIMITATION
Intial cost is high
No initial cost is needed
It requires electric or any power No such thing is needed.

3.

sources
Conveying of sand is difficult

power is high
Cost of Production is high
is Uniformly sand mixing is not

Process can be carried out

at work place

SPECIFICATION

SPECIFICATION

Over all Height of Muller -

900 mm

CYLINDRICAL SHELL
Diameter

600 mm

Height

600 mm

Thickness

3 mm

Base Thickness

5 mm

ROTATING WHEELS
Diameter

30 mm

Length

30 mm

Rpm -

900

MOTOR
Rpm -

1800

Phase

H.P. -

0.25

BASE

Single Phase

Height

350 mm

ADVANTAGES

ADVANTAGES

It requires simple maintenance cares.

. Thus this project does not require any cooling arrangements.

USED as a re production system for foundry sand.

Checking and cleaning are easy because of the main parts are screwed

Easy to Handle.

DISADVANTAGES

DISADVANTAGES

Initial cost is high

Electric power Required
Noise In Operation
High maintenance cost

APPLICATION

APPLICATIONS

It is very much useful for foundry plant.

It is used to recondition the sand

for making moulding sand.

FEATURES OF THIS PROJECT

It can installed easily

LOW electrical power consumption
It can be utilized
It is simple in construction
Low cost
Less weight and easy to handle
Life of system increased
It is simple in operation..

PAINTING AND
FINISHING

PAINTING AND FINISHING

JOB PREPARATION:
Before welding, remove any bend in the L angle with the sludge hammer
on the anvil block. Then it is cut to the required length with the hacksaw
blade and fabricated to required dimensional shape with are welding.
FINISHING OPERATION BEFORE PAINTING:
After welding, any slag on the welded area is removed with the chipping
hammer and cleaned with the metal wire brush. Then all the surfaces are
rubbed with the emery sheet.
Metal primer is applied on the surfaces with the brush. After drying the
metal primer, the second coating is applied with the paint.

DRAWING

FEATURES OF SAND
MULLER

FEATURES OF SAND MULLER

It is compact in size
It can be move
The electrical power consumption is very low

 It can be utilized at our work shop

It is simple in construction
Low cost.
Less weight and easy to handle
It reduces the man power
It is used in mass production

COST ESTIMATION

COST ESTIM ATION

1.

Electric Motor 1/4th HP

---------------------------------

2600.00

2.

Rotating whell and sand guide -------------------------

500.00

3.

Muller Stand ------------------------------------------------

500.00

4.

Muller drum -------------------------------------------------

1800.00

5.

Painting and finishing ------------------------------------

200.00

6.

Transportation Charges ---------------------------------

200.00

7.

Miscellanies charges --------------------------------------

100.00
-----------5900.00

CONCLUSION

CONCLUSION
This project gives all the necessary experience that "which one resembles
as a simple shape, provides a great work under production". This project
cannot be finished by simply buying the products as available in the
outside market. As we it self carried out all the work involved in the
production ofthis project, expect fabrication work. We experienced the
actual difficulties in the production.

We once more thankful to our honourable industrial superiors, professors

and friends those helped mostly for our successful completion of this
project and also thankful to our honourable principal who gave permission
for the use of materials in the college for our project work.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. MANUFACTURING PROCESS BY S.S.MANIAN

2. PRODUCTION TECHNOLOGY BY JAIN

3. MACHINE SHOP TECHNOLOGY BY S.S.MANIAN

4. WORKSHOP TECHNOLOGY BY HAJRA CHOUDRY

5. A TEXT BOOK OF FOUNDRY TECHNOLOGY - O.P.
KHANNA

PHOTO VIEW