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FOUNDRY TECHNOLOGY
Submitted to the dept. Of Mechanical, PCET In the Partial fulfilment of the academic requirements for the award of
B.TECH (MECH) under JNTU by Mr.V.VENKATESH (08L71A0317) Mr.M.RAKESH (08L71A0344) Mr.B.CHAITANYA (08L71A0348) Under the guidence of Mr. RAMESH
Asst.Proffesor PCET Internal Guide
Mr.SURYANARAYANA
HINDUJA FOUNDRIES External Guide
ACKNOWLEDGEMENT
I wish to sincerely thank, Mr Suryanarayana, who was my mentor and guide during the course of this project. His valuable and timely inputs proved immensely useful to me and helped me in the successful completion of the project. I also thank Hinduja Foundries for providing me with grate Opportunity such as this and believed that this training will go along in helping my future endeavours in this aspect of Mechanical Engineering . I wish to sincerely thank, Mr.V.P.RAJU, Head of the Department, Mechanical engineering Department. Princeton college of engineering (pcet), as my internal guide gave his valuable inputs during the course and successful completion of the project work. Finally my humble regards to all the people of Hinduja Foundries and PCET who have given me valuable suggestions during the course of the project were very much beneficial for me and helped me complete it successfully V.VENKATESH M.RAKESH B.CHAITANYA
CONTENT
1.Introduction 2.Process of casting 3.Pattern shop 4.core shop 5.Molding sand preparation 6.Molding shop 7.Molding area 8.Fettling shop(A) 9.Fettling shop(B) 10.Inspection and defects
INTRODUCTION: FOUNDRY:
y A foundry is a factory that produce metal casting. Metals are cast in to shapes by melting them into a liquid, pouring the metal in a mould, and removing the mould material or casting after the metal has solidified as it cools.
The process of production of castings as a whole includes the following improtant processes.
Design and development of pattern Core making Mold preparation (molding) Melting and meltal pouring Shaking out Shot blasting Fettling Painting Quality assessment
PROCESS OF CASTING:
Pattern shop
Core Boxes
pattern
Moulding shop
Moulds
Melting shop
Molten Metal
Core shop
cores
Moulding-Closing Bay
Closed Moulds
Pouring Bay
Pored Moulds
Knockout Section
Rough Casting
Fettling Shop
Finished Casting
Shipping Yard
Casting terms:
1.Flask: A metal or wood frame, without fixed top or bottom, in witch the mold is formed. Depending upon the position of the flask in the moulding structure, it is referred to by varies names such as drag-lower moulding flask, cope- upper moulding flask,cheek-intermediate mouklding flask used in three piece molding. 2.Pattern: It is the replica of the final object to be made. The mould cavity is made with the help of pattern. 3.Parting line: This is the dividing line between the two moulding flasks that makes up the mould. 4.Core: A separate part of the mold, made of sand and generally baked, which is used to creat openings and various shaped cavities in the castings. 5.Pouring basin: A small funnel shaped cavity at the top of the mold into which the molten metal is poured. 6.Spure: The passage through which the molten metal,from the pouring basine,reaches the mold cavity.in many cases it controls the flow of metel in to the mold. 7.Runner: The channel through which the molten metal is carried from the sprue to the gate. 8.Gate: A channel through which the molten metal enters the mold cavity.
9.Chaplets:are used to support the cores inside the mold cavity to take care of its own weight and overcome the metallostatic forces. 10.Riser: A column of molten metal placed in the mold to feed the casting as it shrinks and solidifies. It is also termed as feed head. 11.Vent: Small opening in the mold to facilitate espace of air and gases.
Pattern Shop :
The process of production of castings begins here.
Pattren Making:
1. A pattern is a model or the replica of the object to be cast. 2. Except for various allowances a pattern exactly resembles the cast to be made. 3. A pattern is required even if one object has to be cast. 4. Materials used in pattern making are:1. Cast iron 2. Aluminum 3. Araldite
Functions of patterns:
y A pattern prepares a mold cavity for the purpose of making a casting. y A pattern may contain projections known as core prints if the casting requires a core and need to be made hallow. y Pattern properly made and having finished and smooth surfaces reduce casting defects. y Properly constructed patterns minimize overall cost of casting. y Here in Hinduja Foundries, we use Split type Pattern.
Types Of Patterns:
1. Single piece pattern. 2. Split piece pattern. 3. Loose piece pattern. 4. Match plate pattern. 5. Sweep pattern. 6. Gated pattern. 7. Skeleton pattern. 8. Follow board pattern. 9. Cope and drag pattern.
y Single piece(Solid)pattern: Made from one piece and does not contain loose pieces or joints. Inexpensive. Used for large size simple castings. Pattern is accommodated either in cope or in drag. y Split piece pattern: Pattern of intricate shaped castings cannot be made in one piece because of inherit difficulties associated with molding operation. The upper and lower parts of the split pieces are accommodated in cope and drag portion of the molds respectively. Parting line of pattern forms parting line of mold. Dowel pins are used for keeping the alignment between two parts of pattern.
Pattern layout:
y Get the working drawing of the part for which the pattern is to be made.
y Make two views of the part drawing on a sheet using a shrink rule . A shrink rule is modified form of an ordinary scale which has already taken care of shrinkage allowance for a particular metal to be cast.
Allowances:
y y y y Shrinkage or contraction allowance. Machining or finishing allowance. Distortion or cambered allowance. Shake or rapping allowance.
CORE SHOP
y There are three methods of core making. 1. Cold box process. 2. Hot box process or Shell core process.
b) Polyisocynate
y This is mixed with silica sand ,and tri ethyl amine (TEA) is added as a catalyst for the curing process .
y The mixture of silioca sand the binders is placed in a reservoir and is shot below into the core box using shooter or sand magazine , which is the tool head that shoots into the box.
y Tri ethyl gas is passed into this box to be used as catalyst for curing . The time taken for each core depends on the required core dimension.
Sand Mixe Silica sand Chemical binde Core Machine Gas Catalyst Fume Surbber Core Box Core Finishing Core Rac s
Core Setting The above flow chart shows the core making procedure
Sand Mixer :
y They are of two ie TM 240 and TM 190 . y TM 240 mixer consists of two impellers , one measuring
vessel and an arm whereas TM 190 consists of only one impeller , one measuring cylinder of the arm in the arm.
Permeability :
During pouring and subsequent solidification of a casting , a large amount of gases and steam is generated .These gases
are those that have been absorbed by the metal during melting ,air absorbed from the atmosphere and the steam generated by the molding and core sand .If these gases are not allowed to escape from the mold , they would be entrapped inside the casting and cause casting defects .To overcome this problem the molding material must be porous.Proper venting of the mold also helps in escaping that are generated Iinside the mold cavity.
Green Strength :
The molding sand that contains moisture is termed as green sand particles must have the ability to cling to each other to impart sufficient strength to the mold . The green sand must have enough strength so that the constructed mold retains its shape.
Dry Strength :
When the molten metal is poured in the mold , the sand around the mold cavity is quickly converted into dry sand as the moisture in the sand evaporates due to the heat of the molten metal.At this stage the molding sand must posses the sufficient strength to retain the exact shape of the mold cavity and at the same time it must be able to withstand the metallostactic pressure of the liquid material.
Hot Strength :
As soon as the moisture is eliminated , the sand would reach at a high temperature when the metal in the mold is still in liquid state.The strength of the sand that is required to hold the shape of the cavity is called hot strength.
Collapsibility :
The molding sand should also have collapsibility so that during the contraction of the solidified casting it does not provide any resistance , which may result in cracks in the castings . Besides these specific properties the molding material should be cheap , reusable and should have good thermal conductivity .
Molding Shop :
y A mold is a hollowed-out block that is filled with a liquid like plastic , glass , metal , or ceramic raw materials .The liquid hardens or sets inside the mold , adopting its shape .A mold is the opposite of a cast . The manufacture who makes the molds is called the mold maker . A release agent is typically used to make removal of the hardened/set substance from the mold easier.
y In Hinduja Foundries LTD the mold is prepared using High pressure molding machine
BOX/PALLET CUTTING
TURN OVER
CORE PLACING
CLOSURE
POURING
COOLING
PUNCH OUT
BOX SEPARATION
y It operates on the principle of shoot and squeeze . y Shooting is the process where sand is shot from the top. y Ones the cope/drag goes inside, the cylinde4r lifts it to the top and sand is shot inyo the mold box. y This operation takes place on oneumatic pressure at 2 Bar. y Sand is shot from the top with 2 bar pressure for the uniform distribution. y Squeezing is the process to squeeze the sand in the mold box under high pressure to get the required density and hardness of the mold. y Process of Squeezing takes place with the help of hydraulic press at high pressure between 140 160Bar. y Here this machine has the capacity of making 60 molds per hour.
Venting : It is done for the ferrostatic gases to escape. Closing Devices: They are used to seal the cope and drag.
y Virgin material,external scrap,internal scrap,and alloying elements are used to charge the furnace.
y The process include melting the charge, refining the melt, adjusting the melt chemistry and tapping in to a transport vessel. y In a foundry, molten metal is poured into molds. y Many modern foundries use robots or automatic pouring machines for pouring molten metal y Traditionally ,moulds were poured by hand using ladles. y These ladles are moved with the help of Over Head Cranes(E.O.T)
THE ABOVE IMAGE SHOWS A FOUNDRY MAN WORKING ON LIQUID METAL IN THE LADLE.
y Cast iron and mild steel which is in the form of scrap is used for melting. y Gray Iron : 1400+or -5 degrees pouring temperature . y SG : 1480 to 1500 degrees centigrade pouring temperature. y 100% pouring metal =60% MS scrap+40% foundry returns.
Fettling :
The removal of feeders and excess material from a casting is the first stage of finishing a casting. The metal removal is often achieved using manual cutting or grinding . However, more emphasis is being placed on automatic fettling , where by casting is placed in a machine programmed to remove materials from specific areas. The method of fettling must be taken into account at the initial casting design stage , so that the process is fast and efficient.
Shot Blasting :
Abrasive particles, such as sand , grit or steel shot (3mm diameter), are propelled at high velocity to impact the casting surface to remove surface contaminents. In general shot blasting concentrates
abrasive particles at high speed (65-110 m/s) in a controlled manner at the material thereby removing surface contaminates due to the abrasive impact. Propulsion of the abrasive particles is usually achieved using a centrifuge or compressed air nozzles.
Grinding :
It is done by grinder made up of an abrasive substance like silicon carbide which removes the projections on the casting surface by abrasion.
Heat Treatment :
The application of heat to a casting to alter the material properties making them suitable for the finished product or for subsequent processing.Heat treatments can be achieved in a number of ways , Inncluding induction heating ,furnace heating and localiized flame heating , amongest others.
Cleaning :
It is Non-mechanical removal of surface contaminents .Parts are submerged in different solutions , depending on the requirements of the cleaning process and any subsequent operations .Typical treatments are : molten salt baths used for electrolytic cleaning , acid baths for pickling, chemical cleaning and organic solvent cleaning.
Coating :
Purpose of surface coating is to impart resistance to corrosion , wear and erosion. coating tecniques include electroplating, hot dip coatings ,hard facing ,thermal spraying and painting.
Painting :
Painting is either done by dipping the casting in paint basin of required colour or by spraying uniformly, which is spray painting. At DCU only painting is done ,by dipping the casting in paint basin.The painting is done only for rust : the single coat of primer is applied over the surface of casting.
Casting Defects :
A casting defect is an irregularity ion the metal casting process that is undesired.Some defects can be tolerated while others can be repaired otherswise they must be eliminated .They are broken down into five main categories : gas porosity, shrinkage defects ,mold material defects ,pouring metal defects , and metallurgical defects.
Gas Porosity :
y Blow holes and open blows Blows : They are caused if venting is not done properly. y Air inclusion y Pin holes :There are three reasons for the formation of pin holes . 1) If paint thickness is excess 2) Hydrogen bubbles in the molten metal during poourning . 3) Sand accumulation in gates.
Shrinkage Cavities :
y Shrinkage defects occur when feed metal is not available comensate for shrinkage as the metal solidifies. y Shrinkage has two reasons because of high temperatures and sudden cooling or metal not sufficient.
Cuts and washes Metal penetration Fusion Run out Swell sand mold.If core is not placed properly sand and mold crush takes place.
Gas Porosity :
Shrinkage cavities
Metallurgical defects
y Hot tears y Hot spots
If a casting goes through all the quality checks without showing any defects it is then said to have all the quality standards and is shipped to clients .
CONCLUSION
To prepare a metal/alloy component parts of desired shapes, we have to follow these processes pouring the molten metal/alloy in to a prepared mold(of that shape) and then allowing the metal/alloy to cool and solidify. This will make our required casting.