METAL CASTING (FOUNDRY)

BASICS & APPLICATIONS

BY

PROF. T. V. RAMANA RAO

1

TOPICS FOR DISCUSSION

1. METAL CASTING PROCESS

2. COMPARISON WITH OTHER MANUFACTURING PROCESSES

-ADVANTAGES AND LIMITATIONS

3. MAJOR ACTIVITIES IN FOUNDRY

4. CASTING PROCESS SELECTION

4. STAGES IN CASTING PRODUCTION

5. INDIAN METAL CASTING INDUSTRY:

PROBLEMS FACED / PROSPECTS AND FUTURE TRENDS 2

METAL CASTING PROCESS

THE PROCESS OF FORMING METALLIC OBJECTS BY MELTING

METAL, POURING IT INTO THE SHAPED CAVITY OF A MOLD AND

ALLOWING IT TO SOLIDIFY.

CASTING AS A MANUFACTURING PROCESS ADVANTAGES:

1. ANY METAL / ALLOY CAN BE CAST

2. ANY SHAPE, SIZE, WEIGHT OR INTRICACY CAN BE CAST

3.FLEXIBILITY / ECONOMY FOR SMALL OR MASS PRODUCTION

4.CHEAPEST IN CONVERTING RAW MATERIAL TO FINAL OBJECT

LIMITATIONS:

1. NEEDS HIGH AMOUNTS OF SCARCE ENRGY FOR MELTING

2. LABOUR INTENSIVE

3. RAW MATERIALS INTENSIVE

4. LONGER PROCESSING TIME FOR NEW ITEM

5. POLLUTION AND DIFFICULT WORKING CONDITIONS 3

MAJOR ACTIVITIES IN FOUNDRY

4

1. PLANNING AND METHODING

2. PATTERN EQUIPMENT MAKING

3. MOLDING , CLOSING

4. MELTING

5. POURING , COOLING

6. FETTLING , FINISHING

5

6

7

8

9

NEW PRODUCTS DEVELOPED

It’s the beginning of a journey…...

VALVE CASTINGS

GLOBE VALVE PATTERN

SEMI-FINSH ED CASTING UNDER HEAT-TREATMENT ROUGH CASTINGS FINSHED CASTING (3.7T)

TOP MOULD CORE ASSEMBLY POURING

10

Melting Shop : The melting shop is equipped with

2 Nos. 8T capacity each medium frequency induction furnaces (Dual track).

2 No. 15T capacity each medium frequency induction furnaces.

1 No. 25T capacity each medium frequency induction furnaces.

1 No. 25T Ladle Refining Furnace (LRF)

Immersion pyrometer to ensure accurate temperature control.

FACILITIES : PRODUCTION

11

FACILITIES : PRODUCTION

POURING OF 12E10 GRINDING RING

PRIDE of BCSL Foundry - pouring of 7.6T Valve Casting.

TYPICAL EXAMPLES OF CASTINGS

1. POWER PLANTS: TURBINE CASING, DRIVING GEAR , KAPLAN TURBINE

2. STEEL PLANTS : FURNACE HOPPER, INGOT MOLD, ROLLING MILL ROLLS , TUYER

3. CEMENT: CRUSHER JAWS, GRINDING LINERS , COOLER PLATES, CRUSHING CONE

4. CONSTRUCTION: EXCAVATOR TEETH, SHOVEL BUCKET, HEAVY HOUSINGS, GEARS

5. CHEMICALS: REACTION VESSEL , VALVE BODIES, PUMP CASING , DIGESTORS

6. MACHINE TOOLS: MACHINE FRAME / BED, GEARS, SLIDING HOLDER, HOUSINGS

7. TRANSPORT: AUTO ENGINE CYLENDER -BODY, HEAD, AIR CRAFT JET NOZZLE,

RAILWAY WAGON SUPPORT, SHIP ANCHOR, SATELLITE HOUSING

12

CASTING PROCESS SELECTION

13

1. SAND MOLDING: MOLDS FOR ONE-TIME USE- GREEN SAND, DRY SAND , CHEMICALLY BONDED SAND

MOST COMMON FOR FERROUS METALS AND LARGE CASTINGS

2. PERMANENT MOLD / DIE CASTING: METAL MOLDS FOR REPEATED CASTING OF LARGE QUANTITY

MOSTLY FOR NON-FERROUS AND SMALL FERROUS CATINGS

3. INVESTMENT CASTING: SPECIALLY SINTERED REFRACTORY (CHEMICALLY BONDED ) MOLDS

FOR TINY PRECISION CASTINGS IN ANY COMPOSITION

4. CENTRIFUGAL CASTING:

ROTATING METALLIC MOLDS WITH REFRACTORY LINING DURING CASTING

FOR PIPES, CYLENDERS, RINGS IN ANY METAL

CASTING DESIGN AND METHODING

CASTING DESIGN

• MODIFICATIONS IN DESIGN TO SUIT CASTING PROCESS IN FOUNDRY FOR METAL SPECIFICATIONS / SHAPE / GEOMETRY / INTRICACY , ETC., WITHOUT SACRIFICING THE FUNCTIONAL AND QUALITY REQUIREMENTS OF THE CAST COMPONENT BY THE CUSTOMER (ORDERING THE CASTING)

METHODING TECHNOLOGY/CA“TINGP‘OCE““ DE“IGN :

• PATTERN EQUIPMENT, MOULDING PROCESS, MELTING PROCEDURE, GATING & FEEDING SYSTEM, FINISHING / H.T., QUALITY-ASSURANCE SYSTEM NEEDED TO PRODUCE THE CASTING TO THE QUATITY / COST STANDARDS BY THE FOUNDRY (MAKING THE CASTING)

14

STAGES IN CASTING PRODUCTION

1. PREPRODUCTION: A. STUDY OF CASTING ORDER AND DRAWING – SHAPE, SIZE, WEIGHT, METAL SPECS,

ORDER QUANTITY , DELIVERY REQUIREMENTS , COST / RATE ESTIMATION

B. IF FEASIBLE FOR THE EXISTING FACILITIES OF THE FOUNDRY, PLAN PRODUCTION

2. METHODING / TECHNOLOGY: A. SELECTION OF THE MOLDING PROCESS

B. DRAWINGS OF PATTERN EQUIPMENT, GATING / RISERING

C. INSTRUCTIONS FOR MANUFACTURE / INSPECTION NEEDS

3. PRODUCTION: A. PATTERN AND CORE BOX EQUIPMENT

B. MOLDING AND CORE MAKING , CLOSING / ASSEMBLING THE MOLD

C. MELTING AS PER SPECS , REFINING LIQUID METAL IN FURNACE

D. POURING LIQUID METAL INTO MOLDS

E. COOLING TO SOLIDIFY

F. FETTLING: SEPERATING CASTING FROM MOLD, CLEANING, HEAT TREATMENT

G. INSPECTION , DESPATCH

15

CURRENT STATUS IN THE INDIAN FOUNDRIES

MIS-CONCEPTIONS/MYTHS ABOUT CASTINGS.

LACK OF COLLABORATION BETWEEN DESIGNER AND FOUNDRY.

NOT SUPPLYING 3D SOLID-MODEL DRAWINGS.

MOST OF THE FOUNDRIES NOT USING SCIENTIFIC/STANDARD GATING/RISERING PRACTICES, OR SIMULATION SOFTWARE.

IMPROPER DOCUMENTATION LEADING TO REPEATED REJECTS AND RELATED LOSSES.

LACK OF TRAINING TO SUPERVISORS/WORKERS.

LACK OF ENGINEERS, PREFERING SOFTWARE JOBS NOT MFRG

SHORTAGE OF POWER , LOGISTICS , CAPITAL

16

FUTURE TRENDS 1. MORE COLLABORATION BETWEEN DESIGNERS (ORDERING

CASTING) AND FOUNDRIES AS PARTNERS IN THE SUPPLY CHAIN TO SATISFY END USERS PURCHASING FINAL EQUIPMENT.

2. GLOBAL RESOURCING FOR CASTING BY DEVELOPED COUNTRIES FOR QUALITY PRODUCTS – HIGH POTENTIAL FOR INDIAN FOUNDRIES.

3. ORDERING SUB-ASSEMBLIES (FULLY MACHINED, ASSEMBLED) INSTEAD OF SEPARATE CAST COMPONENT EXAMPLE: VALVES, BEARINGS, GEAR-BOXES WITH GEARS.

4. EXTENSIVE USE OF INTERNET/WEB TOOLS, E-BUSINESS FOR GLOBAL TRANSACTIONS.

5. MAKE IN INDIA LIKELY TO DEVELOPE METAL CA“TING

17

Date of last change Reference/Name of Presentation/SN 18

FACILITIES : PRODUCTION

Pattern Shop : Foundry has a well equipped pattern shop with highly

skilled workmen for the manufacture of wooden, metal and polystyrene

patterns.

Date of last change Reference/Name of Presentation/SN 19

Moulding Shop

• Imported Continuous Sand Mixer of capacity 30, 10 & 5TPH for Fenotec System • Imported Mechanised Reclamation Plant (Italy) of 20TPH • With the introduction of continuous mixer our capacity and capability of ramming is increased in addition to increase the productivity

FACILITIES : PRODUCTION

Date of last change Reference/Name of Presentation/SN 20

Melting Shop : The melting shop is equipped with

2 Nos. 8T capacity each medium frequency induction furnaces (Dual track).

2 No. 15T capacity each medium frequency induction furnaces.

1 No. 25T capacity each medium frequency induction furnaces.

1 No. 25T Ladle Refining Furnace (LRF)

Immersion pyrometer to ensure accurate temperature control.

FACILITIES : PRODUCTION

Date of last change Reference/Name of Presentation/SN 21

FACILITIES : PRODUCTION

POURING OF 12E10 GRINDING RING

PRIDE of BCSL Foundry - pouring of 7.6T Valve Casting.

Date of last change Reference/Name of Presentation/SN 22

NEW PRODUCTS DEVELOPED

It’s the beginning of a journey…...

VALVE CASTINGS

GLOBE VALVE PATTERN

SEMI-FINSH ED CASTING UNDER HEAT-TREATMENT ROUGH CASTINGS FINSHED CASTING (3.7T)

TOP MOULD CORE ASSEMBLY POURING

Date of last change Reference/Name of Presentation/SN 23

NEW PRODUCTS DEVELOPED

It’s the beginning of a journey…...

Item Name : CL API ‘F Body Material : WCB

Weight : 7140 Kgs Weight : 7680 Kgs

Date of last change Reference/Name of Presentation/SN 24

Item Name : Spindle ` Material : ASTM A 148 Gr 105-85

Weight : 8300 Kgs

NEW PRODUCTS DEVELOPED

Date of last change Reference/Name of Presentation/SN 25

Item Name : Boom point Material : IS 2644 Gr 640

Weight : 2380 Kgs

NEW PRODUCTS DEVELOPED

Date of last change Reference/Name of Presentation/SN 26

Item Name : Flywheel Material : IS 1030 Gr 280-520W

Weight : 1980 Kgs

NEW PRODUCTS DEVELOPED

Date of last change Reference/Name of Presentation/SN 27

Item Name : Turbine casing Material : G17 CrMoV 5-10

Weight : 1270(U)+1540(L) Kgs

NEW PRODUCTS DEVELOPED

Date of last change Reference/Name of Presentation/SN 28

NEW PRODUCTS DEVELOPED

It’s the beginning of a journey…...

Item Name : 8 CL ‘F M““ “P Body Material : WCB / CF 8

Weight : 4870 Kgs

Date of last change Reference/Name of Presentation/SN 29

Item Name : PLUG Valve BODY Material: WCB

Weight : 2480 Kgs

NEW PRODUCTS DEVELOPED

Date of last change Reference/Name of Presentation/SN 30

NEW PRODUCTS DEVELOPED

Item Name : Drive end frame Material : WCB

Weight : 4070 Kgs

Date of last change Reference/Name of Presentation/SN 31

Item Name : Spindle ` Material : ASTM A 148 Gr 105-85

Weight : 8300 Kgs

NEW PRODUCTS DEVELOPED

Date of last change Reference/Name of Presentation/SN 32

NEW PRODUCTS DEVELOPED

Item Name : Swing Jaw Casting Material : IS 1030 Gr 340-570W

Weight : 5140 Kgs

Date of last change Reference/Name of Presentation/SN 33

Item Name : Valve Castings Material : G17 CrMoV 5-10

Weight : 800 Kgs

NEW PRODUCTS DEVELOPED

Date of last change Reference/Name of Presentation/SN 34

Item Name : 1312 Jaw Plate Material : IS 276 Gr 3

Weight : 3680 Kgs

NEW PRODUCTS DEVELOPED