KIW Rep PDF

KUDALE IRON WORKS BELAGAVI
INDEX
 Introduction to KUDALE IRON WORKS

 Customers
 Introduction Foundry
 Introduction to Moulding Sand
 Sand Testing
 Patterns
 Core Making
 Moulding Terminologies
 Moulding
 Materials and Material Properties
 Material Suppliers
 Melting Process
 Furnace
 Pouring Process
 Laboratory
 Shot Blasting
 Casting Defects, Advantages and Applications
 Products
 Conclusion
KLECET CHIKODI Page 1

INTRODUCTION TO KUDALE IRON WORKS,
Established in the year 1999, we are a well-established Firm engaged in the manufacturing
and supplying of graded gray iron castings. Our foundry located at Belgaum, which has staff
strength of 100 people. Our range, which includes valve casting, butterfly valve casting, coupling
castings, pulley castings, cast iron coupling, cast iron pulley, auto pumps and many other products
that are widely used in various segments such as motor industry, automobiles, and engineering
industry.
We provide customized solutions to our valuable clients and package consignments as per
their specifications. Under the able guidance of our CEO Mr. Mahesh S Kudale, he enabled us to
achieve a remarkable progress in our field. Our efficient team coupled with advanced machineries
helps us to meet the bulk demands from the market. We have a huge client network throughout the
country.
Quality is our prime focus. Our quality auditors supervise every stage of production and
conduct various quality tests to ensure the supreme quality of our range. We are in process to the
target of achieving ISO certificate for the quality of our product. Our well-equipped manufacturing
unit helps to meet the huge demands from our clients. We have 2 manufacturing units, which are
spread over a large area of 40000 square meters for the sufficient production. Owing to these
reasons we have a wide client base all over the country.
CUSTOMERS:
 Rati – Trans power Equipment, Pune (Coupling Manufactures)
 Dell Valve – Pune (Valve Manufacturer)
 Pragati Automation (CNC machinery Parts)
 Normax Valve Pune ( Non Returning Valve)
 Alex Grinders Lonava, Mumbai ( Machine Parts)

INTRODUCTION TO FOUNDARY
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting
them into a liquid, pouring the metal in a mold, and removing the mold material or casting after
the metal has solidified as it cools. The most common metals processed are aluminum and cast
iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to
produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.

TYPES OF SAND:
1. SILICATE (CO2) SAND

Composition (for 304kg):
Fine Sand – 78.894% (240kg)
Rough sand – 21.10% (64kg)
Silicate – 5.92% (18kg)
Procedure:
 First clean the Muller machine.
 Pour the fine and rough sand in Muller machine.
 Rotate the Muller machine and slowly pour the silicate into it and rotate up to 3 minute.
 Use the sand for 60 minute.
 Use co2 gas for this sand mould.
2. GREEN SAND
Return sand – 90% (360kg)
Fresh sand – 8% (32kg)
Bentonite – 1.125% (4.5kg)
C-coal –0.625% (2.5kg)
Water – 15-30 ltr
Procedure:
 Pour the return sand and fresh sand in Muller machine.
 Mix the water in to it and rotate the muller machine for 2 minute.
 Mix bentonite and c-coal in to it and rotate the muller machine for 3 minute.
 Then the sand is ready for use.

3. OIL CORE SAND:

Fresh fine sand – 36.84% (112kg)
Fresh rough sand – 63.15% (192kg)
Bentonite – 0.328%(1kg)
Dextrin – 0.039% (12kg)
Core oil – 1.973%(6kg)
Procedure:
 Rotate the muller machine and slowly add core oil in to it.
 Mix bentonite and dextrin in to it and rotate for two minute.
 Rotate the muller machine for 3 minute.
 Then the prepared sand is ready for use.
4. NOBACK CORE SAND:

Fresh fine sand – 10.526%(32kg)
Fresh rough sand – 89.47%(272kg)
Resin – 3% (6.750ltr)
Hardener – 1%(3.750ltr)
Procedure:
 Then add slowly resin in to it.
 Rotate the muller machine for 3 minute.
 Then the prepared sand is ready for use.
 As per the weight of core take the prepared sand and add some amount of hardener in to
it, mix it with hand and fill the core.

QUALITY PLAN FOR GREEN SAND TESTINGS:
PARAMETERS ACCEPTANCE CRITERIA
Green compression strength 900 to 1300 gms/cm
Permeability 100 to 200
Moisture 3 to 4.2%
Dead clay Max 4%
Active clay 8 to 10
Total clay 11 to 13
Compatibility 40 to 50

SAND TESTING:
 MOISTURE CONTENT TEST:

Moisture is the property of the moulding sand it is defined as the amount of water
present in the moulding sand.
Low moisture content in the moulding sand does not develop strength properties. High moisture
content decreases permeability.
Procedure:
1. 20 to 50 gms of prepared sand is placed in the pan and is heated by an infrared heater bulb for
2 to 3 minutes.
2. The moisture in the moulding sand is thus evaporated.
3. Moulding sand is taken out of the pan and reweighed.
4. The percentage of moisture can be calculated from the difference in the weights, of the
original moist and the consequently dried sand samples.
Percentage of moisture content = (W1-W2)/ (W1) %
Where, W1- Weight of the sand before drying,
W2- Weight of the sand after drying.
 CLAY CONTENT TEST:
Clay influences strength, permeability and other moulding properties. It is responsible for
bonding sand particles together.
Procedure:
1. Small quantity of prepared moulding sand was dried
2. Separate 50gms of dry moulding sand and transfer wash bottle.
3. Add 475cc of distilled water + 25cc of a 3%NaOH.
4. Agitate this mixture about 10 minutes with the help of sand stirrer.
5. Fill the wash bottle with water up to the marker.
6. After the sand etc., has settled for about 10 minutes, Siphon out the water from the wash
bottle.
7. Dry the settled down sand.
8. The clay content can be determined from the difference in weights of the initial and final sand
samples.
Percentage of clay content = (W1-W2)/ (W1) * 100
Where,
W1-Weight of the sand before drying,
W2- Weight of the sand after drying.

Auto sand washer

 GRAIN FITNESS TEST:

The grain size, distribution, grain fitness are determined with the help of the fitness
testing of moulding sands. The apparatus consists of a number of standard sieves mounted one
above the other
on a power driven shaker. The shaker vibrates the sieves and the sand placed on the top sieve
gets screened and collects on different sieves depending upon the various sizes of grains present
in the moulding sand. The top sieve is coarsest and the bottom-most sieve is the finest of all the
sieves. In between sieve are placed in order of fineness from top to bottom.
Procedures are:
1. Sample of dry sand (clay removed sand) placed in the upper sieve
2. Sand is vibrated for definite period
3. The amount of same retained on each sieve is weighted.
4. Percentage distribution of grain is computed.
Sieve shaker

 PERMEABILITY TEST:
The quantity of air that will pass through a standard specimen of the sand at a
particular pressure condition is called the permeability of the sand.
Following are the major parts of the permeability test equipment:
1. An inverted bell jar, which floats in a water.
2. Specimen tube, for the purpose of hold the equipment
3. A manometer (measure the air pressure)
Procedures are:
1. The air (2000cc volume) held in the bell jar is forced to pass through the sand specimen.
2. At this time air entering the specimen equal to the air escaped through the specimen
3. Take the pressure reading in the manometer.
4. Note the time required for 2000cc of air to pass the sand
5. Calculate the permeability number
6. Permeability number (N) = ((V x H) / (A x P x T))
Where,
V-Volume of air (cc)
H-Height of the specimen (mm)
A-Area of the specimen (mm22)
P-Air pressure (gm / cm2)
T-Time taken by the air to pass through the sand
Permeability meters

 Compression/shear test:
Use: The instrument is used to determine various strength of specimen.
Procedure:
1. Place the compression/shear pads in location.
2. Put cylindrical specimen between two pads.
3. Apply the load till it breaks
4. Note down the pressure which indicates compression/shear strength of sand.
Universal strength machine

PATTERNS:
Everything in the foundry has to start with a “pattern”. A pattern or tooling is a full size
model of the part you are trying to cast. It is replica of the product. Patterns can be made of
various materials such as mahogany, metal, plastic or Styrofoam. It is very important to have
suitable pattern, for the quality of the casting is influenced by the quality of the pattern.
Patterns are made in order to reach customers requirements. In KIW patterns are given
by the customers and as per the requirement of customer the products are made. The production
is batch type production where different products are produced in batches.
There are three main types of patterns

1. LOOSE PATTERNS
 A loose pattern is the wood counterpart of the casting, with the proper allowance in
dimensions for contraction and machining. A loose pattern may be made in one piece or
it may be split into the cope and drag pieces to make moulding easier.
2. MOUNTED PATTERNS
 Patterns fastened permanently to a flat board, called a match plate, are known as mounted
patterns.
 The main advantage of the mounted pattern over the loose pattern is that it is easier to use
and store. For these reasons, a mounted pattern is generally warranted when several of the
castings (say, five or more) are to be made during one "run" or when the casting is made
at frequent intervals.
 Another advantage of the mounted pattern is that a pattern of the gating system also can
be mounted on the match plate. This practice of moulding the gating system eliminates
the loose sand that often results when gates are hand cut. As a result, the castings
produced usually are better than those produced with the loose patterns.

3.

CORE BOXES PATTERN:

 Core boxes are actually negative patterns. When looking at a pattern, one sees the casting
in its actual shape. A core box on the other hand shows the cavity which will be created
by the core.
 Core boxes are used not only to make cores for holes in castings but also to make parts of
a mold.
 In some cases, a pattern cannot be made so that it can be drawn. In such a case, the part
of the casting which would hinder drawing is made as a core that can be placed in the
mold after the pattern proper has been withdrawn.

CORE MAKING:
Core making is an important branch in any foundry and the choice of core making depends
on various factors. To name them depending on type of metal to be cast, depending on the size of
casting, choice based on complexity involved in a casting process, depending on the requirement
of quality is final product, depending on equipments used for production and energy source.
Following are the technologies involved in core making.

A. COLD BOX:

B. SHELL PROCESS:
C. NO BAKES:
D. OIL CORE:

Cold box core
Shell Core

Characteristics of mold:
1. Strong enough to hold the weight of the metal.
2. Resistant to the cutting action of the rapidly moving metal during pouring.
3. Generate a minimum amount of gas when filled with molten metal.
4. Constructed so that any gases formed can pass through the body of the mold itself rather than
penetrate the metal.
5. Refractory enough to withstand the high temperature of the metal, so it will strip away cleanly
from the casting after cooling.
6. Collapsible enough to permit the casting to contract after solidification.

Moulding processes uses the following terminology:-
 DRAG: -
The bottom half of the pattern, flask, mold, or core.
 COP: -
The top half of the pattern, flask, mold, or core.
 RISER: -
An extra void in the mold that fills with molten material to compensate for shrinkage during
solidification.
 PARTING LINE: -
This is the dividing line between the two moulding flask that makes up the sand mould. In split
pattern it is also the diving line between two halves of the pattern.
 CORE PRINT:-
The region added to the pattern, core, or mold used to locate and support the core.
 POURING BASIN: -
A small funnel shaped cavity at the top of the mould into which the molten metal is poured.
 SPRUE: -
The pouring cup attaches to the sprue, which is the vertical part of the gating system. The other
end of the sprue attaches to the runners.
 RUNNER: -
The horizontal portion of the gating system that connects the sprues to the gates.
 MOLD CAVITY: -
The combined open area of the moulding material and core, where the metal is poured to
produce the casting.
 CORE: -
An insert in the mold that produces internal features in the casting, such as holes.
MOULDING:
Moulding is one of the earliest metal-shaping method known to human beings. It
generally 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.
TYPES OF MOULING:
There are mainly three types of moulding used in “Kudale Iron Work”
1. Green sand moulding
2. Silicate sand (co2) sand mouling
3. Shell mouling

MOULD PREPARATION:
AUTOMATIC MOULDING SAND PREPAREATION

AUTOMISED SAND PLANT

The pattern is placed in a bottom plate and a drag box is located around it. After
taking care about the positions of the runner, ingate etc the thickness of sand around the casting
is carefully chosen. This should be about optimum. Otherwise if the thickness of sand layer
around the pattern is too much, it will provide too much of insulation and result in delay in the
solidification of the casting, and it will create back pressure during the escape of gases that
evolve during the casting. If it is too less, it will make the casting cool very fast and a chilling/
quenching effect will be produced which may not be desirable at times. It is now time to fill the
space between the pattern and the mould box with sand. However, the sand which is adjacent to
the pattern/mould cavity is of a different quality than the sand away from it and near to the walls
of the mould box. The inner sand called facing sand is finer and outer sand called backing is
coarse. Backing sand is not used for facing because it cannot develop the required surface finish
and fine details that are present on the faces of pattern. A minimum of 30mm and up to 100mm
of facing sand should be applied on the inside surfaces to obtain an acceptable mould cavity.
The sand is gently rammed / patted to cover all grooves and fine
patterns/markings/slots. Rest of the volume of the drag box is then filled with backing sand and
rammed. The top surface is made level by cutting any heap/bump that might have formed on the
drag box.
The drag box is inverted and the cope half of the two-piece pattern is assembled to the
drag half. Cope box is made to sit on the drag box using alignment and closing pins. Parting
powder is sprinkled on the exposed sand surface of the drag box. Gating, sprue, runner, riser, etc
are placed at appropriate positions around the pattern. Backing sand is again filled in the cope
box and rammed to set. Vent holes are provided for passage of gases.
Then drag and cope are separated. The pattern is removed with utmost care being taken
so as not to cause any damage to the mould cavity or any intricate profile. The cavity is inspected
for visible scar or recess created and is repaired if needed. Cores if necessary, are placed either
solitary or with the help of core-prints. Drag and cope halves are joined and locked with the help
of closing pins. Pouring basin is placed at the sprue’s open end. Sufficient load is placed on the
cope to prevent its lifting under the action of buoyant force when liquid is poured.

Materials and Material Properties

Materials
 Cast Iron (CI)

1. FG -150
2. FG-200
3. FG-220
4. FG-260
5. FG-300
 Spheroidal Graphite Iron (SG-Iron)

1. SG-400/15
2. SG-400/18
3. SG-450/10
4. SG-450/12
5. SG-500/7
6. SG-550/6
7. SG-600/03
8. SG-700/03

Material Properties

FG-150
 Chemical Properties
1. Carbon = 3.2 - 3.7%
2. Silicon = 1.50 - 2.0%
3. Carbon Equivalent = 3.64 -4.20%
4. Manganese = 0.4 -0.8%
5. Phosphorus = 0.06 -0.120%
6. Sulphur = 0.08% max
 Mechanical Properties
1. Tensile Strength = Min 15.00 kg/mm2
2. Brinell Hard Ness Number = 130-180 BHN
 Thermal Properties
1. Melting Temperature or Tapping Temperature = 1400-1450 Deg C
2. Pouring Temperature = 1330-1385 Deg C
 Micro-Structure
1. Ferelite = 85% min
2. Pearlite = 15% max
3. Nodularity =80% max
4. Nodal Count= 175 Max

FG-200
1. Carbon = 3.3 - 3.6%
2. Silicon = 1.50 - 2.20%
4. Manganese = 0.4 -0.8%
5. Phosphorus = 0.06 -0.120%
 Micro-Structure

FG-220
1. Carbon = 3.4 - 3.6%
2. Silicon = 1.80 – 1.95%
4. Manganese = 0.5-0.65%
5. Phosphorus = 0.06 -0.120%
 Micro-Structure

FG-260
1. Carbon = 3.10 - 3.40%
2. Silicon = 1.60 - 2.0%
4. Manganese = 0.6 -0.8%
5. Phosphorus = 0.06 -0.120%
 Micro-Structure

FG-300
1. Carbon = 3.10 - 3.25%
2. Silicon = 1.60 – 1.9%
3. Carbon Equivalent = 3.6-3.9%
4. Manganese = 0.6-0.9%
5. Phosphorus = 0.06-0.120%
7. Chromium = 0.2-0.8
 Micro-Structure

SG-400/15
1. Carbon = 3.4-3.8%
2. Silicon = 2.4-2.8%
4. Manganese = 0.15-0.3%
5. Phosphorus = 0.06% max
7. Magnesium =0.03-0.06% max
1. Tensile Strength = Min 400.00 kg/𝑚𝑚
3. Yield Strength = Min 250.00 kg/𝑚𝑚
4. Elongation = 15% min
 Micro-Structure
1. Ferrite = 90% min
2. Pearlite = <10%
3. Carbides = <5%
4. Nodal Count = 200-250 nodules/𝑚𝑚

SG400/18
1. Carbon = 3.40- 3.8%
2. Silicon = 2.3 - 2.70%
4. Manganese = 0.4% Max
5. Phosphorus = 0.06% Max
6. Sulphur = 0.03% Max
7. Magnesium = 0.03-0.06% Max
1. Tensile Strength = Min 400.00kg/𝑚𝑚
2. Yield Strength = 250.00 kg/𝑚𝑚
 Micro-Structure
2. Pearlite = <10%
3. Carbides = <5%

SG450/10
1. Carbon = 3.4 - 3.8%
2. Silicon = 2.4 – 2.8%
4. Manganese = 0.4-0.4%
7. Magnesium= 0.03 – 0.06 max
1. Tensile Strength = 450 N/𝑚𝑚 min
2. Brinell Hard Ness Number = 149 - 207 BHN
3. Yield strength = 310 N/𝑚𝑚
1. Melting Temperature or Tapping Temperature = 1532 - 1570 Deg C
 Micro-Structure

SG450/12
1. Carbon = 3.40- 3.8%
2. Silicon = 2.3 - 2.70%
4. Manganese = 0.4% Max
5. Phosphorus = 0.06% Max
6. Sulphur = 0.03% Max
7. Magnesium = 0.03-0.06% Max
1. Tensile Strength = Min 400.00kg/𝑚𝑚
2. Yield Strength = 250.00 kg/𝑚𝑚
 Micro-Structure
2. Pearlite = <10%
3. Carbides = <5%

SG500/7
1. Carbon = 3.30 – 3.7%
2. Silicon = 2.3 – 2.8%
3. Carbon Equivalent =4.10 – 4.45%
4. Manganese = 0.25 – 0.40%
7. Magnesium = 0.02 – 0.06 max
8. Cupper = 0.2 – 0.5%
1. Tensile Strength = 500N/𝑚𝑚 min
2. Brinell Hard Ness Number = 160 – 246 BHN
4. Elongation = 07%
1. Melting Temperature or Tapping Temperature = 1530 – 1570 Deg C
 Micro-Structure
1. Ferrite = 40 – 60%
2. Pearlite = 40 - 60% min
3. Carbides = 80% min
4. Nodal Count = 175nodules/𝑚𝑚 min

SG550/6
Chemical Properties
1. Carbon = 3 – 3.6 %
2. Silicon = 2.20 – 2.9%
4. Manganese = 0.32 – 0.6%
8. Cupper = 0.3 – 0.45%
4. Elongation = 06%
1. Melting Temperature or Tapping Temperature = 1530 - 1580 Deg C
 Micro-Structure
1. Ferrite = 40 – 60%
3. Nodularity = 80% min

SG600/03
Chemical Properties
1. Carbon = 3.30 – 3.7%
2. Silicon = 2.2 – 2.7%
4. Manganese = 0.25 – 0.50%
8. Cupper = 0.5 – 1.57%
2. Brinell Hard Ness Number = 187 – 270 BHN
4. Elongation = 03%
 Micro-Structure
1. Ferrite = 15%
2. Pearlite = 85% min
3. Nodularity = 80% min

SG700/03
Chemical Properties
1. Carbon = 3 %
2. Silicon = 2.50%
4. Manganese = 0.4 – 0.75%
8. Cupper = 0.7 – 1.5%
4. Elongation = 03%
Thermal Properties

Micro-Structure
1. Ferrite = 40 – 60%
3. Carbides = 80% min

MATERIAL SUPPLIERS

SL Names of Address Items Supplied Basis of Types & Extent of

No. Suppliers Approval control
1. Deccan Traders Kolhapur Pig iron Past Inward Inspection

(Sesa Experience as per Quality Plan
Coke
Industries)
Past Inward Inspection
2. Chemon Belgaum Pig iron
Experience as per Quality Plan
Enterprises
Belgaum Low Ash Coke Past Inward Inspection
3. Bengal
Kolhapur Manganese Experience as per Quality Plan
Minerals
Belgaum Past Inward Inspection
4. Binnery Udyog Low Ash Coke
Kolhapur Experience as per Quality Plan
5. Konkan Sand Belgaum Silica Sand
Fine Sand
6. N.S. Yadwad Lime Stone
Kankanwadi
7. Ahsapura Belgaum Bentonite
International Powder
Ltd
8. Navjivan Mumbai Bentonite
Corporation Powder
9. Shiva Shakti Belgaum Resin and
Associates Hardner
10. Nova marketing Belgaum Resin and
Hardner
Silicon Past Inward Inspection
11. Oswal Minerals Bangalore
Nickel Experience as per Quality Plan
Manganese
12. Everest Belgaum Coal Dust Past Inward Inspection
Minerals Powder Experience as per Quality Plan

MELTING PROCESS

Melting:
Melting, or fusion, is a physical process that results in the phase transition of a substance from
a solid to a liquid. This occurs when the internal energy of the solid increases, typically by the
application of heat or pressure, which increases the substance's temperature to the melting point.
At the melting point, the ordering of ions or molecules in the solid breaks down to a less ordered
state, and the solid melts to become a liquid.
Substances in the molten state generally have reduced viscosity as the temperature increases. An
exception to this principle is the element sulfur, whose viscosity increases to a point due
to polymerization and then decreases with higher temperatures in its molten state.
Some organic compounds melt through mesophases, states of partial order between solid and
liquid.
Enoclent: Used to maintain Temperature of the molten metal.
Slag Powder: Used to remove slag from the molten metal.
Lime stone: Used to remove unwanted material. ( only used in cupola furnace)

FURNACE

Furnace:
A furnace is a device used for high-temperature heating. The name derives from Latin word
Fornax, which means oven. The heat energy to fuel a furnace may be supplied directly by fuel
combustion, by electricity such as the electric arc furnace, or through induction heating in
induction furnaces.
OR
Furnace is a device that is used to heat a material in order to exchange their shape as like in
shaping and forging or the properties of the material can be changed. These furnaces are mostly
used for melting the metals that are used for casting. Furnace can be termed as a type of oven.
It is an enclosed structure inside, which the material is heated to very high

temperatures. It is a device that is designed to perform the water or air heating and is circulated
throughout a building in a heating system.
Features:
The design of the furnaces is in such a way to consume fuel and heat as less as possible in a
given time that requires low labor cost.
Efficient features:
The amount of heat that is to be given is prior determined to the material. There exists a
sufficiency in the liberation within the furnace to heat the required stock. A proper heat transfer
from the gases to the surface of the heating stock takes pace.
Temperature should be uniform within the stock. The heat loss from the furnace is
minimized to the least possible. In the furnace the product of the flue gases directly comes in
contact with the provided stock.

Components of an industrial furnace:
In industrial furnaces it serves the purpose of heating i.e. it serves as a reactor to provide heats to
the reaction. The design of the furnaces varies, however the basic features are most common
among all of them.
The basic components of a furnace are:

Radiant section
Convection section
Radiant coil
Burner
Soot blower
Stack
Insulation
Foundations
Access doors
Process:
The fuel flows in the burner is burnt from an air blower. The furnaces can have more than one
burner. The furnaces can be arranged in cells with a particular set of tubes, or the burners can be
flooring mount, on wall or roof mounted depending on the design demand. The flame of the
burner heats up the tube those in-turn heats up the fluid that is present inside.

The first part of the furnace i.e. radiant section or fire box, where the combustion takes
place by the action of radiation of the tubes around the fire inside the chamber. The heat fluid
heats up to the desired temperature level. The gas that is formed from the combustion is known
as flue gas. After the fire box the flue gases enters convection section where the heat is recovered
before their vent into the atmosphere by convection. In industries commonly secondary fluids are
heated in these furnaces with special additives like anti rust and with high heat transfer
efficiency. Thus heated fluid is circulated in the whole plant where heat is needed instead of
direct heating of the stock material in the product line. The material can be volatile or may be
prone to cracking with the furnace temperature.
Types:
 Blast furnace
 Open hearth Furnace
 Induction furnace
 Electric Arc Furnace
 Reverberator furnace
 Cupola Furnace
Induction Furnace:
Induction heating of metal will provide heat required for the
electrical furnace. Induction furnace will provide clean, energy efficient and
well controlled process of melting when it is compared with other processes.
In most of the modern foundries use this type of furnaces instead of cupolas
to melt cast iron as the former emits lots of duct along with other pollutants.
The capacity ranges from less than one kilogram to hundred tones capacity
are used in melting iron, steel, copper and aluminum and other precious
metals. As the process does not use combustion, material temperature is not
higher than the required to melt it. This processing prevents the loss of
valuable alloying elements. The induction furnace lacks in the refining
capacity where the charge materials clean the oxidation products and the
known composition. The alloying elements may have a chance to lose
alloying elements due to oxidation.

Cupola Furnace:
A cupola or cupola furnace is a melting device used in foundries that can be used to
melt cast iron, Ni-resist iron and some bronzes. The cupola can be made almost any practical
size. The size of a cupola is expressed in diameters and can range from 1.5 to 13 feet (0.5 to
4.0 m). The overall shape is cylindrical and the equipment is arranged vertically, usually
supported by four legs. The overall look is similar to a large smokestack.
The bottom of the cylinder is fitted with doors which swing down and out to 'drop
bottom'. The top where gases escape can be open or fitted with a cap to prevent rain from
entering the cupola. To control emissions a cupola may be fitted with a cap that is designed to
pull the gases into a device to cool the gases and remove particulate matter.
The shell of the cupola, being usually made of steel, has refractory brick and plastic
refractory patching material lining it. The bottom is lined in a similar manner but often a clay and
sand mixture (bod) may be used, as this lining is temporary. Finely divided coal (sea coal) can be
mixed with the clay lining so when heated the coal decomposes and the bod becomes slightly
friable, easing the opening up of the tap holes.[3] The bottom lining is compressed or 'rammed'
against the bottom doors. Some cupolas are fitted with cooling jackets to keep the sides cool and
with oxygen injection to make the coke fire burn hotter.


Operation:
To begin a production run, called a Cupola campaign, the furnace is filled with layers of
coke and ignited with torches. Some smaller cupolas may be ignited with wood to start the coke
burning. When the coke is ignited, air is introduced to the coke bed through ports in the sides
called Tuyeres.
When the coke is very hot, solid pieces of metal are charged into the furnace through an
opening in the top. The metal is alternated with additional layers of fresh coke. Limestone is
added to act as a flux. As the heat rises within the stack the metal is melted. It drips down
through the coke bed to collect in a pool at the bottom, just above the bottom doors. During the
melting process a thermodynamic reaction takes place between the fuel and the blast air.
The carbon in the coke combines with the oxygen in the air to form carbon monoxide. The
carbon monoxide further burns to form carbon dioxide. Some of the carbon is picked up by the
falling droplets of molten metal which raises the carbon content of the iron.

Pouring Process:
In metalworking, casting involves pouring liquid metal into a mold, which contains a hollow
cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is also
known as a casting, which is ejected or broken out of the mold to complete the process.


LABORATORY

Lab:
Machine used in the Lab is determined the sand testing methods used in your operation to
understand how those readings reflect both the consistency of your molding sand and the quality
of your castings.
Equipment Used in Lab are,

 Micro Polish Machine
 Sand Rammer
 Sieve Shaker
 Clay Test Machine
 Permeability Meter
 Universal Strength Machine(USM)
 Moister Tester Machine
 Burette Stand
 Hot Plate Machine
 Microscope
 Spectrometer
Sand Rammer:
This machine is designed for preparing AFS standard test specimens for the determination of
compression, tensile, transverse, shear and splitting strength by compacting a predetermined
weight of sand in a tube, or a core box of the required shape. This is achieved by dropping a
known weight a fixed distance, and using the energy produced to compact the sand.
Test Producer:
 Spray the tube conditioner swab with liquid release agent. This should be done as
necessary to maintain the swab in a slightly moistened condition.
 Slide the specimen tube down over the conditioner and back again, then place one cup
over the end of the tube and set up vertically with the cup at the base.
 Weigh out sufficient sand to form a test piece when rammed. Transfer to the specimen
tube.
 Use the cam positioned on the left hand side of the rammer to raise the plunger of the
rammer.
 Rotate the cam to release the plunger head to enable it to enter the tube and come to rest
gently on the sand.

Sand Compression Strength Testing:

Compressive strength or compression strength is the capacity of a material or structure to
withstand loads tending to reduce size, as opposed to tensile strength, which withstands loads
tending to elongate. In other words, compressive strength resists compression (being pushed
together), whereas tensile strength resists tension (being pulled apart). In the study of strength of
materials, tensile strength, compressive strength, and shear strength can be analyzed
independently.
Test Producer:
 Prepare the standard specimen of diameter of 50mm ×50mm height on std. sand rammer.
 Place the specimen between the compression pads (Universal Strength Machine) so that
plain surfaces of the specimen touch against the pads.
 Rotate the loading wheel clockwise until the load starts applying on specimen (this will
be seen by movement of the pressure gauge) needle till the specimen collapse with the
forward movement of needle. The red idle pointer also moves along with the needle.
 As soon as the sample collapse the needle returns while the red idle pointer remains at the
maximum reading before collapse of the specimen.
 Compression Strength scale (CS scale) indicated by the idle pointer i.e. compression
strength.
Permeability Test Machine:

Permeability is a property of foundry sand with respect to how well the sand can vent, i.e. how
well gases pass through the sand. And in other words, permeability is the property by which we
can know the ability of material to transmit fluid/gases. The permeability is commonly tested to
see if it is correct for the casting conditions.
Test Producer:
 Prepare the standard sand specimen of Dia 2ˮ×2ˮ height with the help of std. Rammer.
 Take specimen tube with rammed specimen and place it inverted over the rubber sealing
bush.
 Start the instrument indicator will glow and confirm that that permeability meter reads
100mm on WC scale.
 Put the valve on P position and read the permeability number.
 Find the permeability number directly from the pressure gauge according to the orifice
used. Put the valve on O position.
 Whenever the air tank goes downward lift the air drum slowly up keeping valve in D
position to avoid any water entering the air tube.
 Repeat the producer three times by fresh sample of sand test each time and take the
reading..

Sieve Shaker:
A sieve analysis (or gradation test) is a practice or procedure used (commonly used in civil
engineering) to assess the particle size distribution (also called gradation) of a granular material
by allowing the material to pass through a series of sieves of progressively smaller mesh size and
weighing the amount of material that is stopped by each sieve as a fraction of the whole mass.
Test Producer:
 Take 50gm or 100gm of dry sand and place in the top sieve of a series and close the lid.
 Place the whole assembly of sieves on the vibratory sieve shaker and clamp it.
 Switch on the motor and allow the sieve assembly to vibrate for 5 minutes. Then switch
off the motor.
 Collect the sand particles retained in each of the sieve separately and weigh in Electronic
weighing scale and enter into the tabular column. Calculate the percentage weight
retained by each of the sieves. Multiply this value with the multiplier for each sieve.
Clay Test Machine:

Test Producer:
 Take 100g of base sand in a wash bottle and add 475ml of distilled water and 25ml of
NaOH solution to it.
 Using the mechanical stirrer, stir the mixtures for about 5 minutes add distilled water to
make up the level to 6"height. Stir the mixture again for 2 minutes. Now allow the
content of the bottle to settle down.
 Siphon out 5” level of unclean water using a standard siphon.
 Add distilled water again up to 6" height and stir the content again. Allow the mixture to
settle down for 5minutes.
 Siphon out 5” level of water from the bottom of the bottle
 Repeat the above procedure for 3-4times till the water becomes clear in the wash bottle.
 Transfer the wet sand from the bottle in to a tray and dry in it in an oven at 110 o C to
remove moisture. Note down the dry sand weight accurately. Using the calculations find
percentage of clay.

Result:
The clay content in the given green sand is
Dead Clay 3 to 3.5

Active Clay 8 to 10
Total Clay 12 to 12.5
Microscope:
A microscope is an instrument used to see objects that are too small to be seen by the naked
eye. Microscopy is the science of investigating small objects and structures using such an
instrument. Microscopic means invisible to the eye unless aided by a microscope.
Test producer:
 Grind the S.G. Iron sand to be tested.

 Make sure that sample surface is plain/ even.
 Rub the surface of sample with right grade of polish paper to remove the burr
 Then put water, Alumina paste on velvet macro polish meter platform for mirror
finishing.
 Then clean the sample with cotton after mirror polishing.
 Keep the sample on microscope stage & adjust the focus to count the nodularity.
Moister tester:
Moisture tester is used to measure the percentage of water in a given substance. This information
can be used to determine if the material is ready for use, unexpectedly wet or dry, or otherwise in
need of further inspection. Wood and paper products are very sensitive to their moisture content.
Physical properties are strongly affected by moisture content and high moisture content for a
period of time may progressively degrade a material.
Test producer:
 Weight the sample accurately by digital balance un-clamp the cap of the tester.
 Transfer the sand sample in the cap of the moister tester.
 Take one spoons of absorbent compound ( Calcium Carbide)
 Transfer into the body of eh moister tester.
 Hold the body horizontally and place the cap in position.
 Bring the clamp in position and tighten the cap with screw. Shake the instrument
vigorously.

 This ensure sample and the absorbent compound is mixed. Immediately the pointer of the
gauge moves.
 Keep the instrument in position. Observe the reading when pointer stops further
movement.
 This will give the % of moister in the sample directly.
 Note the reading.
Result:
Moister content in the given green sand material is 3 to 3.7%
Spectrometer:
A spectrometer is a scientific instrument used to separate and measure spectral components of a
physical phenomenon. The capability of spectroscopy to determine chemical composition drove
its advancement and continues to be one of its primary uses. Spectrometers are used
in astronomy to analyze the chemical composition of stars and planets, and spectrometers gather
data on the origin of the universe.
Examples of spectrometers are devices that separate particles, atoms, and molecules by
their mass, momentum, or energy. These types of spectrometers are used in chemical
analysis and particle physics.
Startup producer:
 Switch on the instrument.
 Switch on the Organ Gas
 Switch on the computer and open the software by entering your name and password.
 Set the pressure on the regulator of the cylinder to 4 to 6 bar.
 By pressing FB on keyboard, check the flow on Organ flow meter located at the front
side of the instrument to 3 to 4 LPM.
 Instrument is ready for analysis after stabilization period 20 min.
 The next spectro machine stabilization after 15 days.
Analysis producer:
 On main screen select “Analyze” option.
 Select “Base” & matrix/ Types Matrix under which samples to be “Analysed” & click on
“Finish”
 Enter sample ID, GRADE, HEAT NO, & CLICK ON “OK”
 Grind the sample to be burned on specimen preparation machine.
 Place respective sample on spark chamber.

 Press “Ctrl+F7” on the key board till preborn.
 The result will be displayed in few seconds.
 Take 2 to 3 burns on different spots of the sample.
 Save the burns & delete the bad burns by clicking that particular results and then click
“Delete Burn” Button.
 Select the print option for printing the spectro result.

SHOT BLASTING

Shot Blasting:
 After each batch of casting clean the area of steel shots scattered on floored and stored in
container.
 Check the level of steel shot in machines.
 If steel shot level found less by half of the hoper level then put shots in the rotating table
in machine.
 Ensures current in the range 20-25amp.
 Put the castings in appropriate rotating table.
 Push the rotating table in machine.
 Close the door of machine.
 Start the machine.
 Open the door of the shots by manually.
 Shot blasts for 3 to 5 minutes.
 When machine stops wait for some times for shots to settle down.
 Open the door of the machine.
 Pull the rotating table outside of the machine.
 Inspect visually the casting.
 Take of casting from rotating table and keep on floor.
 More the castings for the further processing by hoist only.
 Don’t dump the casting on one another and on the floor to avoid the crack in casting.

CASTING DEFECTS, ADVANTAGES AND

APPLICATIONS

DEFECTS IN CASTING
(a) Improper pattern design
(b) Improper mould and core construction
(c) Improper melting practice
(d) Improper pouring practice
(e) Because of moulding and core making materials
(f) Improper gating system
(g) Improper metal composition
(h) Inadequate melting temp and rate of pouring
Advatages:
1. Molten metal flows into small ant section in the molten cavity. Hence any
complex shape can be easily produced.
2. Practically any material can be casted.
3. Ideal method is by producing small quantities
4. Due to small cooling rate from all directions, the properties of casting are
same in all directions.
5. Any size of casting can be produced up to 200 tons.
6. Casting is the often cheapest and most direct way of producing a shape with
certain desired mechanical properties.
7. Certain metals and alloys such as highly creep resistant metal-based alloys
for gas turbines cannot be worked mechanically and can be cast only.
8. Heavy equipment like machine leads, ship’s propeller, etc. can be thrown
easily in the required size rather than fabricating them by joining several
small pieces.
9. Casting is best suited for composite components requiring different
properties in various directions. These are made by incorporating preferable
inserts in a casting. For example, aluminum conductors into slots in iron
armature for electric motors, wear resistant skins onto shock resistant
components.

Limitations :
1. With normal sand casting process, the dimensional accuracies and surface finish is
less.
2. Defects are unavoidable.
3. Sand casting is labor intensive.
Application:
1. Transport: Automobile, Aerospace, Railways and Shipping.

2. Heavy Equipment: Construction, farming and Mining.
3. Machine tools: Machining, casting, Plastics Moulding, Forging and Extrusion and
forming.
4. Plant Machinery: Chemical, Petroleum, Paper, Sugar, Textiles, Steels and thermal
plants.
5. Defense: Vehicle, Artillery, Munitions, Storage and Supporting Equipment.
6. Electrical Equipment Machine: Motors, Generators, Pumps and Compressor.
7. Hardware: Plumbing Industry Pipes, Joints, Valves and Fittings.
8. Household: Appliances, Kitchen and Gardening Equipment.
9. Art Objects: Sculptures, Idols, Furniture, Lamp stands and decorative items.

PRODUCTS

PRODUCT:
1. VALVE CASTING (Item Code: KIW-0001)
KIW manufactures various types of valves:
a) Non return valve
b) Ball valve
Some of the salient features of valves are:

 Durability
 Dimensional Accuracy
 High tensile strength
 Pressure tight casting
 Anti-corrosive properties
2. BUTTERFLY VALVE CASTING (Item Code: KIW-0003)

KIW have a wide range of butterfly valve castings which are manufactured with
green sand process, no bake process, CO2 process & Shell sand, ranging from sizes 40mm to
600mm.
Some of the salient features of valve are:

 Excellent surface finish
 Dimensional accuracy
3. LUBRICATED PLUG VALVE (Item Code: KIW-0002)

KIW manufacture lubricated plug valve body castings, plugs and covers ranging from ½’’ to 12’’
Size.
Some of the salient features of valves are:

 High Tensile strength
 High Ductility
 Good flexibility

4. Machine Tool Casting (Item Code: KIW-0004)

Brackets:
We provide castings to CNC machine manufacturers & CNC machine tool changers,
turrets, slides & engineering instruments, manufactured in Co2 process, No bake process & Shell
sand.
Salient features
 High ductility
 Specific configurations
 Cost effective
5. MOTOR BODY (Item Code: KIW-0005)

KIW provide castings to electric motor manufacturers such as motor bodies having Collin
fins & end cover in quantities to meet the clients requirement, manufactured in green sand
process, no bake process & shell sand.
Salient features:
 Good surface finish
 Durability
 Cost effective
6. COUPLING CASTINGS (Item Code: KIW-0006)

KIW produce C.I.Couplings in various sizes ranging from 1 kg to 250kgs as per designs of
clients, which are highly durable as the material poured is of high grade with a high tensile
strength.
Salient features:
 High ductility

7. PULLEY CASTINGS (Item Code: KIW-0007)
KIW have a wide range of pulleys manufactured as per the customer design and
requirement, ranging from 1 kg to 250 kgs. These are widely used in industrial purposes.
KIW includes range of pulleys as:

a. Single groove pulleys
b. Multi groove pulleys
c. Conveyor Pulleys
d. Flywheels
Salient features:
 Durability
 Dynamically balanced
8. ENGINEERING PART CASTINGS (Item Code: KIW-0008)

KIW provide a wide range of engineering parts which are highly appreciated by the
clients for their excellent performance and durability.
Range of engineering parts includes:

a. Auto pumps
b. Motor covers
c. Hubs
d. DC motors
e. Engineering instruments
Salient features
 Durability
9. CASTOR WHEELS & TROLLEY CASTINGS (Item Code: KIW-0009)

KIW produce trolley wheels in
various sizes as per client requirements in
machined condition.

10. HOUSING FLYWHEEL FOR DIESEL ENGINE

(Item Code: KIW-0010)
KIW produce housing flywheel casting for diesel engines in the weight range of 50
kgs to 250 kgs, in grade FG 260 & FG 300.
Salient features
11. C.I. GEARS (Item Code: KIW-0011)

KIW manufacture C I Gears required for Sugar Industry and other engineering
industry purpose.
Salient features:

CONCLUSION:
In review this internship has been an excellent and rewarding experience. I have been able
to meet and network with so many people that I am sure will be able to help me with
opportunities in the future.
One main thing that I have learned through this internship is time management skills as
well as self-motivation. When I first started I did not think that I was going to be able to make
myself sit in an office for four hours a day, six days a week. Once I realized what I had to do I
organized my day and work so that I was not overlapping or wasting my hours.
I learned that I needed to be organized and have questions ready for when it was the
correct time to get feedback. From this internship and time management I had to learn how to
motivate myself through being in the office for so many hours.


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KUDALE IRON WORKS BELAGAVI

 Introduction to KUDALE IRON WORKS

KLECET CHIKODI Page 1

INTRODUCTION TO KUDALE IRON WORKS,

KLECET CHIKODI Page 2

KLECET CHIKODI Page 3

1. SILICATE (CO2) SAND

KLECET CHIKODI Page 4

3. OIL CORE SAND:

4. NOBACK CORE SAND:

KLECET CHIKODI Page 5

QUALITY PLAN FOR GREEN SAND TESTINGS:

PARAMETERS ACCEPTANCE CRITERIA

Green compression strength 900 to 1300 gms/cm

Permeability 100 to 200

Dead clay Max 4%

KLECET CHIKODI Page 6

 MOISTURE CONTENT TEST:

 CLAY CONTENT TEST:

KLECET CHIKODI Page 7

Auto sand washer

KLECET CHIKODI Page 8

 GRAIN FITNESS TEST:

KLECET CHIKODI Page 9

KLECET CHIKODI Page 10

Universal strength machine

KLECET CHIKODI Page 11

There are three main types of patterns

KLECET CHIKODI Page 12

KLECET CHIKODI Page 13

CORE BOXES PATTERN:

KLECET CHIKODI Page 14

Following are the technologies involved in core making.

KLECET CHIKODI Page 15

KLECET CHIKODI Page 16

Cold box core

KLECET CHIKODI Page 17

1. Strong enough to hold the weight of the metal.

3. Generate a minimum amount of gas when filled with molten metal.

6. Collapsible enough to permit the casting to contract after solidification.

KLECET CHIKODI Page 18

Moulding processes uses the following terminology:-

KLECET CHIKODI Page 19

AUTOMATIC MOULDING SAND PREPAREATION

KLECET CHIKODI Page 20

AUTOMISED SAND PLANT

KLECET CHIKODI Page 21

KLECET CHIKODI Page 22

Materials and Material Properties

KLECET CHIKODI Page 23

 Cast Iron (CI)

 Spheroidal Graphite Iron (SG-Iron)

KLECET CHIKODI Page 24

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