metal casting (foundry) basics & · pdf filemetal casting process 2. ... the process of...
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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
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1. PLANNING AND METHODING
2. PATTERN EQUIPMENT MAKING
3. MOLDING , CLOSING
4. MELTING
5. POURING , COOLING
6. FETTLING , FINISHING
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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
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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
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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
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CASTING PROCESS SELECTION
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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)
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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
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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
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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
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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