Industrial Training on Simplex Casting Raipur. This foundry 6 step of working process. seen this ppt slide, Kalinga University Naya Raipur

1. INDUSTRIAL TRAINING
ON
SIMPLEX CASTING RAIPUR.
o BISWAJEET BISWAS.
o PRADEEP DEWANGAN.
o SANDEEP YADAV.
o PRINCE YADAV.
o SHESHRAJ SAHU.

2. *CONTENTS :-
1. INTRODUCTION.
2. ELECTRIC FURNACE.
3. MECHANICAL MAINTENANCE.
4. MOULDING.
5. FETTLING.

3. *INTRODUCTION:-
Simplex Castings Limited Is Premier Manufacturing Organization In India,
With Global Business Presence. Company Was Established A Way Back In
The Year 1970 As A Ferrous Foundry, As A Partnership Firm, It Was Converted
Into Private Limited Company Registered Under The Indian Companies Act,
With Its Registered Office At Mumbai, India On 30th Of January “1980.

4. Thereafter, in year 1993, company was listed with Bombay Stock Exchange, turned a public
limited company with shares held by public, financial institutions, rated as SME-II Grade
Company, having its registered office at Mumbai and corporate office in Bhilai, India, since
then rapidly spreading its business presence with branch office & sales agents in
India and worldwide.
Simplex Plants are situated in Bhilai, Raipur & Rajnandgaon, state of Chhattisgarh, the central
part of India, most mineral rich & densely industrialized province in India.

5. ELECTRIC FURNACE

6. *FURNANCE:-
*GRAPHITE ELECTRODE FURNANCE*
An electric arc furnace is essentially a big recycling
machine. Simply put, it’s a large pot into which scrap steel,
like old cars, bicycles, and refrigerators, are dumped.
• Furnaces using 3-phase AC (alternating current) .
• Electricity have 3 electrode columns; DC (direct current).
• The tip of the electrode will reach 3,000 degrees Celsius
or 5,000 degrees Fahrenheit.
• The one melting operation weight more then 25 ton.

7. GRAPHITE :-A Very Soft, Black, Hexagonal
Mineral Of Pure Carbon, Formed In Thin plates
And Found In Metamorphic Rocks: Used In
Making Electrodes, Paints, The Lead Of Pencils, etc.
PROPERTY :-
• Tenacity :- Flexible non- Elastic Section.
• Characteristics :- Electricity.
• Density :- 2.09-2.23 g/cm3.
• Scale :- 1-2.
• Optical Properties :- Uniaxial (-).

8. WORKING OF GRAPHITE ELECTRODE
FURNANCE

9. MECHANICAL MAINTENANCE

10. WHAT IS MAINTENANCE ?
Maintenance is a set of organized activities that are carried out in order
to keep an item in its best operational condition with minimum cost
acquired.

11. Objective Of Maintenance :
• To increase reliability of production facility.
• To maximize the useful life of equipement.
• To maximize the production capacity from the
given equipement.
• To minimize the total production cost.
• To enhance the safety of manpower.
Purpose of Maintenance :
The main purpose of regular maintenance is to ensure that all equipment
required for production is operating at 100% efficiency at all times.
Through short daily inspections, cleaning, lubricating, and making minor
adjustments, minor problems can be detected and corrected before they
become a major problem that can shut down a production line. A good
maintenance program requires company-wide participation and support
by everyone ranging from the top executive to the shop floor personnel.

12. WHAT IS MECHANICAL MAINTENANCE ?
Mechanical Technicians carry out planned or unplanned maintenance and
repair activities on a wide range of equipment e.g. pumps, engines, turbines.
Typical Day/Duties:
 Carries out maintenance and testing activities.
 Fault-finding and repair of plant, systems and equipment.
 Modifies, repairs or replaces plant, systems and equipment.
 Participates in Risk Assessments as part of Integrated Safe System Of Work (ISSOW) /
Permit to Work preparation.
 Interprets technical drawings.
 Prepares reports on work done.

14. MOULDING SHOP

15. What is moulding ?
Molding or moulding is the process of Manufacturing by shaping liquid or
pliable raw material using a rigid frame called a mold or matrix. This itself
may have been made using a pattern or model of the final object.
Types Of Moulding :
 Casting.
 Injection Moulding.
 Blow Moulding.
 Compression Moulding.
 Rotation Moulding.

16. CASTING :
Casting is a basic molding process as it requires the least amount of
complex technology. Plastic is simply heated so it turns into a fluid, and
then transferred into a mold. It is left to cool and the mold is removed. This
process can be used for intricate shapes and performed under a low
pressure. However, it is a common process used for making plastic
sheeting, starting from 0.5 inches thick and greater.

17. INJECTION MOLDING :
Injection molding is used for creating high-quality three-dimensional objects,
that can be commercially reproduced. The molding process begins by
melting plastic in a hopper. Then the plastic is injected into a tightly closed,
chilled mold. The plastic quickly takes the shape of the surrounding mold.
Once it has completely set, the mold is opened and the plastic object is
released. Yogurt pots, butter tubs, toys and bottle caps are made using this
process.

18. BLOW MOLDING :
Blow molding is a process used for making piping and milk bottles. Plastic
is heated until molten. Then it is injected into a cold mold. The mold has a
tube set within it, which has a particular shape when inflated. So, while the
plastic is molten, air is blown into the tube and the plastic is formed around
the tubing. It is then left to cool and removed from the mold.

19. COMPRESSION MOLDING :
The most labor-intensive type of molding process is compression molding.
Therefore, it is only used for large-scale production purposes, and not for
mass production. For example, boat hulls and car tires are made using this
method. Molten plastic is poured into a mold. Then a second mold is
pressed into it. This squeezes the plastic into the desired shape before
being left to cool and removed from the mold.

20. ROTATIONAL MOLDING :
Toys, shipping drums, storage tanks and items of consumer furniture are
made using rotational molding. Each object is made by coating a mold from
the inside. A mold is held in place between two mechanical arms. Then, the
arms rotate the mold constantly at the same level, while molten plastic is
placed inside. As it turns, the plastic coats the inside of the mold to create a
new hollow, plastic object.

21. FETTLING / foundry shop

22. Raw castings often contain irregularities caused by seams and imperfections in the
molds, as well as access ports for pouring material into the molds. The process of
cutting, grinding, shaving or sanding away these unwanted bits is called "fettling".
In modern times robotic processes have been
developed to perform some of the more repetitive parts of the fettling process, but
historically fettlers carried out this arduous work manually, and often in conditions
dangerous to their health.
Fettling can add significantly to the cost of
the resulting product, and designers of molds seek to minimize it through the shape
of the mold, the material being cast, and sometimes by including decorative elements
What is fettling ?

24. Advantages of Automation :
 Excellent repeatability.
 Productivity increased by 30%.
 Dispatch time reduce from 6 days to 2 days.
 Manpower can be use in other work.
 Working environment is like machine shop, help in reducing less
manpower turnover, less or no noise in working area.