Productivity Improvement of Non Ferrous

Foundry
A Project Report
Submitted by

VATSAL DOSHI, JINAL LAD, MOHAK MEHTA ,

PALASH SRIVASTAVA
in partial fulfilment for the award of the degree
of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

At
MUKESH PATEL SCHOOL OF TECHNOLOGY
MANAGEMENT AND ENGINEERING, MUMBAI
NOVEMBER 2015

Table of Contents
Chapter No.

1.

Title

Page No.

List of Figures

Abstract

INTRODUCTION

1.1 About Non Ferrous

Foundry

1.2 Products of Nff

2.

CASTING PROCESSES

7
9

2.1Process flow chart

2.2Melting

2.3 Cupola Construction

10

and Operation
2.4 Sand Processing

3.

4.

15

2.5 Mould making process

19

OUR STUDY

28

3.1Work study

28

3.2Panchal Foundry visit

36

Conclusion & Future aims

44

REFERENCES

45

Table of Figures
Chapter No.

Title

Page No.

1.

INTRODUCTION

2.

CASTING PROCESS
Fig.2.1 Flow Process Chart

Fig2.2 Sectional views of

conventional and watercooled cupolas

3.

Fig 2.3: Sand Flow Chart

14

Fig. 2.4 Essential components

of a conventional vertical
wheel batch-type muller

16

Fig.2.5 Basic steps involved

in making a casting from a
green sand mold

17

Fig 2.6:Moulding
Equipments

24

Fig2.7: Pouring Equipments

25

OUR STUDY
Fig3.1 : Approach to Work

28

Study

Fig3.2 :Types Of Process

31

Fig3.3: Flow process chart

32

(source: ILO)

Fig: 3.4: Flow Process chart

33

by our team

FIG3.5: Company work flow

34
3

FIG 3.6 A cross section of a

36

coreless-type induction
furnace.

Fig3.7: Jolt squeeze

38

moulding machine with solid

squeeze heads

Figure: 3.8 Various problems,

causes, solution and benefits
of operations

40

Figure: 3.9 Various problems,

causes, solution and benefits
of operations

41

Figure: 3.10Various
problems, causes, solution
and benefits of operations

41

Figure: 3.11 Various

problems, causes, solution
and benefits of operations

42

Figure: 3.12 Various

problems, causes, solution
and benefits of operations

42

Abstract
Why this topic?
We choose this project because this would enhance our management skills and give us an
idea about how the industry actually works.
4

This project will help us to:

-Solve Industry Manufacturing Problems
-Manage Different Inventories
-Analyze method study & time study so as to improve it.
-Improving Production Cycles
-Enhance Casting Manufacturing Quality
-Take account of worker ergonomics & safety with increasing production.
-Organize full plant taking account of all possible factors and problems
-Improvise Plant safety, Plant hygiene and environment safety
Further we aim to proceed in this field of project management

Why we choose NFF as our project?

The companys current customer relations are strong not due to its quality of work but solely
due to old business relations. We want quality to become the prime factor for business
relations. So achieving good quality products is the need of the hour for this company to keep
up with ever increasing market competition. The company likes to run the old traditional way
and hence pays less attention on the management and safety of its workers, raw materials,
products & workplace. So we want to apply the industrial engineering techniques on to this
company to upgrade it to the current competitive market.

Methodology
Initiation:
We started with the idea of increasing the overall productivity of NFF. So the first step was
the complete plant visit, then each member listed the various drawbacks and areas for scope
of improvement and work upon it. Later we shifted to Work Study and Time Study
methodology to streamline our project.

Planning:
Activity

Deadline

Major

Minor

Plant layout

25/10/15

Palash

Jinal

Modified plant

30/10/15

Palash

Mohak

9/11/15

Mohak

Palash

Work study

6/11/15

Vatsal

Mohak

Job process

13/11/15

Jinal

Palash

14/11/15

Jinal

Palash

layout
Inventory
Management of
Raw Material
,pattern
&finished
products

details
Value Chain
Mapping
Ergonomics

Table no: 1 Job Assignment Chart

Chapter: 1
Introduction:
About Non Ferrous Foundry
NFF is a casting manufacturing company founded by Shree Dheerajlal Mehta in the year
1970. Currently under Kishor Mehta since 2001. The foundry is located in Vapi, Gujarat. It
manufactures majorly CI(Cast Iron), Aluminium, Bronze, Gun metal castings . Casting
products include motor cover, pump body, pulley, fire bar, types of bushes, rods, circles,
6

square blocks and other customized machinery parts. Field of business is aroundVapi in
Daman, Umargaon, Silvassa, Dadra Nagar Haveli. There are about 10-15 workers working in
the company

Products of Nff:
1. V-Belt Pulley
2. Impellar
3. Pump Body
4. Plate type Pulley
5. Motor Cover
6. Fire Bar
7. Sewage Cover
8. Ingot
9. Other general purpose products like Bush, Rod,
Circle, Square block, CI Hand wheel, Ring.

Chapter 2:
Casting Processes
Casting is a manufacturing process in which molten metal is poured or injected and allowed
to solidify in a suitably shaped mould cavity. During or after cooling, the cast part is removed
from the mould and then processed for delivery. Casting processes and cast -material
technologies vary from simple to highly complex. Material and process selection depends on
the part's complexity and function, the product's quality specifications, and the projected cost
7

Level. Castings are parts that are made close to their final dimensions by a casting process.
With a history dating back 6000 years, the various casting processes are in a state
of continuous refinement and evolutions technological advances are being made.

Process flow chart

Figure 2.1: Process Flow Chart

MELTING:
Furnace used in NFF: Cupola
THE CUPOLA is basically a cylindrical shaft furnace that burns coke intensified by the
blowing of air through tubers (nozzles). Alternate layers of metal, along with replacement
coke, are charged into the top. In its descent, the metal is melted by direct contact with the
counter current flow of hot gases from the coke combustion. The molten metal collects in
the well, where it is discharged for use by intermittent tapping or by continuous flow
In high-tonnage operations, the cupola remains the most reliable source of the continuous
high volumes of iron needed to satisfy multiple moulding lines of high-production foundries
or multiple casting machines of centrifugal pipe producers. The continuous stream of cupolamelted iron is not interrupted by charging, which is done independently upstairs on the
9

back side, nor by slag removal, because the slag flows off to the side continuously from front
or rear slag spout without interrupting the melting process.

Fig.2.2: Sectional views of conventional and water-cooled cupolas

Cupola Construction and Operation:

This section will discuss the shell, intermittent or continuous tapping, tuyere and blower
systems and refractory lining

Shell
A vertical, cylindrical steel shell is the container of the combustion and melting operation

Intermittent or Continuous Tapping

Iron flow can be intermittent or continuous. Cupolas are tapped continuously, with clean
metal flowing under a refractory knife and over a dam. This special trough skims off the
lighter slag on top. This slag then flows continuously down a side spout into a water-sluicing
trough and containers for handling. The levels of metal dam and slag notch must be carefully
calculated and maintained to the proper relationship with blast pressure inside the cupola.

Tuyere and Blower Systems

10

Tuyeres. Air for the combustion of coke is introduced through tuyeres equally spaced around
the cupola, with the number and size proportioned to cupola size for proper air volume,
pressure, and velocity. Total tuyere area usually ranges from 3 to 10% of cupola area for
optimum air velocity for penetration and combustion efficiency. On water-cooled
Cupolas, the tuyeres are projecting water-cooled copper nozzles that protrude into the cupola
152 to 457 mm (6 to18 in.) and are inclined downward 10 to 15
Blowers for generating the necessary blast air volume and pressure have been of the positive
displacement, fan, or centrifugal type. The latest preference on large cupolas has been toward
two or three multistage centrifugal blowers with automatic air weight control.
The air required to melt 900 kg (1 ton) of iron is 620 to 680 m3 (22,000 to 24,000 ft3) STP or
770 to 835 kg (1700 to 1840 lb). Air from the blower is transmitted into tuyeres through a
duct system and windbox. Back pressure normally ranges from 3.3 to 8.5 N (0.75 to 1.9 lbf)
or more, depending on charge density and stack height.

Refractory Lining
Conventional cupolas are lined with refractories to protect the shell against abrasion, heat,
and oxidation. Lining thicknesses range from 114 to 305 mm (4.5 to 12 in.). The most
popular lining is fireclay brick or block. As the heat progresses, the refractory lining in the
melting zone is progressively fluxed away by the high temperature and oxidizing atmosphere.
The newest and most widely used method of lining repair uses a pneumatic gun to blow a
mixture of clay and ganister through a nozzle containing water that becomes entrained in the
stream as it exits the mixing nozzle.

Coke Specifications:
As the major fuel, coke is the most important charge material. High-quality, foundry grade
coke is essential for optimum cupola performance. Good foundry grade coke requires longer
coking time and more careful blending of coals and is therefore higher in price than other
grades of coke. Foundry coke must be strong and sufficiently impact resistant to maintain
adequate lump size to provide permeability, blast penetration, and air availability to the center
of a large cupola. Experiments and production experience have shown

11

that performance is optimized when coke size is within a range proportional to cupola
diameter, preferably 8 to 12% of
cupola diameter. Fine coke should be screened out because it fills interstitial space, limits air
distribution, and overloads the emission system. On large cupolas, the largest available coke
size is preferred, but on small cupolas, coke screened to proper size
ranges provides the best performance.
Coke should have low ash content (<10%) and a chemical structure that provides for
optimum carbon pickup and combustion efficiency. Low sulfur content (<0.70% S) is
required for preventing excessive sulfur pickup. Volatiles should be less than 1.0% and fixed
carbon above 90% for maximum cupola performance.
Metal Charge:
The modern cupola can melt a wide range of charge materials, mostly scrap iron and steel.
Through its efficient use of scrap materials, the casting industry contributes to environmental
cleanup and resource utilization.
Foundry returns, such as gates, runners, and internally generated scrap castings, usually
constitutes 30 to 50% of the pouring weight and should be remelted in the proportions
generated.
Pig iron is considered a premium charge material because of its uniformity of composition
and size and its lack of undesirable trace elements. As economics encouraged the use of
more scrap and less pig iron, pig iron has remained the best material for restoring iron quality
whenever excessive tramp elements or poor-quality iron are produced.
Cast iron scrap has been increasingly used as faster spectrometer analyses have given
assurance of chemical control and as more knowledge has been gained about the
characteristics of various types of scrap. With the cooperation of scrap dealers and their trade
organization, cast iron scrap has been separated and sold in 10 to 15 designated types with
specific composition ranges and inclinations. Through careful blending, anticipation of
trends, avoidance of excessive proportions of certain extremes, and fast spectrometer checks
on trace elements, high proportions of cast iron scrap have been successfully used in some of
the highest-quality irons.
12

Steel scrap in low-carbon malleable irons is in considerable

proportions is needed to obtain a low carbon content.The Scrap Institute has classified steel
scrap into 15 to 20 categories. Based on experimentation and experience,
adjustments can be made to compensate for the effects of size, thickness, and surface-area-tovolume ratio affecting the various reactions in the cupola. With the advent of ductile iron that
requires the lowest possible phosphorus content; steel scrap became a more attractive charge
material for cost reduction. The basic cupola allows the adjustment of fluxes and slag
chemistry to permit the melting of 50 to 80% steel scrap.

Fluxes for Fluidizing Slag

The addition of limestone or dolomite is necessary to fluidize the slag. Natural sources of slag
such as coke ash, oxidized silicon, and lining consumed, as well as any sand and dirt on the
scrap, are predominantly acid and produce a very viscous
slag without the addition of sufficient basic flux.
Limestone or dolomite additions of 2 to 5% are generally needed in an acid cupola to
contribute enough basic constituents of calcium oxide and magnesium oxide to impart
sufficient fluidity for the slag to flow freely through the coke spaces, into the well, and down
the front staging trough. In the basic slag cupola, either with basic refractories or
neutral water cooling, more basic flux is added to net a sufficient excess of basic slag
constituents.

Control Principles:
Melt Rate. A cupola is expected to maintain a melting rate sufficient to meet the needs of
mold production. The cupola size must be chosen for the midrange of production demand. A
general rule is that 4.5 kg (10 lb) of iron can be melted per
hour for each square inch of cross-sectional area.
By increasing or decreasing the blast, melt rate can be varied 20% with reasonably good
efficiency and control. Varying the hot blast and/or oxygen injection can extend this control
range. Beyond these limits, overblowing a cupola increasingly oxidizes the iron, causing
lower carbon and silicon levels and decreasing the temperature. Underblowing will lower the
temperature because the blast will not penetrate the cupola with
13

sufficient air distribution for optimum combustion efficiency

.
Iron Temperature. The iron temperature at the cupola spout must be adequate to survive
handling losses and to be poured into the moulds at sufficient temperature and fluidity to
produce sound castings. Iron temperature is measured by optical pyrometers, thermocouples,
and continuously recording radiometric instruments.
Iron temperature is primarily influenced by the coke concentration in relation to the metal
charge. If coke percentage is increased from 8 to 12% of the metal charge, the iron
temperature is usually increased approximately 65 C (120 F),
while the melting rate is reduced 20 to 25%, especially if air volume is maintained at the
same level. Increasing the preheat temperature on the blast air or increasing the percentage of
oxygen injected will instantaneously increase metal.

SAND PROCESSING:
GREEN SAND MOLDING
It is one of many methods available to the foundryman for making a mold into which molten
metal can be poured. Green sand molding and chemically bonded sand molding are
considered to be the most basic and
widely used mold making processes. Green sand media are prepared by coating the grains of
sand with binder that is later shaped into a rigid mass by the application of force. Green sand
molding is the least expensive, fastest, and most common of all the currently available
molding methods. The mixture of sand and binder can be used immediately after the mixing
process that coats the sand grains.

14

Fig 2.3: Sand Flow Chart

Basic requirements of refractory sand for moulding

Dimensional and thermal stability at elevated temperatures

Suitable particle size and shape
Chemically unreactive with molten metals
Not readily wetted by molten metals
Freedom from volatiles that produce gas upon heating
Economical availability
Consistent cleanliness, composition, and pH
Compatibility with binder systems

SilicaSands
Most green sand molds consist of silica sands bonded with a bentonite-water mixture. (The
term green means that the mold, which is tempered with water, is not dried or baked.) The
composition, size, size distribution, purity, and shape of
the sand are important to the success of the mold making operation.

15

Foundry sands are composed almost entirely of silica (SiO2) in the form of quartz. Some
impurities maybe present, such as ilmenite (FeO-TiO2), magnetite (Fe3O4), or olivine, which
is composed of magnesium and ferrous
orthosilicate [(Mg,Fe) SiO4]. Silica sand is used primarily because it is readily available and
inexpensive.silica reacts with molten iron to form a slag-type compound, which can cause
burn-in, or the formation of arough layer of sand and metal that adheres to the casting
surface. However, because these problems with silica can be
alleviated by proper additions to the sand mix, silica remains the most widely used
moldingaggregate.silica sand, although inexpensive, has some shortcomings as a molding
sand. If done properly, theaddition of other materials can alleviate these deficiencies.
Cereals,which include corn flour, dextrine, and other starches, are adhesive when wetted and
therefore act as a binder.
They stiffen the sand and improve its ability to draw deep pockets. However, use of cereals
makes shakeout more
difficult, and excessive quantities make the sand tough and can cause the sand to form balls in
the muller. Because cereals
are volatile, they can cause gas defects in castings if used improperly.
No binders are used in company,because cereal is costing them cheaper
An additive name molasses is used which is the by-product of refining of sugarcane to sugar
Up to 2% of cereal binders, such as dextrin, starch, sulphite lye, and molasses, can be used to
increase dry strength (the strength of the mold after curing) and improve surface finish.
Cereal binders also improve collapsibility and reduce shakeout time because they burn-off
when the metal is poured.
Batch-Type Muller.Although not a new design, the batch-type muller (Fig. 13) can produce
high-quality molding
sand. It is equipped with plows to move the sand mass under the large, weighted rolling
wheels, which are vertically
oriented. This kneading action provides the capability of consistent control but not short cycle
times.

16

Fig. 2.4 Essential components of a conventional vertical wheel batch-type muller

Pattern used
Loose patterns, also called one-piece patterns or solid patterns, are the simplest, least
expensive type of reusable
pattern and are suited only to very low-quantity production. This type of pattern (Fig. 2a) is
most appropriate for experimental or prototype castings and is only rarely used for short-run
production castings. Molding with a loose pattern requires more manual operations and a
much higher degree of molder skill than molding with other pattern types. Many
foundrymolding departments are not set up to use loose patterns. This increases the cost per
mold and results in variations in casting quality from mold to mold compared to moldmaking
with other pattern types. A loose pattern can be made in one piece or in two pieces (split
patterns). The split in the two-piece pattern corresponds to the parting line in the
pattern. One-piece loose patterns are often used when one side of the pattern is a flat plane
that can serve as the parting line, while two-piece loose patterns are more commonly used
when the shape to be cast is more complex.Moulding with one-piece loose patterns often
requires considerable time and skill on the part of the moulder.
.
Pattern Handling and Storage.Because significant investments are made in pattern
equipment, pattern handling and storage must be carefully considered by the foundry.
Improper storage and handling can cause pattern deterioration and
damage, particularly for wood patterns because humidity and temperature changes can cause
severe distortion. The foundry typically has many patterns in inventory. Obsolete or
discontinued patterns should be routinely destroyed to make
room for new patterns.
17

Fig.2.5 Basic steps involved in making a casting from a green sand mold

18

MOULD MAKING PROCESS (ASM)

The sequence begins with a mechanical drawing of the desired part. Patterns are then
produced and mounted on pattern
plates. Both the cope and drag patterns include core prints, which will produce cavities in the
mold to accommodate extensions on either end of the core. These extensions fit solidly into
the core prints to hold the core in place during pouring. The gate or passageway in the sand
mold through which the molten metal will enter the mold cavity is usually
mounted on the drag pattern plate. Locating pins on either end of the pattern plates allow for
accurately setting the flask over the plate.Cores are produced separately by a variety of
methods. The core boxes, which are rammed with a mixture
of sand and core binder (see the article "Coremaking" in this Section). If the cores must be
assembled from separately made components, they are pasted together after curing. They are
then ready to be inserted into the sand mold. The mold is made by placing a flask (an open
metal box) over the cope pattern plate. Before molding can begin, risers are
added to the pattern at predetermined points to control solidification and supply liquid metal
to the casting to compensate for the shrinkage that takes place during cooling and
solidification. Thus, any shrinkage voids form in the risers, and the casting will be sound. A
hole or holes (called sprues) must also be formed in the cope section of the mold to provide a
channel through which the molten metal can enter the gating system and the mold cavity.
The cope half of the mold is produced by ramming sand into the flask, which is located on
the pattern plate with pins. The flask full of sand is then drawn away from the pattern board,
and the riser and sprue pieces removed.A flask is subsequently placed over the drag pattern
plate using the locating pins on the plate. Sand is rammed around the
pattern, and a bottom board is placed on top of the flask full of sand. The pattern, flask, and
bottom board are then rolled over 180, and the pattern is withdrawn.The completed core is
set into the core prints in the drag half of the mold and the cope half of the mold is set on top
of thedrag. Proper alignment of the mold cavity in the cope and drag portions of the mold is
ensured by the use of closing pins,which align the two flasks. The flasks can be clamped
together, or weights can be placed on top of the cope, to counteract
the buoyant force of the liquid metal, which would otherwise tend to float the cope off the
drag during pouting.Metal is then poured into the mold cavity through the sprue and allowed
to solidify. The casting is shaken from the sand and appears as shown in Fig. 2, with the
19

sprue, gating system, and risers attached. Following shakeout, the flasks, bottom boards, and
clamps are cycled back to the molding station while the casting is moved through the
production process. When the gates and risers are removed from the casting, they are returned
to the furnace to be remelted. After cleaning, finishing, and heat treating, the castings are
ready for shipment.

Tools for Moulding

Hand riddle
It consists of a screen is standard circular wire mesh equipped with circular wodden frame.it
is generally used for cleaning the sand for removing foreign materials such as nails shot metal
splinters of wood etc. from it even the power operated riddles are available for riddling large
volumes of sand

Shovel
It consists of an steel pan fitted with a long handle it is used in mixing tempering and
conditioning the foundry sand by hand.it is also used for moving and transforming the
moulding sand to the container and moulding box or flask

Rammers
There are required for striking the molding sand mass in the molding box to pack or compact
it uniformly all round the pattern.the common forms of rammers used in ramming are hand
rammer,peenrammer,floor rammer and pneumatic rammer which are briefly desecribed as

Types of rammers
Hand rammer:
It is generally made of wood or metal.it is small and one end of which carries a wedge type
construction called peen and the other end posseses a solid cylindrical shape known as butt.it
is used for ramminf the sand in bench molding work

Peen hammer

20

It has a wedge shaped construction formed at the bottom of a metaalic rod.it is generally used
in packing the molding sand in pockets and corners

Floor rammer
It consisits of a long steel bar carrying a peen at one end a flat portion on the other.it is
heavier and larger in comparision to hand rammer.its specific use is in floor molding for
ramming the sand for larger molds.due to its large length the molder can operate it in standing
position

Pneumatic rammer
They save considerable time and labor and are used for making large molds

Sprue pin
Sprue pin is shown in fig It is a tapered rod of wood or
iron which is placed or pushed in cope to join mold cavity while the
molding sand in the cope is being rammed. Later its withdrawal from
cope produce a vertical hole in molding sand, called sprue through
which the molten metal is poured into the mould using gating system.
It helps to make a passage for pouring molten metal in mold through
gating system

Strike off bar:

Strike off bar is a flat bar having straight edge and is made of wood or iron.
It is used to strike off or remove the excess sand from the top of a
molding box aftercompletion of ramming thereby making its surface plane and smooth. Its
one edge is mad beveled and the other end is kept perfectly smooth and plane.

Mallet:
Mallet is similar to a wooden hammer and is generally as used in carpentry or sheet metal
shops. In molding shop, it is used for driving the draw spike into the pattern and then rapping
it for separation from the mould surfaces so that pattern
can be easily withdrawn leaving the mold cavity without damaging the mold surfaces
21

Draw spike:
Draw spike is shown. It is a tapered steel rod having a loop or ring at
its one end and a sharp point at the other. It may have screw threads on the
end to engage metal pattern for it withdrawal from the mold. It is used for driven into pattern
which is embedded in the molding sand and raps the pattern to get separated from the pattern
and finally draws out it from the mold cavity.

Lifters:
They are also known as cleaners or Finishing tool which are made of thin sections of steel of
various length and width with one end bent at right angle. They are used for cleaning,
repairing and finishing the bottom and sides of deep and narrow openings in mold cavity after
withdrawal of pattern. They are also used for removing loose sand from mold cavity.

Trowel:
They are utilized for finishing flat surfaces and joints and partings lines of the mold. They
consist of metal blade made of iron and are equipped with a wooden handle. The common
metal blade shapes of trowels may be pointed or contoured or rectangular oriented. The
trowels are basically employed for smoothing or slicking the surfaces of molds. They may
also be used to cut in-gates and repair the mold surfaces.

Slicks:They are also recognized as small double ended mold finishing tool which are
generally used for repairing and finishing the mold
surfaces and their edges after withdrawal of the pattern. The
commonly used slicks are of the types of heart and leaf, square and heart, spoon and bead and
heart and spoon. The nomenclatures of the slicks are largely due to their shapes.

Smothers:
According to their use and shape they
are given different names. They are also known as finishing tools
which are commonly used for repairing and finishing flat and round surfaces, round or square
corners and edges of molds.

Swab:
22

It is a small hemp fiber brush used for moistening the edges of sand mould, which are in
contact with the
Pattern surface before withdrawing the pattern. It is used for sweeping
away the molding sand from the mold surface and pattern. It is also used for
coating the liquid blacking on the mold faces in dry sand molds.

Spirit level
itis used by molder to check whether the sand bed or
molding box is horizontal or not.

Gate cutter
Gate cutter is a small shaped piece of sheet metal commonly used
to cut runners and feeding gates for connecting sprue hole with the mold
cavity.

Gaggers are pieces of wires or rods bent at one or both ends which
are used for reinforcing the downward projecting sand mass in the cope are known as
gaggers.
Bellows gun: It is hand operated leather
made device equipped with compressed air jet to blow or pump air when
operated. It is used to blow away the loose or unwanted sand from the surfaces of
moldcavities.Theyare made of steel and are used for clamping the molding
boxes firmly together during pouring.

23

Gate cutter

lifters

Vent rod

Draw spike

24

Strike off bar

Sprue pin

Rammer

Shovel

Hand riddle
Fig 2.6: MouldingEquipments

25

Pouring equipment:
Ladles:
Ladles are used to transport molten metal from melting furnance to the mold and vice
versa.these ladles consist of a steel shell lined with a suitable refractory material like fire clay

Fig2.7: Pouring Equipments

Crucibles:

26

Crucibles is used to melt the metal in the furnance.it is packed inside the furnance and raw
material is put in this crucible.
COREMAKING involves coating a refractory aggregate with binder, compacting the coated
sand into the desired shape, and then curing (hardening) the compacted mass so that it can be
handled. Refractory coatings are also often applied to the core surface to prevent sandadhering defects on the casting and to yield a smoother casting finish
COREMAKING PROCESSES
Cores are needed to create the recesses, undercuts, and
interior cavities that are often a part of castings. The sands, binders,
methods, and equipment used to make these cores are described in this
section. with the exception of those for shell cores, which are discussed
in the previous section on shell molding. The processes described here
may also be used in the production of molds as well as cores.
The binder Manufacturers should be consulted concerning precautions necessary for
the various materials

27

CHAPTERS 3: OUR STUDY

WORK STUDY: Work study is the systematic examination of the methods of
carrying on activities so as to improve the effective use of resources
and to set up standards of performance for the activities being
carried out.

Basic procedure of work study

There are eight steps in performing a complete work study. They are:
(1) Select the job or process to be studied.
(2) Record or collect all relevant data about the job or process, using the
most suitable data collection techniques (explained in Part Two), so that
the data will be in the most convenient form to be analysed.
(3) Examine the recorded facts critically and challenge everything that is
done, considering in turn: the purpose of the activity; the place where it is
performed; the sequence in which it is done; the person who is doing it;
the means by which it is done.
(4) Develop the most economic method, taking into account all the
circumstances and drawing as appropriate on various production
management techniques (explained in Part Three), as well as on the
contributions of managers, supervisors, workers and other specialists with
whom new approaches should be explored and discussed.
(5) Evaluate the results attained by the improved method compared with the
quantity of work involved and calculate a standard time for it.
(6) Define the new method and the related time and present it to all those
concerned, either verbally or in writing, using demonstrations.
(7) Install the new method, training those involved, as an agreed practice
with the allotted time of operation.
(8) Maintain the new standard practice by monitoring the results and
comparing them with the original targets.

28

Fig3.1 : Approach to Work Study

29

Method study
Method study is the systematic recording and critical examination
of ways of doing things in order to make improvements

Selecting the work to be studied

There are three factors that should be kept in
mind when selecting a job.
1. Economic or cost-effective considerations.
2. Technical considerations.
3. Human considerations.
(1) Economic considerations: It is obviously a waste of time to start or
to continue a long investigation if the economic importance of a job is small, or
if it is one that is not expected to run for long.
So we decided to select Core Manufacturing processes i.e Moulding, Pouring, Prepouring
where little improvement can make a larger impact on productivity.
(2) Technical or technological considerations: One of the important
considerations is the desire by management to acquire more advanced
technology, whether in equipment or in processes. Thus management may want
to computerize its office paperwork or its inventory system, or to introduce
automation in the production operations.
The owner for the company wanted to introduce new techniques in process of casting,so
moulding pouring and pre pouring process was taken under study
(3) Human considerations: Certain operations are often a cause of
dissatisfaction by workers. They may induce fatigue or monotony or may be
unsafe or clumsy to operate. The level of satisfaction should point to a need for
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method study. Thus an operation which may be perceived as effective by

management may, on the other hand, generate a great deal of resentment by the
workforce. If such operations are addressed by work study specialists as part of
an overall work study programme, the benefits of work study can become more
apparent to the workforce.
The major physical work is done in moulding and pouring process which if enhanced
ergonomically can improve productivity.

Limiting the scope of the work to be studied

One of the first decisions a work study specialist has to make is to define
Exactly the type of work to be studied set up boundaries around it and decide
what exactly it will encompass.so limiting our study to moulding pouring and pre pouring
process was decided by us and factors that affect productivity related to only these processes
are studied.

Record facts:
After selecting the work to be studied, is to record all the facts relating to the existing
method. The success of the whole procedure depends on the accuracy with which the facts
are recorded, because they will provide the basis of both the critical examination and the
development of the improved method. It is therefore essential that the record be clear and
concise
The usual way of recording facts is to write them down. Unfortunately,
this method is not suited to recording the complicated processes which are so
common in modern industry.
The most commonly used of these recording techniques are charts and
Diagrams.There are several types of standard chart available, each with its
own special purposes

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Fig3.2: Types Of Process

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Fig3.3: Flow process chart (source: ILO)

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Fig: 3.4: FLOW PROCESS CHART BY OUR TEAM

FEATURES:
1.Table can help Analyst to record time as well as distance in proper order for the Event
where it is necessary.
2.We can classify the events using symbols which includes symbol of OPERATION
,INSPECTION ,COMBINE,TRANSPORT,DELAY,STORAGE.Also the flow can be analyse
by joining the type of event by its order of flow
3.Analyst can also recommend methods if they find it as a totally incorrect method.
4.This table can be used as FLOW PROCESS CHART for WORKER TYPE,MATERIAL
TYPE,MACHINE TYPE.Analyst can use both for Recording Present Event Study as well as
Proposing the data. So that the analyst can effectively analyse the study comparing both
charts simultaneously.
5.Also a REMARKS space is given in the table for the analyst to record those things which is
to be taken in consideration while analysing and is not directly related to Events of the
process.
6.Table provides space for Adding notes and proposing estimated Saving from the proposed
methods .
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Company Work Flow:

FIG3.5: Company work flow

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Panchal Foundry visit:

Panchal foundry deals in high quality and precise CI, MS and Alloy Castings. The foundry
uses a couple of induction furnaces. However when we were taking the plant visit the primary
furnace was down. The induction furnace was connected to a cooling water line, for the
cooling line a separate water cooling tower was situated just outside the workshop. In the
workshop separate areas were allotted for moulding, pouring and core box making. Moulding
was done on a flat surface area and then arranged in orderly manner (keeping in mind the
pouring process) in other place near the furnace. There were ample number of dead weights,
each mould having its own set of dead weights. They had an automated machine for the
ramming process. The pattern inventory was very less. The mould boxes were new, in proper
shape and were stacked in an orderly manner when not in use. They also used a special type
of one time use filter which is places at the bottom of sprue before pouring. It helps to
separate impurities from the melt. One half of the workshop was dedicated for the surface
finishing of the casting. They did Shot blasting and grinding for high grade surface finish.
The number of young workers were quite high.

MACHINES USED IN PANCHAL FOUNDRY

INDUCTION FURNACES have gradually become the most widely used means for melting
iron and, increasingly, nonferrous alloys as well.
The key to the ready acceptance of this type of furnace has been its excellent metallurgical
control coupled with its relatively pollution-free operation.
Coreless units range in capacity from a few pounds, favoured by the precision cast metal
producers, to 68 Mg (75 tons) powered at 21,000 kW.
Coreless units of 7000 kW in power for ferrous metals and 4000 kW for nonferrous metals
have been built in medium frequencies, and even channel-type units have recently been
equipped with solid-state, medium frequency power supplies.
The advantage of medium frequency is that the power density of the furnace system can be
increased substantially without increasing its size.
Much more melting power can be applied, while maintaining the stirring action at desirable
levels.
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Heat losses, which are a function of furnace size, are reduced, and overall efficiency of the
system is improved.
The furnace is also easier to operate because a single potentiometer will typically provide
efficient and stepless control of the power.

Types of Furnaces

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There are two classifications of induction furnaces: coreless and channel. Cross sections of
each are shown in Fig.

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factory shutdowns and quickly started up again with a cold charge. It is not necessary to
maintain a molten heel or to use precast starter blocks.

MOULDING MACHINE
In Jolt squeeze moulding machines the supplemental compaction takes place as
the result of a squeeze head being forced into the moulding flask, thus compacting the loose
sand at the top. The required pressure can be applied pneumatically or hydraulically. In many
cases, the squeeze head will be one piece and may even have built-up areas to provide more
compaction in deep areas that are hard to ram. In other cases, the squeeze head may be of the
compensating type, which consists of a number of individual cylinders, each exerting a
specified force on the rear mould face.
They can be operated manually or automatically. The operator has the option of
independently adjusting the number of jolts from zero to any number and adjusting the
squeeze pressure from zero up to pressure that is considered excessive. Hand or pneumatic
ramming is often combined with this process.

Fig3.7: Jolt squeeze moulding machine with solid squeeze heads

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Sodium Silicate Bonds.The sodium silicate process is another method of forming a

bond made up of a silicate polymer. In this case, carbon dioxide is used to precipitate sodium
from what are essentially silicic acid containing large quantities of colloidal sodium. The
reaction is:
Na2O 2SiO2 + CO2 .Na2CO3 + 2SiO2
Continued gassing gives:
Na2O 2SiO2 + 2CO2 + H2O .2Na2HCO3 + 2SiO2
This shows that continued gassing dehydrates the amorphous silica gel and increases the
strength of the mould.
Sodium silicate moulds are widely used for large cores and castings where there is a premium
on mould hardness and dimensional control. The bond breaks down easily at high
temperatures and therefore facilitates shakeout. The silicate bonded sand, after pouring and
shakeout, can be reclaimed by mechanical means, and up to 60% of the reclaimed sand can
be reused. Wet reclamation of silicate sand systems is also possible.

CORE MAKING
The cold box core making process. The wet sand mix, prepared by mixing sand with the twocomponent liquid resin binder, is blown into the core box. The core box is then situated
between an upper gas input manifold and a lower gas exhaust manifold. The catalyst gas
enters the core box through the blow ports or vents and passes through the core, causing
almost instantaneous hardening of the resin-coated sand. The core is ready for ejection from
the core box after purging with clean air for a few seconds. After the catalyst gas passes
through the core, it leaves the core box through vents into the exhaust manifold. From the gas
exhaust manifold, the catalyst gas is piped to an appropriate disposal unit.

We observed the following difference:

1.Proper dead weights were used and also present in ample quantity whereas in NFF

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2. The number of dead weights were less, improper and did not serve their purpose
right.
3.They use sodium silicate mixture sand and green sand.

4.Various new machines installed like sand & moulding machine

5. Crushing machine

6. They used induction furnace in place of coal furnace. Also they had a secondary
induction furnace in case the primary furnace is down due to maintenance.
No secondary furnace at NFF

7. To give better surface finish shot blasting of the casting is done whereas at NFF
nothing more than chipping is done for surface finish.
8. Ramming automated tool

9.Special filter kept at the bottom of sprue of the mould to filter out any impurities
present in the melt. No such filter is used in NFF

10. Average age of workers was less as compared to NFF. Young workers can give
better productivity since they can do work faster and do not tire out easily
compared to any worker.

11.There was hardly any pattern inventory hence less cost and maintenance of inventory.
Pattern inventory of NFF is extremely large.

12.The mould boxes were new and had proper border shapes and when not in use they were
stacked properly. Mould boxes are clumsy and not handled properly.

13. Moulding is done at a separate flat surface area and then all the mould is properly
arranged at another place where pouring is done.

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Figure :3.8 Various problems ,causes, solution and benefits of operations

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Figure: 3.9 Various problems, causes, solution and benefits of operations

Figure: 3.10 Various problems, causes, solution and benefits of operations

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Figure: 3.11Various problems, causes, solution and benefits of operations

Figure: 3.12 Various problems, causes, solution and benefits of operations

CHAPTER: 4
Future Aims
Working on the current problems which we have found, like lack of ergonomically good.
dead weights, proper mould boxes, flat surfaces for moulding , time constraints.
Value chain mapping, method study and process detailing of 5 major products at NFF.
Planning for Industrial visits to understand the working and get ideas from other companies
for improvements.
Designing an ideal layout for minimum material handling.

Conclusion:
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The current casting process done by the company has been followed and the major areas of
concern have been found. These processes now will be compared to the standard process set
by ASM and improvements in the current process will be brought to enhance the companys
productivity.

REFERENCES

[1] ASM HandBook Volume 15 Casting.pg 510

[2]INTRODUCTION TO WORK STUDY Edited by George Kanawaty Fourth (revised)
edition.pg85
[3]Panchal Foundry ,Vapi
[4] Tool and Manufacturing Engineers Handbook Forming by ASTME. Pg 300

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