METAL CASTING (FOUNDRY) BASICS & APPLICATIONS BY PROF. T. V. RAMANA RAO

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1 METAL CASTING (FOUNDRY) BASICS & APPLICATIONS BY PROF. T. V. RAMANA RAO 1

2 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: 2 PROBLEMS FACED / PROSPECTS AND FUTURE TRENDS

3 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 3 5. POLLUTION AND DIFFICULT WORKING CONDITIONS

4 MAJOR ACTIVITIES IN FOUNDRY 1. PLANNING AND METHODING 2. PATTERN EQUIPMENT MAKING 3. MOLDING, CLOSING 4. MELTING 5. POURING, COOLING 6. FETTLING, FINISHING 4

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9 NEW PRODUCTS DEVELOPED VALVE CASTINGS GLOBE VALVE PATTERN TOP MOULD CORE ASSEMBLY POURING ROUGH CASTINGS UNDER HEAT-TREATMENT SEMI-FINSH ED CASTING FINSHED CASTING (3.7T) It s the beginning of a journey... 9

10 FACILITIES : PRODUCTION 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. 10

11 FACILITIES : PRODUCTION POURING OF 12E10 GRINDING RING PRIDE of BCSL Foundry - pouring of 7.6T Valve Casting. 11

12 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

13 CASTING PROCESS SELECTION 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 13

14 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

15 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

16 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

17 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

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 18

19 FACILITIES : PRODUCTION 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 Date of last change Reference/Name of Presentation/SN 19

20 FACILITIES : PRODUCTION 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. Date of last change Reference/Name of Presentation/SN 20

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 21

22 NEW PRODUCTS DEVELOPED VALVE CASTINGS GLOBE VALVE PATTERN TOP MOULD CORE ASSEMBLY POURING ROUGH CASTINGS UNDER HEAT-TREATMENT SEMI-FINSH ED CASTING FINSHED CASTING (3.7T) Date of last change It s the beginning of a journey... Reference/Name of Presentation/SN 22

23 NEW PRODUCTS DEVELOPED Item Name : CL API F Body Material : WCB Weight Weight :: Kgs Kgs Date of last change It s the beginning of a journey... Reference/Name of Presentation/SN 23

24 NEW PRODUCTS DEVELOPED Item Name : Spindle ` Material : ASTM A 148 Gr Weight : 8300 Kgs Date of last change Reference/Name of Presentation/SN 24

25 NEW PRODUCTS DEVELOPED Item Name : Boom point Material : IS 2644 Gr 640 Weight : 2380 Kgs Date of last change Reference/Name of Presentation/SN 25

26 NEW PRODUCTS DEVELOPED Item Name : Flywheel Material : IS 1030 Gr W Weight : 1980 Kgs Date of last change Reference/Name of Presentation/SN 26

27 NEW PRODUCTS DEVELOPED Item Name : Turbine casing Material : G17 CrMoV 5-10 Weight : 1270(U)+1540(L) Kgs Date of last change Reference/Name of Presentation/SN 27

28 NEW PRODUCTS DEVELOPED Item Name : 8 CL F M P Body Material : WCB / CF 8 Weight : 4870 Kgs Date of last change It s the beginning of a journey... Reference/Name of Presentation/SN 28

29 NEW PRODUCTS DEVELOPED Item Name : PLUG Valve BODY Material: WCB Weight : 2480 Kgs Date of last change Reference/Name of Presentation/SN 29

30 NEW PRODUCTS DEVELOPED Item Name : Drive end frame Material : WCB Weight : 4070 Kgs Date of last change Reference/Name of Presentation/SN 30

31 NEW PRODUCTS DEVELOPED Item Name : Spindle ` Material : ASTM A 148 Gr Weight : 8300 Kgs Date of last change Reference/Name of Presentation/SN 31

32 NEW PRODUCTS DEVELOPED Item Name : Swing Jaw Casting Material : IS 1030 Gr W Weight : 5140 Kgs Date of last change Reference/Name of Presentation/SN 32

33 NEW PRODUCTS DEVELOPED Item Name : Valve Castings Material : G17 CrMoV 5-10 Weight : 800 Kgs Date of last change Reference/Name of Presentation/SN 33

34 NEW PRODUCTS DEVELOPED Item Name : 1312 Jaw Plate Material : IS 276 Gr 3 Weight : 3680 Kgs Date of last change Reference/Name of Presentation/SN 34

CENTRIFUGAL CASTING. Email: [email protected] [email protected]

CENTRIFUGAL CASTING. Email: amitjoshi@iitb.ac.in amitjoshi1000@yahoo.ca CENTRIFUGAL CASTING Amit M Joshi (B.Engg. Mechanical, A.M.I.Prod.E, A.I.E) Dept. of Metallurgical Engg. & Material Science, Indian Institute of Technology Bombay, India. Email: [email protected] [email protected]