ACKNOWLEDGEMENT

First of all I thank my God Almighty for giving his grace to do this inplant
training successfully.

It is one of the most difficult tasks in life to choose the appropriate words to
express one’s gratitude towards the beneficiaries.

I would like to express our sincere gratitude to Mr. M. SUBRAMANIAM,

AMSTEEL CASTINGS PVT LTD. for his keen interest and affection towards us

I would like to express our sincere gratitude to our beloved principal

Dr.G.RANGANATH, M.E., Ph.D., for his keen interest and affection towards us.

I am highly indebted to Dr.CHANNANKAIAH,M.E.,Ph.D., Professor and

Head, Department of Mechanical Engineering, Adhiyamaan College of Engineering,
Hosur, for his guidance and valuable comments received through our mini project.

I am also grateful to Dr. S. V. SURESH BABU, M.E.,Ph.D., Professor,

Department of Mechanical Engineering, Adhiyamaan College of Engineering, for his
valuable guidance throughout our inplant training .

And last but not least, I express my deep gratitude to our parents and to my
friends for their encouragement and support.

iii
 DECLARATION

I affirm that the Inplant Training Report entitled “A Study on the Working

of AMSTEEL CASTINGS PVT LTD” being submitted for the partial fulfillment

for the award of Bachelor of engineering in mechanical engineering is the original

work carried out by me. It has not formed the part of the any other project submitted

for the award of the any Bachelor of engineering in this college.

` (Signature of the candidate)

NAME OF THE CANDIDATE :

REGISTER NUMBER :
I certify that the declaration made above by the candidate is true

Signature of the Incharge

(Dr. S.V. SURESH BABU, M.E.,Ph.D.,)

iii
 LIST OF CONTENTS

TITLE PAGE

TABLE OF CONTENT V

LIST OF TABLE viii

INTRODUCTION 1

COMPANY PROFILE 2

FUNCTION OF VARIOUS
DEPARTMENTS
3.1 HUMAN RESOURCES

3.2 TOOL ROOM

3.3 DESIGN

3.4 PRODUCTION

3.4.1 BASIC PROCESS 4

3.4.2 SAND CASTING STEPS 5

3.4.3 PATTERN 5

3.4.4 SPLIT PATTERN 5

3.4.5 MOULDING 6

3.4.6 TYPES OF VALVE 7

iv
 3.4.7 FURNACE

3.4.8 POURING

3.4.9 LADDLES

3.4.10 SHAKE OUT MACHINE

3.5 QUALITY INSPECTION AND TESTING

3.5.1 HEAT TREATMENT

3.5.2 NORMALIZING

3.5.3 TEMPERING

3.5.4 TYPES QUENCHING

3.5.5 SHOT BLASTING MACHINE

3.5.6 IMPACT TEST

3.5.7 TENSILE TEST

3.5.8 DEFECT IN CASTING

3.5.9 SURFACE DEFECTS

3.5.10 BLOW

3.5.11 SCAR

3.5.12 SCAB

3.5.13 INTERNAL DEFECTS

3.5.14 DEFECT CATEGORY

3.5.15 NON DESTRUCTIVE TEST

3.5.16 ULTRA SONIC TESTING

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3.5.17 MAGNETIC PARTICALS TESTING

3.5.18 LIQUID PENETRANT TESTING

3.5.19 PICKERING

3.5.20 ELECTRODE

3.5.21 THERPHONES

CONCLUSION

vi
 LIST OF TABLES

TABLE NO. TITLE PAGE NO.

3.1 Din grade 6

3.2 Material grade 6

vii
 CHAPTER 1

INTRODUCTION

1.1 CASTING

It means pouring molten metal into a refractory mould with cavity of the
shape to be made, and allowing it to solidify. When solidified, the desired metal
objects is taken out from the refractory mould either by breaking the mould or by
taking the apart. The solidified object is called casting. This process is called casting.
Time period is 8 hours.

1.2 SAND CASTING

The term "sand casting" can also refer to an object produced via the sand
casting process. Sand castings are produced in specialized factories called foundries .
Silica sand and chromite sand are used by thi s company. Sodium silicate is the oil
which is blend with sand for 4 to 5 mins. For example 5% of oil is mixed with 100 kg
of sand . Fresh sand are used for core and recycled sand are used for molding
purpose.
1
 CHAPTER 2

COMPANY PROFILE

Electralloy Special Steel Castings Private Limited, with its reduced capacity
and smaller furnace sizes, allows Amsteel Castings’ clientele the flexibility in order
sizes and quantities needed for optimal inventory control policies. This flexibility in
supply chain practices gives Amsteel Castings a unique advantage over its
competitors.

YEAR ESTABLISHED : 1981

INSTALLED CAPACITY : 1500 METRIC TONS (ANNUAL)

EMPLOYEES : 100

BUILD UP AREA : 25,000 SQ. FEET

PRODUCTION % : 85 %
EXPORTED

Electralloy Special Steel Castings has a global footprint for its products, with
a significant customer base in North America and Europe, driven by its ardent focus
on quality.

FURNACE TYPE : Induction Melting

FURNACE CAPACITY : 650 kg / 1500 lb

MAX SINGLE : 400 kg / 880 lb

CASTING WEIGHT

MOLDING PROCESSES : Silicate – CO2 **

Resin – Bond

SOLIDIFICATION : Soft-Cast
MODELING

2
 The company has a technically sound engineering department, accompanied
with an equally adept pattern development staff that supports Amsteel Castings’
quality policy. Patterns are developed and frequently improved to sustain our
continuous improvement philosophy.

QUALITY ASSURANCE : Mechanical Testing

Corrosion Testing
Chemical Analysis
NDT Analysis

NDT CAPABILITY : Radiographic Inspection

Ultrasonic Inspection
Liquid Dye Penetrant Test
Magnetic Particle Inspection

HEAT TREATMENT

FURNACE CAPACITY : Up to 10,000 kg / 22,000 lb

FURNACE TYPE : Bogie Type hearth furnaces

Forced draft-tempering furnaces

QUENCH CAPABILITY : Oil quench with circulation

Water quench with circulation

2
 CHAPTER 3

FUNCTION OF VARIOUS DEPARTMENT

• Human resource development

• Tool room.
• Design
• Production.
• Assembly.
• Quality Inspection & Testing.

3.1 HUMAN RESOURCE DEVELOPMENT

Human resource development involves developing and administering programs

that are designed to increase the effectiveness of an organization or business. It
includes the entire spectrum of creating, managing, and cultivating the employer-
employee relationship.

3.2 TOOL ROOM

A tool room is a room where tools are stored or, in a factory, a space where
tools are made and repaired for use throughout the rest of the factory. In engineering
and manufacturing, tool room activity is everything related to tool-and-die facilities
in contrast to production line activity.

3.3 DESIGN

All manufacturing-related departments are directly affected by the design

department, although, in most companies, manufacturing engineering acts as a buffer
for the shop floor. Indeed, manufacturing costs are simply a reflection of design
engineering methods.

3
3.4 PRODUCTION

3.4.1 BASIC PROCESS

There are six steps in this process:

1. Place a pattern in sand to create a mold.

2. Incorporate the pattern and sand in a gating system.

3. Remove the pattern.

4. Fill the mold cavity with molten metal.

5. Allow the metal to cool.

6. Break away the sand mold and remove the casting

Figure 3 .1 Steps in Sand Casting

4
3.4.2 SAND CASTING STEPS

sand

Melting of pouring Mould molding

metal into mould

casting

heat treatment

cleaning &

finishing

inspection

3.4.3 PATTERN
Pattern is the model of casting . wood piece pattern are used in this company.
The most commonly used pattern material is wood, the main reason being the easy
availability and low weight. It can be easily shaped and is relatively cheap. But the
main disadvantage of wood is its absorption of moisture as result of which distortions
and dimensional changes occur.

3.4.4 SPLIT PATTERN OR TWO PIECE PATTERN

This is the most widely used type of pattern for intricate castings. When the
contour of casting makes its withdrawal from the mould difficult, or when the depth
of the casting is too high, then the pattern is split into two parts so that one part is in
the drag and the other in the cope.

5
 Figure 3.2. Split Pattern

MATERIAL CODE

Table No. 3.1 Material code

MATERIAL CODE NO’S

WCB 031
WC6 033
LCC 504
C12 412
CF8 035
CF3 140

3.4.5 MOULDING
The sand is filled in the mold which is hardened by carbon di oxide(Co2) or
rammer. Here Pneumatic rammer is used. After finishing the mold , paint coating is
given to the mold and then paint coating is heated . The purpose of chill is uniform
solidification. Runner and riser are made up of ceramics.

6
3.4.6 TYPES OF VALVE PRODUCED BY THE COMPANY
GTV - GATE VALVE

GLV - GLOBE VALVE

SCV - CHECK VALVE

BV – BALL VALVE

3.4 .7 FURNACE
Induction furnace is an electrical furnace in which the heat is applied by
induction heating of metal. The principal of induction melting is that a high voltage
electrical source from a primary coil induces a low voltage , high current in the metal
or secondary coil. It is simply a method of transferring heat energy. Capacity of
furnace is nearly 3.6 tonnes . temperature is about 1600 c. laddle patch powder
consist
of aluminium, laddle lover, fire clay powder. Deactivation material such as calcium
silicate , aluminium etc, Thickness of furnace coating is 4 – 5 inches.

Figure 3.3 Furnace

7
3.4.8 POURING
This can be restricted by using super-heated metal, but in this case solubility
will be a problem. If the molten metal is poured very faster, it can carode the mould
cavity. So gating design is important and it depends on the metal and molten metal
composition.

3.4.9 LADDLES
Ladles are used to transport molten metal from the melting furnace to the
mould
and vice versa. These ladles consist of steel shell lined with a suitable refractory
material like fire clay. The graphite ball is used to stop the metal flow rate . The
graphite ball withstands the high temperature.

Figure 3.4. Laddles

8
3.4.10 SHAKE OUT MACHINE
Shakeout Tables separate the poured mold into the flask, casting, and sand. It
can be made removable for change out. The shakeout and passes down through the
casting deck openings and is collected for discharge through a bottom outlet.
Capacity
is about 6.3 tonnes.

3.5 QUALITY ISPECTION AND TESTING

It ensures that the processes used to design, test, and produce products will be
done correctly. In manufacturing, quality assurance approaches, like ISO 9001, help
manage and improve many processes, including Designing and using inspection
procedures. Complying with production processes.

3.5.1 HEAT TREATMENT

Heat Treatment is a method of controlled heating and cooling of metals to
alter
their mechanical and physical properties without changing the product shape.
Temperature about 920 c. Air quenching and Water quenching are the two methods
used by this company. Time period for water quenching 1.3 mins (manual) & 0.45
sec
( automatic) .

Figure 3.5 Heat treatment

9
3.5.2 NORMALIZING
A type of heat treatment applicable to ferrous metals only, normalizing differs
from annealing in that the metal is heated to a higher temperature, which is then
removed from the furnace for air cooling. The basic objective of normalizing is to
remove the internal stresses caused by heat treating, welding, casting, forging,
forming, or machining. If not controlled, stress can result in metal failure. Soaking
time period of the casting is 4 hours.

3.5.3 TEMPERING
To relieve the internal stresses and to reduce brittleness, the steel should be
tempered after it is hardened. Tempering process comprises of heating the steel to a
particular temperature ,holding it at that temperature for a definite time, and then
cooling it, generally install air. The final hardness, strength, and ductility depends on
the temperature to which the steel is heated during tempering.

3.5.4 TYPES OF QUENCHING

AIR QUENCHING

Air quenching is used for cooling some highly alloyed steels. Parts cooled with
circulated air are placed in the same manner and arranged for uniform cooling.

WATER QUENCHING

Quenching time period – 20 mins

10
3.5.5 SHOT BLASTING MACHINE
Shot blasting is a method used to clean, strengthen polish metal. Capacity of
shot blast is 5 tonnes. At high pressure , the ball will strikes the casting . It is used to
remove scaling and impurities of cast. Time period is 8 minutes.

Figure 3.6. Shot Blasting Machines

3.5.6 IMPACT TEST

Figure 3.7. Impact Test

Conducted on test specimens of standardized dimensions. Charpy impact

testing determines the amount of energy absorbed during fracture and is used to
gauge
ductility and strength. A sudden impact load is given to the material to test the
hardness of material below zero degree Celsius.
11
3.5.7 TENSILE TEST

Tensile test provides ultimate tensile strength , yield strength , elongation,

reduction area etc… extensometer is very sensitive and accurate.

Figure.3.8. Tensile Test

3.5.8 DEFECTS IN CASTING

These defects may be the result of:

(a) Improper pattern design

(b) Improper mould and core construction

(c) Improper melting practice

(d) Improper pouring practice

(e) Because of molding and core making materials

(f) Improper gating system

(g) Improper metal composition

(h) Inadequate melting temp and rate of pouring

12
3.5.9 SURFACE DEFECTS
Due to design and quality of sand molds and general cause is poor ramming.

3.5.10 BLOW
Blow is relatively large cavity produced by gases which displace molten metal
form.

Figure 3.8 Blow

3.5.11 SCAR
Due to improper permeability or venting. A scare is a shallow blow. It
generally occurs on flat surf; whereas a blow occurs on Convex casting surface. A
blister is a shallow blow like a scar with thin layer of metal covering it.

Figure 3.9 Scare

13
 3.5.12 SCAB
This defect occurs when a portion of the face of a mould lifts or breaks down
and the recess thus made is filled by metal. When the metal is poured into the cavity,
gas may be disengaged with such violence as to break up the sand which is then
washed away and the resulting cavity filled with metal. The reasons can be: to fine
sand, low permeability of sand, high moisture content of sand and uneven moulds
ramming.

Figure 3.10 Scab

3.5.13 INTERNAL DEFECTS

PIN HOLES
Pin holes are small gas holes either at the surface or just below the surface.
When these are present, they occur in large numbers and are fairly uniformly
dispersed
over the surface.

Figure 3.11 Pin Holes

14
WASH
A cut or wash is a low; projection on the drag face of a casting that extends
along
the surface, decreasing in height as it extends from one side of the casting to the other
end. It usually occurs with bottom gating castings in which the molding sand has
insufficient hot strength, and when too much metal is made to flow through one gate
into the mold cavity.

Figure 3.12 wash

RAT TAIL
A rat tail is a long, shallow, angular depression in the surface of a flat rating
and resembles a buckle, except that, it is not shaped like a broad vee. The reasons for
this defect are the same for buckle.

Figure 3.13 Rat Tail

15
SHRINKAGE
A shrinkage cavity is a depression or an internal void in a casting that results
from the volume contraction that occurs during solidification.

Figure 3.14 Shrinkage

SWELL
A swell is a slight, smooth bulge usually found on vertical faces of castings,
resulting from liquid metal pressure. It may be due to low strength of mould because
of too high a water content or when the mould is not ramed sufficiently.

Figure 3.15 Swell

16
3.5.14 DEFECTS CATEGORY
Table no. 3.3 Defects category
A B C D E
GAS HOLES INCLUSION SHRINKAGE CRACK HOT TEAR

3.5.15 NON-DESTRUCTIVE TESTING

Some of the methods used:

• Ultrasonic Testing.
• Magnetic particle inspection.
• Dye penetrant inspection/Liquid penetrant inspection.
• Radiographic testing.

3.5.16 ULTRASONIC TESTING

Use of High Frequency Sound Waves to detect imperfections or to locate
changes in material properties. Time travel between transmission and reception of
pulses gives clues regarding internal structure of the material. The probe used is of
split type, having transmitter on one end and receiver on the other end. Defect can be
analysed more than 200 mm.

Figure 3.16 Ultrasonic Testing

17
3.5.17 MAGNETIC PARTICLE TESTING
Magnetic particle test are mostly used for carbon steel to detect the defects.
Testing performed on Ferromagnetic materials with a smooth surface. Fast approach,
relatively easy to apply and surface preparation is not critical. Physical Principle
Magnetization (Faraday's Law of Magnetic Induction) Applicable for surface,
subsurface defects and all other defects (excluding transverse direction). Defects can
be analysed upto 5mm. In this test depth can be analysed.

Figure 3.17 Magnetic Particle Testing

3.5.18 LIQUID PENETRANT TESTING

It is mostly used for stainless steel . Use of Penetrant, Developer and Cleaner
on test specimen. Defects open to surface like cracks after rolling, casting, weld
cracks, hot tears, cold shuts, and shrinkages can be detected.

Figure 3.18 Liquid Penetrant Testing

18
3.5.19 PICKERING
It is used to remove the impurities from the object. It is used only for stainless
steel. It has three levels. Acid act as a removing agent. Acids such as nitric acid
(HNO3) , sulphuric acid (H2SO4) and ( HNO3 + HF).

3.5.20 ELECTRODE
Before using the electrode , the electrode should be heated in oven upto 300 c
and then it is maintained at 100 c for 1 hour. Heating the electrode is necessary to
remove the moisture content.

3.5.21THERMOPENS
Thermopens are used to check the temperature of the welding. Thermopens
available in 150c, 200c ,500c , 600c, etc..

19
 CHAPTER 4

CONCLUSION
Thus the inplant training was a useful experience. I have gained new
knowledge, skills and met many new people. I achieved several of my learning goals,
however for some the conditions did not permit. I got insight into professional
practice. I experienced that financing, as in many organizations, is an important
factor
for the progress of projects. Related to my study I learned more about the biology
and
ecology of river dolphins and the threats they face. There is still a lot to discover and
to improve. The methods used at the moment are still not standardized and a
consistent
method is in development. I have seen that local people can contribute to
conservation,
for example with their knowledge. Furthermore I experienced that it is of importance
that the education is objective and that you have to be aware of the view of other
people. Environmental education is not one sided, but it is a way of sharing
knowledge, ideas and opinions. The inplant training was also good to find out what
my strengths and weaknesses are. This helped me to define what skills and
knowledge
I have to improve in the coming time. It would be better that the knowledge level of
the language is sufficient to contribute fully to projects. After my master I think that I
could start my working career. However I could perform certain tasks in research
better if I practice know more the research methodologies applied in cetacean studies.
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