INDUSTRIAL TRAINING ON INVESTMENT

CASTING
HELD AT

PCI PRECISION CASTING LTD. (MANESAR)

SUBMITTED BY
NAME: RAM PANDEY
ROLL NO.: 02510403613
DEPARTMENT OF MECHANICAL ENGINEERING
AMITY SCHOOL OF ENGINEERING AND
TECHNOLOGY

ACKNOWLEDGEMENT
The internship opportunity I had with PCI PRECISION CASTING LTD
was a great chance for learning and professional development.
Therefore, I consider myself as a very lucky individual as I was provided
with an opportunity to be a part of it. I am also grateful for having a
chance to meet so many wonderful people and professionals who led
me though this internship period.
Bearing in mind previous I am using this opportunity to express my
deepest gratitude and special thanks to the VP of PCI PRECISION
CASTING LTD. who in spite of being extraordinarily busy with his duties,
took time out to hear, guide and keep me on the correct path and
allowing me to carry out my training at their esteemed organization.
I perceive as this opportunity as a big milestone in my career
development. I will strive to use gained skills and knowledge in the best
possible way, and I will continue to work on their improvement, in order
to attain desired career objectives. Hope to continue cooperation with
all of you in the future.
Sincerely,
Ram pandey

CONTENTS OF REPORT
1. INTRODUCTION TO TOOL ROOM
2. UNDERSTANDING DRAWING AND BREAKING IT INTO SIMPLER PARTS

INTRODUCTION

1. COMMON TOOLS AND MACHINES USED IN

TOOL ROOM
Grinding Machine It consists of a grinding wheel which is made up of

abrasive particles that rub against the work piece on which operation is to be
performed and material is removed layer by layer, grinding wheel is categorized
based upon size of grains used in making of wheel. In addition to their abrasive and
bonding materials, grinding wheels often contain additional ingredients that
produce pores within the
wheel or assist chemically when a
particular abrasive is used
to grind a special material.

Grinding wheel
One important aspect of a grinding wheel that can be created or altered through
additives is porosity, which also contributes to the cutting characteristics of the
grinding wheel. Porosity refers to the open spaces within the bond that allow room
for small chips of metal and abrasive generated during the grinding process.
Porosity also provides pathways that carry fluids used to control heat and improve
the cutting characteristics of the abrasive grains. Without adequate porosity and
spacing between abrasive grains, the wheel can become loaded with chips and
cease to cut properly.
Abrasive grain
The abrasive aggregate is selected according to the hardness of the material being
cut.

Aluminium oxide (A)

Silicon carbide (S)

Ceramic (C)

Diamond (D, MD, SD)

Cubic boron nitride (CBN)

Grinding wheels with diamond or CBN grains are called super abrasives. Grinding
wheels with aluminium oxide (corundum), silicon carbide, or ceramic grains are
called conventional abrasives.

Grain size
From 8 (coarsest) to 1200 (finest), determines the average physical size of the
abrasive grains in the wheel. A larger grain will cut freely, allowing fast cutting but
poor surface finish. Ultra-fine grain sizes are for precision finish work.
Wheel grade
From A (soft) to Z (hard), determines how tightly the bond holds the abrasive. A to
H for softer structure, I to P for moderately hard structure and Q to Z for hard
structure. Grade affects almost all considerations of grinding, such as wheel speed,
coolant flow, maximum and minimum feed rates, and grinding depth.
Grain spacing
Spacing or structure, from 1 (densest) to 16 (least dense). Density is the ratio of
bond and abrasive to air space. A less-dense wheel will cut freely, and has a large
effect on surface finish. It is also able to take a deeper or wider cut with less
coolant, as the chip clearance on the wheel is greater.

Types of grinding machines available in tool room

Die grinder
Which is a high-speed hand-held rotary tool with a small diameter grinding bit?
They are typically air driven (using compressed air), but can be driven with a small
electric motor directly or via a flexible shaft.
Cylindrical grinder
Which includes both types that use centre and the centerless types? The workpiece
is rotated and fed past the wheel to form a cylinder. It is used to make precision
rods, tubes, bearing races, bushings, and many other parts.
Surface grinder
The most common surface grinders have a grinding wheel rotating on a horizontal
axis cutting around the circumference of the grinding wheel. This type of machine
removes large amounts of material and grinds flat surfaces with noted spiral grind
marks. It can also be used to make and sharpen metal stamping die sets, flat shear
blades or any flat and parallel surfaces. Surface grinders can be manually operated
or have CNC controls.

Size of surface grinder available in tool room is 600X200 mm.

Speed- 2700 rpm
Speed(cylindrical)- 90-1000 rpm
Die grinder
This is a high-speed hand-held rotary tool with a small diameter grinding bit. They
are typically air driven (using compressed air), but can be driven with a small
electric motor directly or via a flexible shaft.

Milling Machines These are used to shape the metals and solid materials as
per the defined or custom specifications. It is executed manually or automatically
based on the types of milling devices that are manual milling, mechanical milling
and digital CNC milling for automatic execution.

Mounting and Unmounting

milling tool

Size of worktable
Size of table is 250X1350 mm
Speed of rotation is 80-5400 rpm and 90-2240 rpm

VMC and CNC vertical machining center (VMC) is a machining center with its

spindle in a vertical orientation. High-end VMCs are high-precision machines often

used for tight-tolerance milling, such as fine die and mold work. Low-cost vertical
machining centers are among the most basic CNC machine tools. A low-cost VMC is
often a new machine shops first machine tool purchase. Cutting oil with 5-6 %
concentration (by volume) is used in normal machining operations which are
performed on VMC, water is mixed with cutting oil or coolant as it increases cooling
properties and makes work piece more wet and covers larger surface area while
performing operations.

The CNC machine comprises of the computer in which the program is fed for
cutting of the metal of the job as per the requirements. All the cutting processes
that are to be carried out and all the final dimensions are fed into the computer via
the program. The computer thus knows what exactly is to be done and carries out
all the cutting processes. This machine is very helpful when operations with same
sequence are to be performed many times. CNC machines also used coolant if
required.

Components of VMC
Spindle, Spindle motor, axis motor, slide cover, tool magazine
Tool magazine can hold from 8 to 24 tools depending upon size of machine.

Specifications of VMC and CNC available in tool room

VMCBed size- 600x400 mm
Maximum movement possible ( X Y Z resp.)- 600x400x500 mm
Speed- 600rpm

Amount of coolant used by volume in different machining processes:

Total ACANTIS HM Grade 32(coolant)

Normal machining operations: 4 - 6 %

Difficult machining operations: 10 %

Grinding: 2 - 4 %

VMC and CNCs are programmed with help of G and M codes which specify
operations as well as their sequence that are to be performed on work piece.

For example

G00 rapid traverse

G21 dimensions in metric units.
M03/- spindle start clockwise
M04 spindle start counter clockwise

Power Hacksaw Machine A hacksaw is a fine-toothed saw, originally and

principally for cutting metal. They can also cut various other materials, such as
plastic and wood. There are hand saw versions available, which is mostly used to
cut work piece of smaller width. Most hacksaws are hand saws with a C-shaped
frame that holds a blade under tension. Such hacksaws have a handle, usually a
pistol grip, with pins for attaching a narrow blade. The frames may also be
adjustable to accommodate blades of different sizes. A screw or other mechanism
is used to put the thin blade under tension.

Lathe A lathe is a machine tool that rotates the workpiece on its axis to perform

various operations such as cutting, knurling, drilling, or facing, turning, with tools
that are applied to the workpiece to create an object with symmetry about an axis
of rotation.
Operations that can be performed on lathe
1. Drilling
2. Turning
3. Facing
4. Threading
5. Knurling
6. Boring
7. Chamfering
8. Grooving

Types of late chucks

1. Self aligning (3 jaw)

Three jaw lathes are also called self aligning lathe as workpiece is aligned itself
when placed and fastened by key, this happens as all three jaws move equally to
centre when key is fastened and there are no separate keys available for each jaw.
They are mostly used for cylindrical workpiece.
2. 4 Jaw chuck
Four jaw chucks are not self aligning and each jaw has its own mechanism for
fastening. They are most suitable for rectangular or any other irregular shaped
workpiece
Specification of Late available in tool room
Bed size 4.5 feet, 6.5 feet, and 8 feet
Number of gears- 6
Speed 10 - 1500 rpm
Feed- 0.05 to 2 mm

Drilling Machine (Radial) Drilling machines are used for drilling different
sized holes in a variety of materials at many different depths. It is a necessary tool
in many types of industrial jobs and can perform several other functions aside from
drilling. Tapping is one of the other functions a drilling machine performs, referring
to drilling holes in pipelines that are under pressure. Reaming makes holes more
dimensional and improves the finished surface. Countersinking creates a space at
the top of the hole to hold a bolt screw head in place. Counterboring makes an
existing hole larger to fit the size of specific screws.
Specification of drill machine in tool room
90-1800 rpm

Boring machine
In machining, boring is the process of enlarging a hole that has already
been drilled (or cast), by means of a single-point cutting tool. Boring is used to
achieve greater accuracy of the diameter of a hole, and can be used to cut a
tapered hole. Boring can be viewed as the internal-diameter counterpart to turning,
which cuts external diameters.
Operations that can be performed
Boring machine can perform all operations that a lathe can perform but it has a
major difference that it has tool mounted on headstock and larger workpiece can
be machined, boring machine has another advantage that it can move in 6
directions whereas in lathe only 4 directions are possible.
Specifications of boring machine
Size- 700x700 mm and 1500X1500 mm
Feed- 0.05 to 2 mm
Speed- 15-250 rpm
Capacity- 5 tonne

Components of die
1. Base plate
Base plate is the bottom most plate on which upper and lower halves of die are
mounted, main function of base plate to make clamping of die easy on machine.
Base plate is generally made of mild steel.
2. Upper/Lower plate
Upper plate can have both core as well as cavity, while lower plate can have cavity
only. Both plates can have cooling system if required. These plates are made of
aluminum or mild steel.
3. Inserts
Inserts are those parts of a die which have complex shapes and cant be made with
that accuracy within plates so, they are prepared separately and then assembled in
die.
4. Bush and pillars (Guiding pins)
Bush and pillars are used to lock upper and lower halves of die in correct alignment
and also protects horizontal misalignment due to vibrations produced during
operation.

5. Dowell pins
Dowel pins are also used for aligning both plates and act as additional guidance in
case when pillar gets damaged while performing operation on wax machine.
6. Ejector pins
Ejector pins are provided below bottom plate to take out wax pattern formed if
pattern cant be easily taken out of cavity then lever is pushed downward and
ejector pins apply force on wax pattern from downward and removes pattern from
cavity.
7. Allen bolt
Allen bolts are used to fix inserts in upper and lower plates so that while performing
operation when vibrations are produced in machine, they do not change in their
position.

Inspecting Component According to Drawing

General symbols of Machining and Surface roughness

End Fitting (Honda)

S.N
o.
1
2
3

Drawing
dimensions(mm)
32
22.9
20.6

4
5
6
7
8
9
10

16.8
16
14
12
6.5
9.5
13

11

19.54

12
13
14

R1
R1
R1

Tolerance(m
m)
-0.3
-0.06
-0.05
to
-0.11
-0.30
-0.3
-0.3
+0.30
+0.2
+0.1 to -0.1
+0.15
to
-0.15
+0.15
to
-0.15
-0.2
-0.2
-0.2

Casting
Dimensions(mm)
32.04
23.8
20.7
16.7
16.42
16
11.92
5.62
8.76
14.16
20.11
R1.5
R1
R1

Making of Shell and Wax pattern

Although its called wax but material can also include plastic and other
materials with low melting point to strengthen pattern.
Types of wax
1.Filled Pattern Wax
2.Unfilled Pattern Wax
3.Water soluble Wax
4.Repair wax
Filled Pattern wax
Filled pattern wax is of green color and have lesser shrinkage when
compared with other types of wax, it can be reused as unfilled 6-7
times.
Unfilled pattern wax
Unfilled pattern wax has more shrinkage than filled pattern but it is
more economical as it can be reused 6-7 times.
Making of Unfilled Pattern wax
1.Wax (ester gum)
150 C

30%

2.HCO (Hydrogenated Castor Oil)

120 C
3.Monton
120 C
4. Paraffin
90 C
5.Microcrystalline
80 C

5%
37.5%
25%
2.5%

All above constituents are poured into conditioning tank and mixed
there up to 4 hours.
Water Soluble Wax
Water soluble wax cant be reused and is used for making cores for
shapes that cant be casted without cores.

Repair wax
Repair wax is made my mixing petroleum jelly with Microsoft(wax) for
repairing damaged wax patterns.
After preparing wax it is poured into Wax injection machine where it is
injected into mold cavity to obtain pattern after cooling. Wax pattern is
inspected visually and repaired by applying repair wax and after that
gating is done to make a branched structure of wax patterns mounted
on gate by melting with help of Hot plate.
Wax patterns are coated with primary and secondary slurry in order to
obtain shells after melting wax in which molten metal can be pored
Preparing Slurry for primary coating
Constituents
1.Take 38 kg of zircon flour
2.10 kg of refrabin PCB (Primary coating binder)

3.100 ml of 1-Octanol (Anti foaming agent)

4.Teepol solution 75ml (Keeps solution wet)
Process
Take Teepol solution and add 75 ml of distilled water in it and heat this
solution for 4-5 minutes on 60 C temperature, now add PCB,1-Octanol
and stir it well after that add zircon flour and mix whole mixture up to
48 hours on jar mill.
Secondary slurry
1.Colloidal silica
2.Kynite dense powder

50%
50%

Viscosity is measured from Ford B4 cup which is measured in terms of

time by using a stopwatch and it should be under 17-22 seconds
Wax tree is coated with 7-8 layers of secondary slurry to provide support to primary
coating

Foundry
Dewaxing
Dewaxing is the process of collecting molten wax of shell in a tank by
providing heat to shell with the help of boiler
Boiler temperature 160 C to 180 C
Baking
After dewaxing next process is baking in which shells are kept in baking
furnace for 2 hours which has minimum temperature of 1000 C which
is enough to de-moisturize and open pores for gases in shells.
Temperature provided in baking furnace is decided according to
component dimension sharper the component higher the temperature.
Inductance furnace
Induction furnace works on principle of induction in which eddy currents
are introduced in raw materials which heats up metal using its own

resistance and results in melting o metal, Induction furnace is coated

with kynite sand from inside to prevent leakage of molten metal.
Alloying and Raw material testing
Before and after melting materials are tested on spectrometer which
has two electrodes for sparking and works on principle of optics,
spectrometer measures the composition of raw material and
accordingly alloying can be done to obtain desired composition
Meanwhile temperature of molten metal is checked by help of
thermocouples.
After Alloying calcium or Aluminum are also mixed with molten metal in
order to remove oxygen content and slag 30 is used to remove slag
from molten material as it forms a layer of slag above which can easily
be removed with help of stick.
After pouring molten metal into shells they are allowed to cool slowly to
avoid uneven shrinkage of material.
Knocking
Knocking is the process of removing sand and other ceramic materials
from components by introducing vibration and shots in component
Cutting and shot Blasting
Casted components are removed from gates with help of gas welding
and then they are placed inside shot blasting machine where shots of
glass or steel are bombarded on casting to remove sand particles that
cant be removed with help of knocking and drilling
Reworking and repairing
Reworking and repairing is done if required after visual inspection of
component which includes grinding, straitening, welding, heat
treatment
Passivation

Passivation is the process of adding protective metal oxide layer over

casting to avoid corrosion which is done by using a bath of nitric acid or
HF acid.
Final Inspection
After all this process inspection of component is done and rejected
components are scraped that can later be melted into furnace.