1

A REPORT ON VACATIONAL INDUSTRIAL TRAINING COMPLETED AT

SUBMITTED BY ,

MR. GOPI NAIDU MR. VIJAY SHINDE MR. SAGAR GAVALI MR. SANDESH AWATI MR. SAGAR PAWAR MR. RUSHIKESH PARAGONKAR MR. SWAPNIL KOSHTI

P.V.P.I.T , BUDHGAON

INDEX

SR.NO 1 2 3 4 5 6

TOPIC FOUNDRY INTRODUCTION RAW MATERIAL CORE SHOP PATTERN SHOP MOULDING SHOP MELTING AND POURING SHOP FINISHING PROCESS FINAL INSPECTION

PAGE NO 3-5 6-13 14-22 23-24 25-34 35-44

7 8

45-48 49

FOUNDRY : -

INTRODUCTION:

- A foundry is where the elaborate metal casting process takes place. A metal foundry may specialize in making one particular item or a variety of products using different alloys. Based on the production requirement, there are small foundries that employ few people and large industrial foundries that employ thousands of workers.

HISTORY: -

Foundry operations of the present day is an outcome of thousands of years of experimenting with different metals and casting methods. Very little documented evidence of casting and foundry operations are available of the ancient time. The proof of castings are in the form of jeweleries, household items and religious times that were unearthed during excavations or preserved as historic relics. The foundry process was first documented circa 1500 by Vannoccio Biringuccio who is know as the "father of the foundry industry". Rapid growth in the casting industyr took place in the industrialization age. With the invention of machines and equipment in the industiral age, casting could be done on a large scale. The scientific revolution in this century increased the demand of casting products for automobiles, machines, weapons, etc. In the modern era, metal casting finds its application from kitchen wares to aircraft components.

TYPES OF FOUDRIES: -Depending upon the type of end users, the wide variety of
molding or the casting process can be basically divided into- Commercial foundry and Hobby foundry.

COMMERCIAL FOUNDRIES: - Here the production activity is on a large scale and in

abidance to the international standards of manufacturing practice. This type of foundry offers semi-finished or fully finished products like Railroad Equipment, Machine Tools, Farm Machinery, Mining Machine, etc. Major types of casting employed in commercial foudries are sand casting, die casting, investmet casting and lost foam casting. According the type of foundry activity that the foundries are involved in, commercial foundries are known as:

TYPES OF COMMERCIAL FOUNDRIES: y y y Captive foundry: - These foundries are part of a manufacturing company which uses the casted products to meet the companies own production need. Independent foundry:- Here casting are produced as per the customers specification. Jobbing foundry: - These are fully equipped foundry which does not have its own individual casting business, but undertake contractual casting for other companies. Mostly, production are taken up for small quantity only.

Production foundry: - In such foundries casting operations are done in bulk for one types of casting. The advantage in this method is that this fully equipped foundry unit can deliver flawless products at the most economical rates. Semi production shop:- It is the kind of operations where the company operations follow both the jobbing and the production casting.

HOBBY FOUNDRIES:

- These are small but fully equipped foundry units setup inside a house or in the backyards. Such foundries are set up by amateurs who loves tocreate casting products according to ones desire. The home foundries also serves other purpose like mending the worn our metal items and for casting special part or component that are not available in the market.

BASIC ASPECTS TO BE CONSIDERED FOR SETTING UP FOUNDRIES: Many factors are taken into account while setting up a foundry operation. The basic settings are done in consultation with experts and by taking suggestions from potential customer who are the ultimate beneficiaries of the foundry operations. Some of the basic conserns are: y Environmental: - The environmental study is done to ensure that the foundry operations does not effect the natural surroundings. It is essential for the foundries to follow the standard guidelines for setting up the industry, so that the residential areas near the foundry are not affected in any way. While setting up a foundry care must be taken also to protect the flora and fauna, and the water bodies in the surrounding areas. Economical: - The economic capacity of the foundry owners and the end-users is an important aspect while selecting the equipment and machines for the foundry operations. Cost effective and premium quality castings can be manufactured by selecting the appropriate metallurgical designs and making optimum use of alloys. Foundry operations can also be made cost-effective and convenient by avoiding patterns which are difficult to draw or molds . In addition, coring can either be eliminated or reduced for economic reasons. Technicians: - Mutual understanding and coordination between the professional working in different foundry activities is essential. Especially, the patternmakers and the molders should work in close coordination because patternmaking is an art whereas, molding is technical in nature. A pattermmaker can do simple molding and the molder can make simple patterns, but beyond a point they are dependent on each other for sophisitcated and innovative castings.

FOUNDRY LAYOUT : Layout of foundry is shown below:-

Raw Material ( Store )

Production Department

Inspection Department

Core Shop

Pattern Shop

Moulding Shop

Melting and Pouring

Finishing Process

Inspection Of Raw Materials

Shot Blasting

Chipping

Grinding

Painting

Dispatch

RAW MATERIAL:We have mentioned the required raw materials and the amount consumed in different sectors as follows : 1) STORE :Raw material Inoculants for S.G Scrap boring C.I Scrap boring S.G Scrap C.I Scrap Cu Scrap C.R.C Scrap M.S Scrap Pig Iron C.I Scrap Pig Iron S.G Hydraulic oil ( 68 No. oil ) (320 No. oil ) Activator Amine Gazer Sleeves Insulating Table Grinding Wheel Champion Sheet Import per month 1.5 ton As per Required As per Required As per Required As per Required 78 ton As per Required As per Required As per Required 420 lit

700 lit 1200 lit 700 lit As per Required 25 As per Required

Mask Transmission Belts Ferro Chromium Lumps Ferro Manganese Ferro Silicon Ferro Silicon Manganese

As per Required As per Required

5 ton 500 Kg

CORE SHOP : RAW MATERIAL Activator Gazer Catalyst (Amine) S.R Bond Champion Sheet Arkofix White Die Coat Black Die Coat Polish Wax Resin Wax Resin Sand Dry Sand Home Rubber CONSUMPTION PER DAY 15 Kg 15Kg 5 lit 1 Kg per 15 Days 1Kg 10 lit 2 Kg 2 Kg 100 gm 100 gm 200-250 Kg 1.5 2ton 1 Kg

PATTERN SHOP : -

RAW MATERIAL Allen Key Nut M Seal Fevi Quick File Thinner Wood Patterns (size 24*28 )

CONSUMPTION As per utilization As per utilization As per utilization As per utilization As per utilization As per utilization Imported From Kolhapur as per demand

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MOULDING SHOP : -

RAW MATERIAL New Sand Bentonite Coal Powder (Ferron ) Return Sand

CONSUMPTION 10 Kg per Box 2-2.5 Kg 800gm 1 Kg 200 Kg for 1 Box, 35 ton per Day

Filter Insulating Sleeves Core Diesel

As per required Pattern As per required Pattern As per required Pattern 1.5 2 lit

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MELTING AND POURING : -

RAW MATERIAL CRC Bundle Carbon (coconut Shell Charcoal ) Silicon 500/7 Grade Cu For C.I Metal Chromium Magnesium Sulphur Magnesium Scrap ( Copper ) Innoculation For C.I casting CRC Silicon Powder

CONSUMPTION 6000 3.5% for 210 Kg of Sand 1.7% for 102 Kg of Sand As per required As Per Grade

8 Kg for 550 Kg 180 Kg 800 gm for 550 Kg 100 Kg

As per Design

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FINISHING PROCESS : -

Raw Material Steel Shots Grinding Wheels Hammer Epoxy Paint (Anti Corrosive)

Consumption 3 to 4 ton per month As per Utilization As per Utilization As per Climatic condition and utilization As per demand Colour Code requirement of assembly Dept.

Fast Dry Primmer Red oxide Primmer (Glossy )

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INSPECTION : ( LABORATORY ) :-

RAW MATERIAL Sulphuric Acid Acetone Nitric Acid Disc Paper Polish Paper Grade 200 Grade 420 Grade 500 Distilled Water Alcohol

CONSUMPTION 2.5 lit for 8 to 9 months 2.5 lit for 8 to 9 months 2.5 lit for 8 to 9 months 15 Per Day 9 Per Day 9 Per Day 9 Per Day

15 lit per Day As per required

CORE SHOP

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INTRODUCTION :-

A core is a device used in casting and molding processes to produce internal cavities and reentrant angles. The core is normally a disposable item that is destroyed to get it out of the piece. They are most commonly used in sand casting, but are also used in injection molding. An intriguing example of the use of cores is in the casting of engine blocks .

Advantages and Disadvantages : Cores are useful for features that cannot tolerate draft or to provide detail that cannot otherwise be integrated into a core-less casting or mold. The main disadvantage is the additional cost to incorporate cores .

Requirements : There are seven requirements for core . y y y y y y y In the green condition there must be adequate strength for handling. In the hardened state it must be strong enough to handle the forces of casting; therefore the compression strength should be 100 to 300 psi (0.69 to 2.1 MPa). Permeability must be very high to allow for the escape of gases. As the casting or molding cools the core must be weak enough to break down as the material shrinks. Moreover, they must be easy to remove during shakeout. Good refractoriness is required as the core is usually surrounded by hot metal during casting or molding. A smooth surface finish. A minimum generation of gases during metal pouring .

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TYPES OF CORES : -

y Dry-sand cores : Dry-sand cores overcome some of the disadvantages of the green-sand cores. They are formed independently of the mold and then inserted into the core prints in the mold, which hold the core in position. They are made by mixing sand with a binder in a wooden or metal core box, which contains a cavity in the shape of the desired core . The most simple way to make dry-sand cores is in a dump core box, in which sand is packed into the box and scraped level with the top. A wood or metal plate is then placed over the box, and then the two are flipped over and the core segment falls out of the core box. The core segment is then baked or hardened. Multiple core segments are then hot glued together or attached by some other means. Any rough spots are filed or sanded down. Finally, the core is lightly coated with graphite, silica, or mica to give a smoother surface finish and greater resistance to heat . Single-piece cores do not need to be assembled because they are made in a split core box. A split core box, like it sounds, is made of two halves and has at least one hole for sand to be introduced. For simple cores that have constant cross-sections they can be created on special core-producing extruders. The extrusions are then just cut to the proper length and hardened. More complex single-piece cores can be made in a manner similar to injection moldings and die castings .

Resin Sand Cores : Resin coated sand is used for only Hot box process . In which at high temperature resin sand get heated at about 350c and get bounded hardly.

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SAND TESTS CONDUCTED IN THIS DEPTARTMENT :A.F.S G.F.N No ( American foundrymen Society Analysis ):In to this test sieve shaker is used on which 11 no of sieves are placed which are used to filter the sand . The sizes of that sieves are in microns. The sizes and the multiple factors of that sieves are given below . The table below indicates the size no and multiple factor of each sieve.

Methodology : y y y y y y y y Take about gm of Dry sand in a crucible. Then drop it in 1700 No sieve . Start the Sieve Shaker . The Vibration of sieve shaker will deposit the fine particles of to the bottom most sieve . Collect and measure the weight of sand deposited in all sieves and mention in the table given below . Then multiply it with multiple factor . Make a sum of ( Wt * Multiple Factor ) . This gives the AFS No of the sand .

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Size No. 1700 850 600 425 300 212 150 106 75 53 Pan

Wt

Multiple factor 5 10 20 30 40 50 70 100 140 200 300 Total

Wt * M.F

50 to 60

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The next processes in to the Core shop are:y y y Sand mixing Core making Core finishing

SAND MIXING:In this process mixture of sand and other additives mixed in sand mixture machine required for core making . In this method sand mixture is used for mixing sand & other constituents are discussed below:Mixture contents are :-1. Gazer 2. activator 3. sand Chemical ratio :- 1. Gazer is used 10ml per Kg of sand 2. activator is used 10ml per Kg of sand

Sand mixing process :y y y y y 50kg sand input in to mixer Add 500ml gazer . Add 500 ml activator . Starting mixing for about 3 minutes . Sand mixture loaded to hopper of core shooter machine.

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TYPES OF CORE MAKING MACHINES

y COLD BOX CORE MACHINE : The cold box core machine uses dry sand for core making. Span machine and Kelson machine are used for making cores.

Span machine:Hopper Specifications:y y Capacity of hopper: - 70 Kg Actual Sand feeding in to hopper: - 60 kg

Machine Cycle: y y y Blow Time - 3 Sec Exhaust on time: - 3 sec Shutter Valve: - 3 sec for 2 Kg of Sand

For Example : Turbo Charger: y y y L.P Gassing Time: - 5 sec H.P Gassing time: - 15 sec Pump Priming Time: - 12 sec

y y

Total Manual time of Span machine: - 52 sec Total automatic cycling time: - 44 sec

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Span Machine Cycle : y y y y y y y Machine Start Die Closing or Two Half of core closed Blow Time Exhaust Time Vibrator Time: - L.P time H.P time Pump Priming Time Die Opening Time

Span Machine Process: y y y y y y y y y y y Core box cleaned with pressurized air . Core box (R.H and L.H) closed. Top press closed. Sand Shooting. Sand press up. Top press removed. Gassing Down. Gas Shooting. (Amine Gas ) Top press up gassing out. R.H and L.H core box opened. Core ejection.

After all this processes core is transferred for finishing.

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y Hot Box core machine:Machine Specification:        Heating Temperature: - about 360c Electric Power input. Working principle: - Electric power to Heat. Heating coil is used for heating process Heater Specification No. of Heater Type of Heater -

Machine Process:        Core box closed. Core box clamping. Resin coated sand filling (input). Heating Core up to 2 min (Depending upon weight and thickness of core ) Core box out. De-clamping . Core out.

Defects into Core:       Un filling Problem. Parting Line (Extra Thick). Core crack. Rough surface area. Ejection pin marks. Air vent marks.

Methods used to remove the defects in to the Core are listed Below:     Extra Core cutting and finishing ( Extra Gate ). Parting Line finishing. Ejection mark removal and Vent mark removal . Fillet paste : - White Core Coat Black Core Coat (Graphite Powder Paste )

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Inspection and Quality Parameters:       Un filling . Dimensional Inspection Core Shift and Core Swelling: - this is because of the improper dowell (Bush and dowell Pin) positioning. Surface finish Cracks Scratch hardness : - Hardness of the hot box and cold box are as follows: Hot Box: - 75 to 85 Cold Box: - 55 to 65. Instruments Used: Core hardness tester and visual inspection.

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PATTERN MAKING : INTRODUCTION

In casting, a pattern is a replica of the object to be cast, used to prepare the cavity into which molten material will be poured during the casting process.[1][2] Patterns used in sand casting may be made of wood, metal, plastics or other materials. Patterns are made to exacting standards of construction, so that they can last for a reasonable length of time, according to the quality grade of the pattern being built, and so that they will repeatably provide a dimensionally acceptable casting. Under certain circumstances an original item may be adapted to be used as a pattern. The making of patterns, called patternmaking (sometimes styled pattern-making or pattern making), is a skilled trade that is related to the trades of tool and die making and moldmaking, but also often incorporates elements of fine woodworking. Patternmakers (sometimes styled pattern-makers or pattern makers) learn their skills through apprenticeships and trade schools over many years of experience. Although an engineer may help to design the pattern, it is usually a patternmaker who executes the design.

Contraction allowances The pattern needs to incorporate suitable allowances for shrinkage; these are called contraction allowances, and their exact values depend on the alloy being cast and the exact sand casting method being used. Some alloys will have overall linear shrinkage of up to 2.5%, whereas other alloys may actually experience no shrinkage or a slight "positive" shrinkage or increase in size in the casting process (notably type metal and certain cast irons). The shrinkage amount is also dependent on the sand casting process employed, for example clay-bonded sand, chemical bonded sands, or other bonding materials used within the sand. This was traditionally accounted for using a shrink rule, which is an oversized rule.

Draft allowances The pattern needs to incorporate suitable allowances for draft, which means that its sides are tapered so that when it is pulled from the sand, it will tend not to drag sand out of place along with it. This is also known as taper which is normally between 1 and 3 degrees.

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Sprues, gates, risers, cores, and chills The patternmaker or foundry engineer decides where the sprues, gating systems, and risers are placed with respect to the pattern. Where a hole is desired in a casting, a core may be used which defines a volume or location in a casting where metal will not flow into. Sometimes chills may be located on a pattern surface, which are then formed into the sand mould. Chills are heat sinks which enable localized rapid cooling. The rapid cooling may be desired to refine the grain structure or determine the freezing sequence of the molten metal which is poured into the mould.

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MOULDING SHOP
INTRODUCTION : Moulding is the process of manufacturing by shaping pliable raw material using a rigid frame or model called a pattern . In the casting process a pattern is made in the shape of the desired part. This pattern is made out of wax, wood, plastic or metal. Simple designs can be made in a single piece or solid pattern. More complex designs are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom or lower section called a drag. Both solid and split patterns can have cores inserted to complete the final part shape. Where the cope and drag separates is called the parting line. When making a pattern it is best to taper the edges so that the pattern can be removed without breaking the mold. This is called draft. The opposite of draft is an undercut where there is part of the pattern under the sand making it impossible to remove the pattern without damaging the mould. The molds are constructed by several different processes dependent upon the type of foundry, metal to be poured, quantity of parts to be produced, size of the casting and complexity of the casting. These mold processes include:
    

Sand casting- Green or resin bonded sand mold. Lost-foam casting- Polystyrene pattern with a mixture of ceramic and sand mold. Investment casting- Wax or similar sacrificial pattern with a ceramic mold. Ceramic mold casting- Plaster mold. V-process casting- Vacuum is used in conjunction with thermoformed plastic to form sand molds. No moisture, clay or resin is needed for sand to retain shape. Die casting- Metal mold. Billet (ingot) casting- Simple mold for producing ingots of metal normally for use in other foundries.

 

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In our Foundry under consideration Sand Casting type of Moulding is in use . In moulding, sand is the vital part and which is given in detail below. Green sand is the main constituent of the moulding. In green sand, the following contents are required, y y y y Silica sand: - 98% Bentonite: - 1 to 1.2% Moisture: - 3.5 to 4.5% Ferron: - 0..4 to 0.7%

Sand requires following properties: y y Strength in G.C.S : 1200 TO 1500 gm/cm2 Compatibility: 38 to 45%

Moisture : - 3.5 to 4.5 %

Permeability : - 80 to 150 No.

SAND TESTING : It is the inspection test to find out the contents requires for moulding process. In sand testing following test are carried out: Clay contents Permeability test G.C.S. test (Green Compressive Strength ) Moisture test

y y y y

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Return sand Temp. test

Sand Processing: SAND MIXING: Sand mixing in which following parameters are requires For every 200 kg (mixture capacity) y y y y y Return sand:- 175 kg Fresh sand:- 15 kg ( it improve permeability) Water: - 6 lit (depend on temp. of return sand and ambient temperature) Ferron: 900 gm(used as sand anti sticking agent) Bentonite : - 2700 gm (Binder)

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MOULDING SAND CYCLE : In moulding shop following cycle is carried out:

MOULDING BOX KNOCK OUT HOPPER

MAGNETIC BELT

MIXER

BUCKET ELEVATOR

Skip Charger

Sand Cooler

Belt Conveyor

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Moulding Sand has to go through the above Cycle to attain its primary objective of producing a defect less casting .

The Cycle Processes are described in short below . y y Knock out: - It shakes out sand from casting and mould box Magnetic belt: - It separate Metal Particles from return sand before going to bucket elevator . y y y Bucket elevator: It carries return sand to polygon sieve . Screw conveyor: it produces fine sand and send it to bucket elevator. Sand Cooler : - After Polygon Sieve sand passed through sand cooler in order to reduce temperature of hot return sand before going to storage hooper . y y Belt Conveyor : - Carries sand from storage hooper to skip charger . Skip charger : - In bucket elevator mixture of sand from belt conveyor bentonite ferron and fresh sand (Skip Charger Capacity 200Kg )

Mixture of sand (prepared sand):(Capacity of sand mixture 250kg, actual feed=200kg) Bentonite= 2700 gm Ferron= 900gm Water= 6ltr (depend on temperature of return sand) Fresh sand= 15kg (depend on moisture of return sand)

y y y y

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y y

Return sand= 175kg Mixing time= 135 sec

MOULDING PROCESS
Moulding process is carried out on jolt and sqeeze machine. Moulding is the process of manufacturing by shaping pliable raw material using a rigid frame or model called a pattern.

Jolt & squeeze machine

cycle time: y y y Squeeze jolt time= 1sec Squeeze time= 1.5 sec First jolt time = 2sec

Operation: y y y y Pin lift Pin down Swing out (Squeezing Plate Swing in ) Squeezing and jolting (Squeezing Plate Swing out )

Machine process: y y y y y y Required pattern is placed on the base of machine. Placing moulding box on the pattern. Prepared sand is falling in moulding box. The box is vibrated in order to pack the sand in the box. It is squeezed by Pneumatic swelling ( pressure 6 bar) Same process is carried out on other half of mould.

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y y y y y

Mould cavity is cleaned by air. The respective cores are placed in mould cavity. Sleeves are forced with filters in mould. Then cope and drag are placed on each other and connected by dowell pin and properly clamped . Ready mould are send to pouring tracks .

Production:Production per day = 750 to 800 boxes. Material handling:The moulding boxes are moved by semi-automised cranes. The moulds prepared by moved by railing. Jolt squeezing machine are operated fully automatic. Sand preparation is also automised.

y y y y

Inspection of moulding sand in lab:Clay content test : Determination of total clay: y y y y y Sample of 25gm sand and distilled water taken in 1000ml conical flask. Add 4-5 pieces of potassium hydroxide. Mixture stirred in clay washer 8-10 min. And kept steady for 8-10 min. Remove water (siphon method) Repeat this method 3-4 times till clear water appears . y Remaining sand filtered (53 micron filter)

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Dry it in rapid dryer and Wt taken. Percentage



Range= total clay 10 to 13 % Dead clay= 4% Instrument= conical flask, Wt machine, Rapid dryer.

 Determination M.B. clayy Sample with 5gm sand and 50 cc distil water kept in conical flask. Flask kept on hot plate and boiled. y y Cooled to room temperature and 3 -4 drops of conc. H2SO4 and stirred. 10cc M.B. solution taken in burette and stirred and with the help of glass rod solution placed on filter paper. y If there is no blue circle around drop taken on filter paper again 5cc M.B. solution mixed and again stirred. y y Process continues till blue circle around drop. After blue colour obtained burette reading taking.    Range = 7-9 % Instrument= one conical flask, wgt machine, burette. Dead clay= total clay active clay

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Moisture test: Procedure: - Take 6 gm sand sample in tester. Take 2 gm calcium carbide powder in closer of tester then flat the tester and cover it opening with closer and shake it and note down reading on moisture meter which is below the tester. Range= 3.5- 4.2% Instrument= moisture tester, weight machine and spoon.

Permeability Test: Take 150 gm Green Sand Sample in a Tube of length 100 mm. Hammer the sample with Sand rammer for 3 times. Then keep sand block obtained in permeability tester and note the reading in manometer .Compare it with Permeability tester. Range: 100 to 150. Instruments: Weighing Balance Sand Rammer Permeability Tester

Green Sand Tester : - (Compressive Test) 145 to 150gm moulding sand sample and put in 500 mm tube. Hammer tube for 3 times. Put sample in machine and turn machine handle. Because of this Pressure is created on sample and break down the sample then note down reading Range:-

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1000 to 1400 gm/cm2 Instrument:y y y Universal Strength Machine Weighing Balance ( Range max 300gm ) Rammer

Compatibility Test :Take Green Sand Sample in 50 ml tube .Required tube height is 100 mm. Then ramming 3 times and this reduces height of sample block. Then that is taken out and put measuring Scale into tube and record the reading on the scale . Finally note down reading. Range: - 38 to 48 % Instrument: o o o o 56 mm tube Weighing Balance Rammer scale

Loss on Ignition (L.O.I) test: 5 gm weighted sample taken in crucible and closed tightly . It is kept in muffle furnace for 2 hr ( 915 to 935c )Temperature is maintained and for every 30 min sample is stirred .Sample is removed from furnace cooled and then weighted . % of LOI Range: - 2 to 5% Volatile Matter : 

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5 gm sand sample is taken in crucible and closed tightly .Sample is kept in muffle furnace for 7 min ( 915 to 935c ) temperature is maintained and sample is removed from furnace cooled and then weighted %V.M = Range: - 2 to 3.5% Instruments: - Weighing Balance Muffle furnace Silica Crucible Cup


MELTING SHOP
INTRODUCTION:Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and alloying elements are used to charge the furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy. Alloying elements are either pure forms of an alloying element, like electrolytic nickel, or alloys of limited composition, such as ferroalloys or master alloys. External scrap is material from other forming processes such as punching, forging, or machining. Internal scrap consists of the gates, risers, or defective castings. The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refining is done to remove deleterious gases and elements from the molten metal to avoid casting defects. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. During the tap, final chemistry adjustments are made. Furnace Several specialised furnaces are used to melt the metal. Furnaces are refractory lined vessels that contain the material to be melted and provide the energy to melt it. Modern furnace types include electric arc furnaces (EAF), induction furnaces, cupolas, reverberatory, and crucible furnaces. Furnace choice is dependent on the alloy system and quantities produced. For ferrous materials, EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminum castings.

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Furnace design is a complex process, and the design can be optimized based on multiple factors. Furnaces in foundries can be any size, ranging from mere ounces to hundreds of tons, and they are designed according to the type of metals that are to be melted. Also, furnaces must be designed around the fuel being used to produce the desired temperature. For low temperature melting point alloys, such as zinc or tin, melting furnaces may reach around 327 Celsius. Electricity, propane, or natural gas are usually used for these temperatures. For high melting point alloys such as steel or nickel based alloys, the furnace must be designed for temperatures over 1600 Celsius. The fuel used to reach these high temperatures can be electricity or coke. The majority of foundries specialize in a particular metal and have furnaces dedicated to these metals. For example, an iron foundry (for cast iron) may use a cupola, induction furnace, or EAF, while a steel foundry will use an EAF or induction furnace. Bronze or brass foundries use crucible furnaces or induction furnaces. Most aluminum foundries use either an electric resistance or gas heatedcrucible furnaces or reverberatory furnaces.

Melting Shop involves melting of Raw materials according to chemical & mechanical requirement of castings. Induction furnace is used to melt raw material for casting process of Grey & S.G. Cast Iron metal. In to this shop metal is heated up to required temperature and made available for pouring. There is ladle is used for pouring of the metal. Metal from the furnace is collected in to the ladle and it transfer in to pouring department. At this place the work is done manually by rotating the ladle wheel. The innoculant is mixed at the time of pouring for improving machinability of the material and microstructure .

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Metals used in to melting shop: SG (Speroidal Graphite) Cast Iron C.I (Grey Cast Iron) Inoculants: - Fine Silica Powder.

The furnace used in to this shop is:CORELESS INDUCTION FURNACE Specification: y y y y y y y y y y y y y IF 04 Induction Furnace 750kw/750kg Electrotherm- 10 HP - 2 Nos. Motors, 7.5 HP 2 Nos. Motors Distil Water - 7.5 HP - 1 No Motor Lining 500 kg Ramming Mass Copper Coil Type Round Type Height 830 mm (710 mm) Asbestos Coating 3 mm thick Ramming Mass 30 Kg After Ramming Height of furnace 100m bottom to top Made up of copper and White C Cement For Furnace Handling, Hydraulics are used.

700mm

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Temperature Measurement: For measurement of temperature in to furnace Thermocouple is used. Thermocouple consist of following elements:y y y Thermocouple Temperature Tip Indicator Display

Temperature tip has U-shaped glass tube at the end the pyrometer and display are connect to temperature tip and temperature is displayed on the display. Temperature in Furnace: - 1550c (Tapping Temperature) 1350c (Pouring Temperature)

Raw material for single furnace at single cycle:Raw Material Scrap( CRC,CA for SG ) Scrap R.R ,SG Shell Coke Ferro Silicon Ferro Magnesium Innoculant for SG Total Quantity 410 190 30 6 8 2.4 646 Kg Total Weight 410 190 30 6 8 2 646 Kg

% of Carbon in Molten Metal: - 3.2 3.5 % % of Silicon in Molten Metal: - 1.7 - 1.9 % Inspection of molten metal in to lab:Spectro Machine: The Molten Metal after attaining the tapping temperature of 1550c undergoes spectra test. A small amount of molten metal is converted into coin and passed on to Spectro machine. The elements detected by Spectro Machine are: C, Si, Mn, P, S, Cr, Ni, Mo, Al, Cu, Co, Ti, Nb, V, W, Pb, Mg, B, Sn, Zn, As, Bi, Co, Zr, La, Fe.

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Starting Of Induction Furnace Procedure: y y y y y y Start the furnace at 0 Power for 15 min. Maintain the Power at 25 for next 15 min. Maintain the Power at 50 for next 1 hr .Finally stabilise the furnace at full Power. Maintain GLD (Ground Leakage Detector) between 1.8 to 3.5 Adjust the power accordingly. Stabilize the power at 50 till the metal goes above the coil.

Lining of furnace: -

y y y y y

Basically the working temperature of furnace is 1550c. Copper is the basic induction coil material in Induction Furnace. The Melting Point of Copper is very less comparatively. So some Mechanism should be provided to avoid the copper contact with molten metal. This Mechanism is called is Lining.

POURING: Temperature: - 1400c (SG Cast Iron) y y y Pouring should be completed within 6 min to avoid temperature loss and Mg loss. Innoculant (Silica) is added accordingly to activate molten metal and increase its flow rate within cavity. Insulating Sheet is Provided to avoid Radiation loss .Insulating Sheet consists of glass wool in a perfect manner .It avoids the temperature loss to a great extent.

Inspection: For Grade 400/12 : Nodule Count > 180

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Nodulity: - 80 to 90 Pearlite< 10% Remaining Ferrite.

For Grade 500/7: Pearlite 40 to 50 % Remaining ferrite. C.I: Grade 260 Pearlite 90 to 96 % Ferrite 5 to 10% Machinery: -

y y y

Spectro Meter: - It gives the Chemical content of 27 metal as mentioned above. Pro Metal. 3.3.1 Metal Soft Technology MV 12.50

Cause of Defects during Pouring: y Metallic Projections :-

Joint flash or fins. Flat projection of irregular thickness, often with lacy edges, perpendicular to one of the faces of the casting. It occurs along the joint or parting line of the

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mold, at a core print, or wherever two elements of the mold intersect.

Possible Causes Clearance between two elements of the mold or between mold and core; Poorly fit mold joint. Remedies Care in pattern making, molding and core making; Control of their dimensions; Care in core setting and mold assembly; Sealing of joints where possible. y Cavities Blowholes, pinholes. Smooth-walled cavities, essentially spherical, often not contacting the external casting surface (blowholes). The largest cavities are most often isolated; the smallest (pinholes) appear in groups of varying dimensions. In specific cases, the casting section can be strewn with blowholes of pinholes. The interior walls of blowholes and pinholes can be shiny, more or less oxidized or, in the case of cast iron, can be covered with a thin layer of graphite. The defect can appear in all regions of the casting.

Possible Causes Blowholes and pinholes are produced because of gas entrapped in the metal during the course of solidification: Excessive gas content in metal bath (charge materials, melting method, atmosphere, etc.); Dissolved gases are released during solidification; In the case of steel and cast irons: formation of carbon monoxide by the reaction of carbon and oxygen, presents as a gas or in oxide form. Blowholes from carbon monoxide may increase in size by diffusion of hydrogen or, less often, nitrogen; Excessive moisture in molds or cores; Core binders which liberate large amounts of gas; Excessive amounts of additives containing hydrocarbons; Blacking and washes which tend to liberate too much gas; Insufficient evacuation of air and gas from the mold cavity; -insufficient mold and core permeability; Entrainment of air due to turbulence in the runner system. Remedies Make adequate provision for evacuation of air and gas from the mold cavity; Increase permeability of mold and cores;

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Avoid improper gating systems; Assure adequate baking of dry sand molds; Control moisture levels in green sand molding; Reduce amounts of binders and additives used or change to other types; -use blackings and washes, which provide a reducing atmosphere; -keep the spree filled and reduce pouring height; Increase static pressure by enlarging runner height. y Discontinuities Hot cracking. A crack often scarcely visible because the casting in general has not separated into fragments. The fracture surfaces may be discolored because of oxidation. The design of the casting is such that the crack would not be expected to result from constraints during cooling.

Possible Causes Damage to the casting while hot due to rough handling or excessive temperature at shakeout. Remedies Care in shakeout and in handling the casting while it is still hot; Sufficient cooling of the casting in the mold; For metallic molds; delay knockout, assure mold alignment, use ejector pins.

Defective Surface Flow marks. On the surfaces of otherwise sound castings, the defect appears as lines which trace the flow of the streams of liquid metal. Possible Causes Oxide films which lodge at the surface, partially marking the paths of metal flow through the mold. Remedies Increase mold temperature; Lower the pouring temperature; Modify gate size and location (for permanent molding by gravity or low pressure); Tilt the mold during pouring; In die casting: vapor blast or sand blast mold surfaces which are perpendicular, or nearly perpendicular, to the mold parting line.

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Incomplete Casting Poured short. The upper portion of the casting is missing. The edges adjacent to the missing section are slightly rounded, all other contours conform to the pattern. The spree, risers and lateral vents are filled only to the same height above the parting line, as is the casting (contrary to what is observed in the case of defect).

Possible Causes Insufficient quantity of liquid metal in the ladle; Premature interruption of pouring due to workman??s error. Remedies Have sufficient metal in the ladle to fill the mold; Check the gating system; Instruct pouring crew and supervise pouring practice.

Incorrect Dimensions or Shape Distorted casting. Inadequate thickness, extending over large areas of the cope or drag surfaces at the time the mold is rammed. Possible Causes Rigidity of the pattern or pattern plate is not sufficient to withstand the ramming pressure applied to the sand. The result is an elastic deformation of the pattern and a corresponding, permanent deformation of the mold cavity. In diagnosing the condition, the compare the surfaces of the pattern with those of the mold itself. Remedy Assure adequate rigidity of patterns and pattern plates, especially when squeeze pressures are being increased. Inclusions or Structural Anomalies Metallic Inclusions. Metallic or intermetallic inclusions of various sizes which are distinctly different in structure and color from the base material, and most especially different in properties. These defects most often appear after machining. Possible Causes Combinations formed as intermetallics between the melt and metallic impurities (foreign impurities); Charge materials or alloy additions which have not completely dissolved in the melt; Exposed core wires or rods; During solidification, insoluble intermetallic compounds form and segregate, concentrating in the residual liquid.

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Remedies Assure that charge materials are clean; eliminate foreign metals; Use small pieces of alloying material and master alloys in making up the charge; Be sure that the bath is hot enough when making the additions; Do not make addition too near to the time of pouring; For nonferrous alloys, protect cast iron crucibles with a suitable wash coating. Knockout: -this is process of removing casting from moulding box. In which after cooling moulding box is vibrated on springs or vibrator & casting is removed. After this following processes are done.

FINISHING PROCESS
Finishing Process

Shot Blasting

Fettling

Inspection

Chipping

Grinding

Stationary Grinding

Buffing Grinding

Shipping Grinding

Hannd Grinding

Inspection

Painting (If Required)

Final Inspection

Dispatch

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The Instrument required for feting and finishing process are given below:y y y y y Number of shots blasting = 1 Number of stationary grinding machine = 8 Number of shifting grinding machine = 1 Number of buffing grinding machine = 1 Number of hand grinding machine = 3

SHOT BLASTING: Shot blasting is the process in which, with the use of steel shots finishing of casting i.e. removal of sand layer on casting , removal of burs on casting, finishing it. Specifications: y y y y Impeller motor: -2No Power required: - 15HP Speed: - 20000rpm Hopper capacity: - 350Kg

Process:         Clamping of casting over the hanger Door 1 & 2 open Movement of hanger in to blasting chamber Door 1 closed Door 2 closed Set up initial time according to requirement Impeller 1 on Impeller 2 on

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Process of shot blasting started Impeller 1 & 2 off (10 to 15 sec before opening time of door) Door 1 & 2 open Hanger out from blasting chamber

Visual inspection: Casting is inspected for presence of any crack, blow holes, defects, unfilling etc. Defects found in this are:       Sand drop Bad mould Scrap Wrong knock out Core shift wall thickness variation Broken casting

Chipping process:The inspected casting from shot blasting undergoes chipping. The extra unwanted material is manually removed by hammering over it.

Grinding: Raw material required: y Grinding wheel for stationary machine 400*50*38 1LB No. 1550 370245VK Provider grindwall Norton lmt

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Speed 1800 rpm y Grinding wheel for buffing machine 125mm diameter 11000rpm 180mm diameter 8500rpm 230mm diameter 6700rpm Buffing machine specification: Motor 2HP Power 1.5KW Current 3.7A Phase 3 Speed 2600rpm Process: y y y y y The casting after chipping is passed over to grinding. The material removal is done manually. Parting lines are adjusted accordingly. The complex sections grind with buffing machine & hand grinder. For high pressurized grinding the shaping machine is used.

Inspection: The casting after grinding is inspected for hardness. For this fine testing machine (brinell hardness tester) is used. If BHN is not within range then casting is rejected. The range of the casting is as per requirement.

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PAINTING

Painting

Manual Painting

Painting Station

Manual painting:In this casting is dipped in to epoxy paint manually or the painting is done with help of brush manually.

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Painting station:Casting is circulated through the painting chamber with the help of roller and bearing arrangement. sprays are used for painting.

FINAL INSPECTION
y y y y The final casting is inspected for dimensional analysis. The machine allowance and tolerances are checked for machine shop. They are usually 2-3mm. And then casting is ready for dispatch. Instruments : y Divider : -

It helps the user to simplify the job lay out. It helps him to bring in reality the 3 views of the component namely : Top view Front View Side View It also simplifies angular measurement .

Height Gauge :

It is Vernier arranged in a vertical manner .It facilitates the measurement of dimensions.It can also enlarge the measured dimensions with the lenses . help of magnifying

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BRINELL HARDNESS TEST

The Brinell hardness test is commonly used to determine the hardness of materials like metals and alloys.

Methodology The test is achieved by applying a known load to the surface of the tested material through a hardened steel ball of known diameter. The diameter of the resulting permanent impression in the tested metal is measured and the Brinell Hardness Number is calculated as BHN = 2 P / ( D (D - (D2 - d2)1/2)) where BHN = Brinell Hardness Number P = load on the indenting tool (kg) D = diameter of steel ball (mm) d = measure diameter at the rim of the impression (mm) It is desirable that the test load are limited to a impression diameter in the range of 2.5 to 4.75 mm. Approximate loads and Brinell Hardness Numbers:

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Brinell Hardness Number 160 - 600 80 - 300 26 - 100

Load (kg)

3000 1500 500

Typical Brinell Hardness Numbers for Metals

Material

Brinell Hardness Number 60 130 235 415 750

Soft brass Mild steel Annealed chissel steel White cast iron Nitrided surface

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Brinell

Vickers

Rockwell

Equivalent Rm

Steel Hardness versus Strength

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Impression Diameter (mm)

Hardness HB

Hardness HV

Hardness B

Hardness C

(tonf/in2)

(kgf/mm2)

(N/mm2)

2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.55 3.60 3.65 3.70 3.75 3.80 3.85 3.90 3.95 4.00

601 578 555 534 514 495 477 461 444 429 415 401 388 375 363 352 341 331 321 311 302 293 285 277 269 262 255 248 241 235 229

640 615 591 569 547 528 508 491 474 455 440 425 410 396 383 372 360 350 339 328 319 309 301 292 284 276 269 261 253 247 241

120 119 119 117 117 116 115 115 114 113 112 112 110 110 109 109 108 108 107 106 105 104 104 103 102 102 100 99 98

57.0 56.0 54.5 53.5 52.0 51.0 49.5 48.5 47.0 45.5 44.5 43.0 42.0 40.5 39.0 38.0 36.5 35.5 34.5 33.0 32.0 31.0 30.0 29.0 27.5 26.5 25.5 24.0 23.0 22.0 20.5

101 98 95 92 88 85 82 80 77 75 73 71 68 66 64 63 61 59 58 56 55 53 51 50

160 155 150 145 139 134 129 126 121 118 114 111 107 104 101 99 96 93 91 89 87 84 81 79

1569 1520 1471 1422 1363 1314 1265 1236 1187 1157 1118 1089 1049 1020 990 971 941 912 892 873 853 824 794 775

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4.05 4.10 4.15 4.20 4.30 4.40 4.50 4.60 4.70 4.80 4.90 5.00 5.10 5.20 5.30 5.40 5.50 5.60 5.70 5.80

223 217 212 207 197 187 179 170 163 156 149 143 137 131 126 121 116 111 107 103

235 228 223 218 208 197 189 179 172 165 157 150 144 138 133 127 122 117 113 108

97 96 96 95 93 91 89 87 85 83 81 79 77 74 72 70 68 66 64 61

49 48 46 45 43 41 39 36 35 34 32 31 31 30 29 28 27 26 25 24

77 76 73 71 68 65 62 57 55 54 51 49 49 47 46 44 43 41 39 38

755 745 716 696 667 637 608 559 539 530 500 481 481 461 451 431 422 402 382 373