INDUSTRIAL TRAINING AT Amtek India limited

1. A
Training Report
On
FOUNDRY DEPARTMENT
Submitted for partial fulfilment of required award of degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
BY
VIMAL SAGAR
ROLL NO: 14557
Under the guidance of
Mr. TEJBIR SINGH
TO
Training In-charge
Prof. AMIT MEDHAVI Prof. ANIL KUMAR
DEPARTMENT OF MECHANICAL ENGINEERING
KAMLA NEHRU INSITUTE OF TECHNOLOGY, SULTANPUR

2. ACKNOWLEDGEMENT
Industrial training is an indispensable part of our engineering curriculum. It provides the
students an opportunity to gain experience on the practical applications of their knowledge.
My training at CASTEX TECHNOLOGIES LIMITED, BHIWADI has been very fruitful.
I sure that the hands of experience I am gaining here will go a long way towards making me a
competent engineer.
I would like to start the series of thanks, which might not be covered in this page, with my
Industry Guide Mr. PAWAN TYAGI who always entertained me and clear my doubts in the
plant where the production takes place. Even though he has a busy schedule he never left me,
feel alone in the plant. Mr. PAWAN TYAGI is a Senior Executive Engineer in Plant at
CASTEX TECHNOLOGIES LIMITED.
I would like to thank production head Mr.TEJBIR SINGH who made me feel encouraged
and confident throughout the training period so that I can do my best in the Industry with
ever-filled confidence and patience.
My training would not be possible without the Human Resources Department of castex
engineering Ltd. I would like to thank Mr. V S Yadav Hr head.
Last but not the least I would like to thank Mr PARVESH and all experienced engineers for
providing constant encouragement, support and valuable suggestion during the Training.
I hereby also declare that the contents in this report are true to the best of my knowledge.
VIMAL SAGAR
B. Tech:4th year
Roll No: 14557
KNIT, SULTANPUR

3. ABSTRACT
I have done my training at “CASTEX TECHNOLOGIES LIMITED.”
On the basis of what I have learnt in the company I am here by submitting a report.
The report is about the production products of CASTEX TECHNOLOGIES LIMITED,
BHIWADI.
It also include the specification of the products like ring gear specifications etc. A well
planned and properly executed industrial training helps a lot in calculating good work culture.
It is also about the company plant.
The main motive of the industrial training is to understanding the production of the company.
The basic idea of the training is to understand the production of the products made in
CASTEX TECHNOLOGIES LIMITED.
My main focus on the production department . My report will also be consisting some extra
relevant information, as this information is the part of the whole procedure.
However I have tried, my best to avoid any sort of errors but as I also belong to the Homo
sapiens species so one can except some errors or faults.

4. TABLES OF CONTENT
S.NO. TOPIC PAGE NO
1. ABOUT CASTEXTECHNOLOGIES LIMITED 6-11
1. INTRODUCTION
2. HISTORY OF COMPANY
3. COMPANY PROFILE
4. CUSTOMER PROFILE
5. LIST OF MANUFACTURED PARTS
2. CASTING 12
3. SAND PREPARATION 13
4. INDUSTRIAL LABORATORY 15
5. FOUNDRY SHOP 21
6. CORE & SHELL SHOTTER MACHINE 26
7. CORE INSPECTION AREA 27
8. METAL SHOP 31
9. DISAMATIC MACHINE 37
10. FETTLING SHOP 41
11. INSPECTION DEPARTEMENT 43

5. 1. INTRODUCTION
Amtek is a leading multi-national manufacturer of automotive components and assemblies
with production facilities located strategically across Asia, Europe and USA. The Group’s
extensive manufacturing capabilities encompass Iron and Aluminium Casting, Forging,
Machining & Assemblies.
Amtek Auto Ltd. has established itself amongst the top players in the Indian auto ancillary
industry and has also grown to become one of the largest manufacturers of Forgings,
Castings, Machined Components and Assemblies, which includes Piston Connecting Rod
modules and Gear Shifter Forks and Yokes, Flywheel Ring Gears in the country. Amtek also
holds the distinction of being among the largest manufacturer of Flywheel Ring Gear
Assemblies and Turbocharger Housings in the World. The uptrend in outsourcing by global
OEM majors due to rising cost pressures, the booming domestic Auto industry, particularly
the high – growth diesel engine segment, and Amtek’s aggressive acquisition and expansion
strategy have propelled the Company into a higher growth trajectory.
Castex Technologies Limited (NSE: CASTEXTECH, BSE: 532282) is a leading provider of
iron cast automotive components in India. The Company's product portfolio consists of a
range of components for 2/3 wheelers, cars, tractors, light commercial vehicles (LCV), heavy
commercial vehicles (HCV) and stationary engines. The categories of components
manufactured are connecting rod assemblies, cylinder blocks, flywheel assemblies and turbo
charger housing.

6. 2. HISTORY OF THE COMPANY
The Amtek Group was established in the year 1985 with the incorporation of the Flagship
Company, Amtek Auto Limited. Over the course of next two decades, the group grew rapidly
to emerge as a global frontrunner in the automotive industry through a number of strategic
acquisitions across India, Europe and the USA, production segment rationalization measures.
The current turnover of the group exceeds $ 750 million.
Amtek Group is a leading international manufacturer of automotive components and
assemblies with production facilities located strategically across North America, Europe &
Asia. The Group's extensive manufacturing capabilities encompass Sub assemblies, Iron,
Gravity & Aluminum Castings, Forgings, Complex Machining & Ring Gears Flywheel
Assembly.
AAL entered into a joint venture with Benda Kogyo of Japan to form Benda Amtek in 1997
for manufacturing of flywheel ring gears located Gurgoan. Later, in 1999 the company
entered a JV with Ateliers de Siccardi to form Amtek Siccardi for manufacturing crankshafts
at Manesar. In 2001 the company acquired auto component manufacturing firm Wesman
Halverscheidt Forgings. The same year it also acquired Indusial Auto components
Coimbatore (India).
In 2002 the company established an iron casting facility at Bhiwadi. The same year
AAL acquired 14.8% equity stake in Ahmednagar Forgings. The next year in 2003 the
company acquired an additional 20% stake in Ahmednagar Forgings.
In 2006 the company formed 50:50 JV with Canada based Magna Power train to commence
manufacturing facility for 2–piece flex plate assemblies for automotive applications. It also
established a new manufacturing facility at Dharuhera (India) the same year.
In order to manufacture fractured connecting rod modules company entered JV with Magna
Powertrain to form MPT Magna India. The Company set up another manufacturing facility at
Sanaswadi, Pune for forging, casting and machining in the year of 2007. The same year it
acquired Triplex– Kelton Group– which was amongst the largest automotive precision
machining companies and it also had presence in UK.

7. In February 2008, the company formed 50:50 joint ventures with American Railcar Industries
in order to diversify by the setting up of the company's Amtek Transportations systems
division. In June 2008 Amtek Transportation Systems became subsidiary of AAL
Amtek acquired Ahmednagar Forgings Limited (AFL) in order to establish a manufacturing
business in Western India, as there were a number of automotive companies which were
being supplied by AFL in that region.
3. COMPANYPROFILE
The Amtek Group, headquartered in India, is one of the largest integrated component
manufacturers in India with a strong global presence. It has also become one of the world’s
largest global forging and integrated machining companies. The Group has operations across
Forging, Iron and Aluminium Casting, Machining and Sub-Assemblies. It has world-class
facilities across India, UK, Germany, Brazil, Italy, Mexico, Hungary and US. The Amtek
Group is comprised of the listed corporate entities Amtek Auto, Amtek India, Ahmednagar
Forgings, JMT Auto and other subsidiaries. With the infrastructure and technology platform
developed over 25 years, the Group is well positioned in the Indian Auto and Non-Auto
component markets.

8. Fig No 1.1 Company Building
Different divisions of the company are:
1. Amtek Centre of Excellence (ACE)
2. Amtek Forging Division (AFD)
3. Amtek Iron Casting Division (AICD)
4. Amtek Aluminium Casting Division (AACD)
5. Amtek Automotive Machining Division (AAMD)
6. Amtek Ring Gear Division (ARGD)
7. Amtek JVS
Business Divisions
Forgings: -
Forging is the process of forming hot / cold metal. The Forging divisions of the group are
Baddi (H.P). Connecting Rods, Crankshafts, Steering Knuckles, Gears shifter Forks, Sector
Gears & Shafts, Stub Axles, Front Impact Beams etc. are some of the products in the Amtek
Forging suite.
Castings: -
Casting is the process of forming from molten metal. The Group has facilities for Iron
Castings at Bhiwadi (Rajasthan), Baddi (H.P), Coimbatore (Tamil Nadu) & Tipton (UK).
Besides Iron Castings, Amtek has facilities for Aluminium Castings at Bourne (U.K) and is in
the process of commissioning another Aluminium Casting facility at Ranjangaon.
Machining:-
Machining is the term used for a set of metal – cutting processes which are performed on
Forgings and / or Castings to give them the exact shape and size for assembling in the
vehicle. The Group has Machining facilities within India at Gurgaon (Haryana), Sanaswadi,

9. Manesar & Dharuhera (both in Haryana), Baddi (H.P), and across the World at Letch worth,
Coventry & Bourne (in U.K) & Hennef (Germany), Stanberry, Bay City & Kellogg (in USA).
Assembly: -
The Assembling activities are carried at Letch worth, Coventry, Gurgaon, Dharuhera, &
Hennef (Germany). The products include Bridge Fork Assemblies, Strut Assemblies, Wheel
Corner Modules, Axle Assemblies, Turbochargers, Piston Cylinder Modules, Spindle
Assemblies, and Fuel Delivery Systems.
4. Manufacturing Plants
Technology and Transcends Boundaries
Thriving on challenges Amtek registered its presence across North America, Europe & Asia
to cater a number of clients. And is poised to explore new global frontiers to invent new
products and scale to new heights.
AMTEK WORLDWIDE CENTERS
INDIA
U.S.A
MEXIO
BRAZIL
ITALY
U. K
HUNGARY
GERMANY
FIG No. 1.2 Amtek Map

10. 5. CUSTOMER PROFILE
AUTO SECTOR CUSTOMERS
2/3 WHEELERS
HEAVY COMMERCIAL VEHICAL
LIGHT COMMERCIAL VEHICAL
PASSENGER CARS

11. 6 .MANUFACTURED PARTS
Product range of the company includes:
Amtek product portfolio consists of an extensive range of components for 2–3 wheelers, Car,
Tractors, LCV, HCV and Stationary engines. The major categories of components
manufactured are,
1. Connecting Rod Assemblies
2. Flywheel Ring Gears and Assembly
3. Steering Knuckles
4. Suspension and Steering Arms
5. CV joints
6. Crankshaft Assemblies
7. Torque Links.
FIG No.3 Manufacture Parts

12. CASTING
Casting is a manufacturing process in which a liquid material is usually poured into a mold,
which contains a hollow cavity of the desired shape, and then allowed to solidify. The
solidified part is also known as a casting, which is ejected or broken out of the mold to
complete the process. Types-
METAL CASTING
In metalworking,metal isheateduntil itbecomesliquidandisthenpouredintoamold.The moldis
a hollowcavitythatincludesthe desiredshape,butthe moldalsoincludes runners andrisersthat
enable the metal tofill the mold.The moldandthe metal are thencooleduntil the metal solidifies.
Plaster, concrete,orplastic resin casting
Plaster and other chemical curing materials such as concrete and plastic resin may be cast
using single-use waste molds as noted above, multiple-use 'piece' molds, or molds made of
small rigid pieces or of flexible material such as latex rubber (which is in turn supported by
an exterior mold).
Foundry process

13. Sand Preparation
I visited castex industry where two types of sand where used for production of mould. There
were two type of cores were prepared-
1. Cold box core uses core sand or quartz sand
2. Shell box core uses resin coated sand
The resin coated sand was buyed directly from different industry while the quartz sand was
prepared there itself with help of sand mixer machines.
Cold box core was used for manufacturing Wabco, turbine housing and cover core parts,
while shell box core used for manufacturing Tata Mondo cylinders, Sona housing cylinder.
RESIN COATED SAND
An improved resin binder for shell-moulding operations having improved shake-out
properties is disclosed. The resin binder utilizes a lubricant-containing phenolic resin of the
novolac or resoles type or a mixture of novolac and resoles types, incorporated therewith is
an organic chloride. The organic chloride is characterized by having 20% by weight of the
heating loss in the temperature range of 130° to 550° C. The organic chloride may be selected
from chloride-containing polymers and cyclo-organic chlorides. Chlorinated polymeric
material may be selected from polyvinyl chlorides, polyvinyldene chloride resins, chlorinated
paraffins and chlorinated polyolefins.
Resin-coated foundry sand for shell-moulding operations comprising foundry aggregates
coated with a lubricant-containing phenolic resin and one or more organic chlorides, said
chlorides characterized by a 20% weight of heating loss in the range of 130°-550° C. said
organic chlorides

14. CORE SAND
Core sand is usually a mixture of sand grains and organic binders which develop great
strength after baking at 250–650 F. With the help of core sand, it is possible to create intricate
castings by casting metal around thin sand projections without having them break.
Generally, with quartz sand resin are added to provide strength and hardener to bind sand
particles compactly or increase sand binding property.
The sand prepared with help of WESMAN VAM-SERIES CORE SAND MIXERS
These machines were operated by employer manually as per requirement.
 Material – quartz sand, resin , hardener, anti-finning powder, amine gas
 Operation – Sand mixing
 Part produced – Wabco and turbine housing
Core Sand Mixing Work Instruction
The mentioned materials are mixed at different interval.
1. Switch on the mixer pannel.Now check weight setting on the panel for sand.

15. 2. Keep the setting of all items as per requirement i.e. for 50 gm quartz sand mix + 650 gm
resin+650 gm hardener + 500gm anti Finn powder.
3. Weight all item and add resin, hardener, anti-fin with quartz sand properly. Always add
these items in the centre of hopper.
4. Add sand + anti Finn for 60 second, then add resin mox for 90 seconds, then add hardener
for 90 seconds.
5. Check that there is no gap at sand gate and now mix for 240 seconds entire material.
6. Discharge mixed sand to required machine hopper.
7. Industry use amine gas for preparing mould sand properly. Amine gas acts as binder
component which completely mix and hardens entire elements.
INDUSTRYLABORATORY
There were several departments for research and development of sand brought there. They
are classified as –
1. Sample preparation room
1.1 Micro polishing machine
1.2 Spectrographic polishing machine
2. Optical emission spectrometry
3. Chemical analysis room
3.1 Muffle furnace
3.2 Stroheim apparatus
3.3 Analatical apparatus
4. Argon store room
5. Sand testing room

16. Sand Testing Methods | Sand Testing Equipment
Methods of Sand testing:
The moulding sand after it is prepared should be properly tested to see that require properties
are achieved. Tests conducted on a sample of the standard sand. The moulding sand should
be prepared exactly as it is done in the shop on the standard equipment and then carefully
enclosed in a container to safeguard its moisture content.
Sand tests indicate the moulding sand performance and help the foundry men in controlling
the properties of moulding sands. Sand testing controls the moulding sand properties through
the control of its composition.
The following are the various types of sand control tests:
1. Moisture content test
2. Clay content test
3. Grain fitness test
4. Air Permeability test
5. Strength test
6. Refractoriness test
7. Mould hardness test (Brinell hardness,Rockwell)
Moisturecontent 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.

17. Procedures are:
1. 20 to 50 gm of prepared sand placed in the pan and 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.
Claycontent test:
Clay influences strength, permeability and other moulding properties. It is responsible for
bonding sand particles together.
Procedures are:
1. Small quantity of prepared moulding sand dried

18. 2. Separate 50 gm 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 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.
Grain fitness test (Sand Sieve Analysis):
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 placed in order of fineness from top to bottom.

19. Procedures are:
1. Sample of dry sand (clay removed sand) placed in the upper sieve
2. Sand vibrated for definite period
3. The amount of same retained on each sieve weighted.
4. Percentage distribution of grain is computed.
Air Permeabilitytest:
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)
Steps involved are-
1. The air (2000cc volume) held in the bell jar 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

20. 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 (mm2)
P-Air pressure (gm / cm2)
T-Time taken by the air to pass through the sand (seconds)
Strength test:
Measurements of strength of moulding sands carried out on the universal sand strength
testing machine. The strength measured such as compression, shear and tension. The sands
that could be tested are green sand, dry sand or core sand. The compression and shear test
involve the standard cylindrical specimen that was used for the permeability test.
a. Green compression strength:
Green compression strength or simply green strength generally refers to the stress required to
rupture the sand specimen under compressive loading. The sand specimen taken out of the
specimen tube and immediately put on the strength testing machine and the force required to
cause the compression failure is determined. The green strength of sands is generally in the
range of 30 to 160 KPa.
b. Green shearstrength:
With a sand sample similar to the above test, a different adapter is fitted in the universal
machine so that the loading now be made for the shearing of the sand sample. The stress

21. required to shear the specimen along the axis is then represented as the green shear strength.
It may vary from 10 to 50 KPa.
c. Dry strength:
This test uses the standard specimens dried between 105 and 1100 C for 2 hours. Since the
strength increases with drying, it may be necessary to apply larger stresses than the previous
tests. The range of dry compression strengths found in moulding sands is from 140 to 1800
KPa, depending on the sand sample.
Steps involved are:
1. Specimen held between the grips
2. Apply the hydraulic pressure by rotating the hand wheel
3. Taking the deformation use of the indicators.
Mould hardness test:
Hardness of the mould surface tested with the help of an “indentation hardness tester”. It
consists of indicator, spring loaded spherical indenter.
The spherical indenter is penetrates into the mould surface at the time of testing. The depth of
penetration w.r.t. the flat reference surface of the tester.
Mould hardness number = ((P) / (D – (D2-d2))
Where,
P- Applied Force (N)
D- Diameter of the indenter (mm)
d- Diameter of the indentation (mm)

22. FOUNDRY SHOP
A Foundry is a factory that produces metal casting. Metal are cast into shapes by melting
them into liquid, pouring the metal in a mould, and removing the mould material or casting
after the metal has solidified as it cools.
The most common metals processed are aluminium and cast iron. However other metals,
Such as bronze, brass, steel, magnesium, and zinc are also used to produce casting in
foundries. In this process, parts of desired shapes and sizes can be formed.
WORKING PROCESSES IN FOUNDRY
The working process is done by following steps:
1. Core Making
2. Mould making
3. Furnace
4. Pouring
5. Surface cleaning
6. Finishing

23. Core Shop:-A core is a device used in casting and moulding processes to produce internal
cavities and re-entrant angles. The core is normally a disposable item that is destroyed to get
it out of the piece. They are most commonly used in sand casting, but are also used in
injection moulding.
Mould making:-In the casting process a pattern is made in the shape of the desired part.
Simple designs can be made in a single piece or solid pattern. More complex designs are
made in two parts, called split patterns. A split pattern has a top or upper section, called a
cope, and a bottom or lower section called a drag. Cores are used to create hollow areas in the
mould that would otherwise be impossible to achieve
Furnace:-Furnaces are used to melt the metal. Furnaces are refractory lined vessels that
contain the material to be melted and provide the energy to melt it.
Pouring:-In a foundry, molten metal is poured into moulds. Pouring can be accomplished
with gravity, or it may be assisted with a vacuum or pressurized gas.
Surface cleaning:-Sand or other moulding media may adhere to the casting. To remove this
surface is cleaned using a blasting process. The blasting media is selected to develop the
colour and reflectance of the cast surface.
Finishing- The final step in the process usually involves grinding, sanding, or machining the
component in order to achieve the desired dimensional accuracies, physical shape and surface
finish.
CORE SHOP
In my training session first fifteen days I worked at foundry plant in core shop. A core is a
device used in casting and moulding processes to produce internal cavities and re-entrant
angles.
They are most commonly used in sand casting, but are also used in injection moulding.
There are many types of cores available. The selection of the correct type of core depends on
production quantity, production rate, required precision, required surface finish, and the type
of metal being used.

24. In core shop core are made by machines and manually both ways. There were two machines
for core making one was a cold box shooter machine and another one was a hot box
processing machine.
BASIC OF CORE
A core isa device usedin castingandmouldingprocessestoproduce internal cavitiesand reentrant
angles.The core is normallyadisposable itemthatis destroyedtogetitout of the piece.Theyare
mostcommonlyusedin sandcasting,but are alsousedin injectionmoulding
Materials required to make core
 core sand
 bentonite clay
 pulverizedcoal
 RESIN OIL
Types of core
There are many types of cores available. The selection of the correct type of core depends on
production quantity, production rate, required precision, required surface finish, and the type
of metal being used. For example, certain metals are sensitive to gases that are given off by
the binder for removal during the shakeout certain types of core sands; other metals have too
low of a melting point to properly break down the binder.
Green-sandcores
Green-sand cores make casting long narrow features difficult or impossible. Even for long
features that can be cast it still leave much material to be machined. A typical application is a
through hole in a casting.
Dry-sandcores
The simplest way to make dry-sand cores is in a dump core box, in which sand is packed into
the box and scraped level with the top. A wood or metal plate is then placed over the box, and
then the two are flipped over and the core segment falls out of the core box. The core
segment is then baked or hardened. Multiple core segments are then hot glued together or
attached by some other means. Any rough spots are filed or sanded down. Finally, the core is
lightly coated with graphite, silica, or mica to give a smoother surface finish and greater
resistance to heat. More complex single-piece cores can be made in a manner similar to
injection mouldings and die castings. Types of core
 ColdBox
 half core box

25. Lost cores
Cores are used for complex injection mouldings in the fusible core injection moulding
process. First, a core is made from a fusible alloy or low melting temperature polymer. It is
then placed inside the injection mould’s dies and the plastic is shot into the mould. The
moulding is then removed from the mould with the core still in it. Finally, the core is melted
or washed out of the moulding in a hot bath.
DIFFERENT TYPE OF COMPONENTS PRODUCED
SHELL SHOTTER MACHINE-
1) 728 BW /993 BW
2) B54 CTT turbine part
3) Tata Mondo cylinder
4) Sonsa housing Maruti part
5) RVI cylinder
CORE SHOTTER MACHINE-
1) WABCO parts
2) Cover parts
3) Turbine housing
Kao Kuen Industrial Co., a professional manufacturer of core shooting machine and shell
molding machines, has accumulated a solid knowledge and experience in making most
effective, economic and durable machines for more than 30 years. In modern foundry
industry, core making has become one of key elements for successful casting. While foundry
industry is looking for high yield moulding machine, core making became a bottleneck of
casting process.
Kao Kuen has come out to provide the industry most needed equipment: core shooting
machine and shell moulding machine. Kao Kuen core shooting and shell moulding
machines have following features:
1. Excellent machine for making hollow cores.
2. The same machine can make cores or shells.
3. Sand blowing tank is specially designed and made. Very low air pressure will be required.
4. Small and thin cores can be made by this machine.

26. 5. Install loose pieces and slide, difficult drawn core can be made in our machines.
6. Core can be removed automatically by ejector and conveyer.
7. Core box and shell mould change is easy and fast.
8. Machine is durable. Very few numbers of consumption parts are required.
9. Maintenance is easy and minimal.
CORE SHOTTERS MACHINE
Core Machines are rugged and capable of operating with Cold Box (Gas cured) process.
These machines are manufactured for dedicated use with either horizontally or vertically
parted core boxes. They feature fast, automatic operation including sand blowing, gassing
and purging cycles and mechanized core removal on selected models.
Liquid catalyst such as Tri Methyl Amine is vaporised in an electrically heated container. The
core shootingmachinescanbe categorizedintothose forflowable,dryshell mouldmaterials,for
dampand dry mouldmaterials.
Reason to use
Core shooter is a machine used to produce cores of different shapes required by end users.
Previously cores are manufactured manually, that means in that process the sand is rammed
manually so that the process was very time consuming and having demerits such as low
strength, low surface finish etc. The cores produced by using this machine may be hardened
either by heating the core box (shell type) or by pouring gases such as amine, CO2 inside the

27. core box (cold box type). So the hot box or cold box methods are selected according to
application of core.
Working
1. Preparation of sand - Initially silica sand is taken and in that 3% of carbo-pane (Binder) is
added by weight, the process of mixing is carried out in Sand Muller. After that the prepared
sand from Muller is taken out and poured into the sand hopper.
2. By switching on the butterfly valve manually the sand from sand hopper is taken into the
sand magazine. Once the sand magazine is filled with sand, the butterfly valve switched off,
in order to avoid back splashing of sand.
3. Now core box of required shape is mounted on work table. After that the work table moved
upward by pneumatic actuator to clamp the core box against sand magazine.
4. Now the sand from sand magazine is shoot in to the core box by using shooting guns, the
number of shoots taken according to the shape core box size.
5. Once the shooting of sand is completed, the work table along with core box is taken
downward by pneumatic actuator.
6. Now, certain number of holes is made on the core box in order to fill up the entire core box
with CO2 gas. After pouring the CO2 the reaction will takes place and the grains of sand
clustered and core becomes hard.
7. Finally core is removed from the core box.
Vertical core shooter machine
1. Flowable mould material can be filled into the hot core box using various process
principles. The core box temperatures are between 250 and 350°C. In the simplest case, the
mould material is poured into the core box using tilt able pouring containers.
2. Higher core hardness and better surfaces are achieved when the mould material is poured
in under additional pressure in the core box. Due to the good flowability of the mould
material, only a low pressure of 0.2 to 0.4 MPa is necessary.

28. 3. When using the pouring-blowing principle, the mould material container is locked with the
core box and then turned by 180°. The mould material falls into the core box and is
compacted under the additional pressure.
4. After the sintering time (hardening time) is up, a layer of mould material sticks to the hot
core box contour. After the variable hardening times are up and after being turned back, the
thermally unaffected mould material flows out of the core box back into the mould material
container and can be used again for the next cycle.
5. The mould material fed in after the machine bunker has be prepared. It is then shot into the
core box. The core box is clamped hydraulically which prevents the core box from moving
during shooting and gassing.
6. The clamping and separating devices can be changed so that it is possible to work with
vertically and horizontally core boxes. After the mould material has been shot via the
shooting unit which is pressed the movable part of the core box is turned and the core is
pushed out of the solid core box part onto the transport belt (Film). The separating process
then begins.
SHELL SHOTTER MACHINE

29. Working
1. It is a machine formakingshell moulds and-coresaccordingCroningmethod.The applicationof
the resincoatingsandcan be done by shaking,blowingorshooting.The tool temperaturesare
generallybetween250 and350 ° C.
2. The mouldingmaterial isgivenbytiltingbulkvesselsintothe mould.Underinfluence of gravity
takesplace contoursforming.Higherstrengthandbettersurfacesare achievedwhenresincoating
sand ispouredunderadditional pressure intothe tool.
3. The core box islockedto the mouldingsandbinandrotatedby 180 °. The mouldingmaterialfalls
intothe mouldand can be additionallycompressed.Aftercuring time the mouldingsandbinis
rotatedagainand the thermallyuninfluenced mouldingmaterial tricklesback.The heightof
temperature anddurationof curingtime affectthe layerthicknessof mouldhalf respectively core.
Afterthiscore are finalisedand sendtocore inspectionarea.
CORE FINISHING
This department include – core painting area and core inspection area.
After that core is ready for metal shop where molten metal are poured for producing final
assembly.
After painting life of shell core is 6 month and cold core is 4 month.
Reason for painting- for providing finishing and smooth surface of core, so that while casting
no holes are formed on the surface of core.
PAINT USED
1. TRIBONOL is a range of mould and core coatings for electrostatic deposition.
2. SPUNCOTE is specialist products formulated to provide a permeable coating with very
low gas evolution for the centrifugal casting process. They can also assist metal flow and
promote easier stripping of the finished casting.
COATING OF CORE

30. 1. Prepare coating in dipping tank by using paint and water, mix it properly.
2. Check viscosity as per the part and adjust viscosity by adding water or paint if needed.
3. Dip the core manually into the coating up to core paint area (3-5 seconds).
4. Shake the core to remove the excess paint material.
5. Allow wet coated core to dry in oven.
CORE INSPECTION AREA
Before sending core to melting shop inspection are done to remove unwanted materials.
1. Take out baked core out of oven handle the core carefully so that it does not get damaged.
2. Now with the help of rod file remove paint droplets so that these droplets should not create
any defect in casted product.
3. After removing paint droplets, place this finish core in trolley on foam.

31. METAL SHOP
After core get prepared it send into melt shop for further process which is pouring molten
metal then solidify it.Basically aluminium alloy are used for this purpose.
There had been separate melting furnaces for melting different elements i.e. cast iron, steel,
grey cast iron, aluminium. Some additional elements are added for increasing the strength,
hardeness, toughness etc.
Types of Industrial furnace
A furnace is a machines utilized for heating. Industrial furnace utilized for numerous
Things, for example the extraction of metal from ore (refining) or in oil refineries and other
substance plants, for instance as the hotness resource for fragmentary distillation sections.
Types of Industrial Furnaces
Bogie Hearth Furnace
Bell furnace
Pit Type Furnace
Forging furnace
Shell baking furnace
Nonferrous Melting furnace
Industrial Furnace
Laboratory Furnace
Rotary Furnace
These rotary furnaces are heartily built and have exceedingly dependable with great tensile
quality. Rotary furnaces accompanies distinctive sorts, they are Rotary Retort Furnace and
Rotary Melting Furnace. The aforementioned rotary heater are kindled with Oil, gas and
electrical.
Hardening & Tempering Furnace
Quenching furnace stands for its strength, hearty and long continuing on. We moreover deal
diverse sorts of furnaces such as Automatic Quenching Furnace, Drop Bottom Quench
Furnace and Fork Arm Quenching Furnace.
Non Ferrous Melting Furnaces
Non Ferrous Melting Furnaces that are widely utilized as a part of different mechanical
requisitions. These are fundamentally used to liquefy the non-ferrous metals like aluminum,
zinc, copper, lead, and so forth.

32. Laboratory furnaces
Laboratory furnace is fabricated by utilizing fine metal parts, which stands for its strength.
Lab ovens are ovens for heightened-compelled volume thermal convection provisions.
VARIOUS CASTING METHODS
INDUSTRY USE BASICALLY DIE CASTING AND GRAVITY CASTING TECHNIQUE
1. CastingAluminium(HighPressure Die CastingandGravityDie Casting)
2. CastingIron (HighPressure Die CastingandGravityDie Casting)
Productclassification
1. Aluminiumcasted –
 Clutchcases
 Transmissioncases
 Camshaftcovers
 Bearingladdersetc.
2. Iron casted-
 Cylinderblockand head
 Turbo charger

33.  Flwheel housingetc.
Advantages and Limitations of Aluminium Castings
• Machining requirements are reduced.
• Aluminium castings display controlled variations in as-cast finish.
• Contrasts between as-cast and machined finishes can be highlighted to create pleasing
cosmetic effects.
• Capital requirements are typically less than for wrought products.
• Tooling can range from simple patterns to complex tool steel dies depending on product
requirements and production volume.
• Metallurgically or mechanically bonded bimetal parts can be routinely cast.
• Aluminium parts are routinely cast by every known process, offering a broad range of
volume, productivity, quality, mechanization, and specialized capabilities.
• Most aluminium casting alloys display solidification characteristics compatible with
foundry requirements for the production of quality parts.
• Many aluminium casting alloys display excellent fluidity for casting thin sections and fine
detail.
• Aluminium casting alloys melt at relatively low temperatures.
• Aluminium casting processes can be highly automated.
Aluminium Casting Alloys
Aluminium casting alloy compositions parallel wrought alloy compositions in many respects.
Hardening and desired properties are achieved through the addition of alloying elements and
through heat treatment.
Although a large number of aluminium casting alloys have been developed, there are seven
basic families:
• Aluminum-copper • Aluminum-silicon-copper
• Aluminum-silicon • Aluminum-silicon-magnesium
• Aluminum-magnesium • Aluminum-zinc-magnesium
Aluminum-Silicon-Copper

34. Among the most widely used aluminium casting alloys are those that contain silicon and
copper. The amounts of both additions vary widely, so that copper predominates in some
alloys and silicon in others. Copper contributes to strengthening and machinability, and
silicon improves cast ability and reduces hot shortness.
Aluminum-Silicon-Magnesium
The addition of magnesium to aluminium-silicon alloys forms the basis for an extremely
important and useful family of compositions that combines outstanding casting characteristics
with excellent properties after heat treatment. Corrosion resistance is also excellent, and a
low level of thermal expansion is retained.
The mechanical properties of several Al-Si-Mg alloys provide mechanical properties in the
premium-strength range. Beryllium additions improve strength and ductility by affecting the
morphology and chemistry of the iron-containing intermetallic.
Aluminum-Silicon
Binary aluminium-silicon alloys exhibit excellent fluidity, cast ability, and corrosion
resistance. These alloys display low strength and poor machinability. Ductility, which can be
exceptional, is a function of low impurity concentrations and microstructural features.
The strength, ductility, and cast ability of hypoeutectic aluminium- silicon alloys can be
further improved by modification of the aluminium-silicon eutectic. Modification is
particularly advantageous in sand castings and can be effectively achieved through the
controlled addition of sodium and/or strontium. Higher solidification rates also promote a
finer unmodified eutectic microstructure.
IRON CASTING MATERIAL
S.G. Iron possesses greater tensile strength, machinability than ordinary cast iron and also has
a considerable measure of ductility, resistance to impact comparable to that of steel and low
cost involved that justifies it as the metal of future.
S.G Iron is a high carbon ferrous material with graphite in the spheroidal form achieved with
a small amount of magnesium and therefore the name derived. To make S.G. Iron, mild steel
scrap, Fe-Si, Coke etc. is melted in induction furnace. Once the melt is ready, it is inoculated
with small addition of Magnesium or Chromium available in Ferro blends. The metal is then
poured into moulds, cooled and fettled.

35. Die Casting
A die is a specialized tool used in manufacturing industries to cut or shape material mostly
using a press tool, mould & die casting. Like moulds, dies are generally customized to the
item they are used to create.
Die casting is a metal casting process that is characterized by forcing molten metal under
high pressure into a mould cavity. The mould cavity is created using two hardened tool
steel dies which have been machined into shape and work similarly to an injection mould
during the process.
Most die castings are made from non-ferrous metals, specifically
1.) Zinc
2.) Copper
3.) Aluminium
4.) Magnesium
5.) Lead
6.) Pewter: 85–99% tin along with copper, antimony, bismuth.
7.) Tin based alloys
GRAVITY DIE CASTING

36. Gravity die casting is a simple casting process which utilises reusable metallic moulds. The
process is primarily used for simple shapes with some basic coring possible. It is mostly
suited to casting light alloys but can also be used for steel and cast irons.
The two halves of the mould are sprayed with a coating (usually silicate based) and then put
together using locating pins to align the two halves and clamped.
The mould is heated using gas burners prior to pouring the molten metal. The mould will
typically have a runner for pouring and a riser to allow the molten metal to run through, the
filling process is normally aided by spraying the mould with lubricants just prior to pouring.
The coating serves two purposes:
1. To act as a release agent that prevents the molten metal adhering to the metal die
2. To prevent premature solidification of the molten metal
3. Once poured the mould is allowed to cool before being opened to release the casting
HIGH PRESSUREDIE CASTING
1. In the high pressure die casting process the metal is forced into a high grade steel tool at
high speed and -pressure. The casting temperature is roughly 700°C during casting.
2. This equipment consists of two vertical platens on which bolsters are located which hold
the die halves. One platen is fixed and the other can move so that the die can be opened and
closed. A measured amount of metal is poured into the shot sleeve and then introduced into
the mould cavity using a hydraulically-driven piston. Once the metal has solidified, the die is
opened and the casting removed.
3. In this process, special precautions must be taken to avoid too many gas inclusions which
cause blistering during subsequent heat-treatment or welding of the casting product.
Both the machine and its dies are very expensive, and for this reason pressure die casting is
economical only for high-volume production.

37. DISA MATIC MACHINE
Currently, all Metal Technologies foundries utilize DISAMATIC® moulding machines to
produce moulds for our castings.
DISAMATIC consists of a moulding machine and mould transporting conveyor. A moulding
sand mixture, usually green sand or bentonite, is blown into a rectangular steel chamber
using compressed air. The moulding sand is then squeezed against two patterns, which are on
the two ends of the chamber. After squeezing, one of the chamber plates swings open and the
opposite plate pushes the finished mould onto a conveyor. Finally, any cores are
automatically set into the mould cavity while the next mould is being prepared. The cycle
repeats until a chain of finished moulds butt up to each other on the conveyor.
The moulds are then filled with molten metal and placed on a cooling conveyor, which moves
at the same pace as the fabrication conveyor. At the end of the conveyor
the solidified castings are separated from the moulds and processed further, while the sand is
directed to the sand preparation plant for reconditioning and reuse in the next cycles of the
DISAMATIC moulding process.

38. In disa matic machine green sand is used as mould this sand is prepared in the entire system
itself.
Block diagram of machine
Step 1. Sand is blown into the moulding Chamber from above.
Step 2. The Ram advances,pushing the Ram Pattern. This compresses the sand in the moulding Chamber to
form mould impressions.

39. The compressioncreatesoppositehalvesof consecutive mouldsplacedinthe mould string.
Castingscannotbe formedusinga single mould,butwhenanew mouldisplacedinthe mould
string;itsleadingedge meetsthe trailingedge of the previous mouldtocreate acompleted mould
cavity.
Step3. The SwingPatternmovesbackandup to allow the mould toexitthe mouldingChamber
Step4. The Ram extends,pushingthe new mouldintothe existingmouldstring.
Step5. The Ram and Swingpatternsreturntotheiroriginal positiontobeginthe processagain

40. Step 6. Automatic mould conveyor (AMC)
It is a unique mould transport system available in two standard lengths of 12 m and 15 m.
The perfectly synchronised movement of disa machine and AMC ensures optimum control of
force between the moulded
During transport of mould over the AMC the molten metal is poured manually or
automatically using machine, even mould remain on same level.
Step 7.Synchronised belt conveyor (SMC)
This belt extends the cooling zone beyond the AMC when cooling required. The SMC
provided by synchronised mechanical link avoiding mould gap at transition point between the
AMC and SMC.It is provided with heat resistant rubber brakes and pneumatic brakes.
The SBC available as basic length of 4.5m and can be extended up to 35m.
Step 8. Now the cooled mould reaches the cylinder where excess material of component says
turbine housing is removed automatically. As the cylinder is rotating at very high-speed lot of
component are striking the walls of cylinder as a result solidifies metal remain and remaining
sand drops there.
Step 9. Now solidify metal travels up on inclined conveyor which reaches another hollow
system where this metal cooled if additional material there left are removed Step 10. Finally
component is collected by the worker and sends to the fettling area for finishing purpose.

41. FETTLING SHOP
General meaning of fettling
• Mostly used for the words related to cleaning, polishing, and maintaining systems so that
they will be functional or will remain functional.
• The word itself is derived from a root word referring to “condition,” as seen in the phrase
“in fine fettle,” which is meant to describe good condition, shape, or health.
Fettling is the means by which a crude casting is turned into a cost effective quality
component that meets all the standards required by the customer
. • In context with the casting process, fettling means the removal of unwanted metal, e.g.
flashings, risers etc from turbine housing, flywheel etc.
. • It can include processes like chipping, grinding, shot blasting etc.

42. Fettling Operations-
1. Knocking dry sand cores
2. Removal of gates & riser
3. Removal of fins and unwanted projections
Knocking of dry sand core
• Knocking out of dry sand cores from turbine housing. Dry sand cores may be removed by
knocking with iron bar.
• For quick knocking pneumatic or hydraulic devices are employed, this method is used for
small, medium work. For large castings the hydro blast process is mostly employed.
REMOVAL OF GATE AND RISER
1. with chipping hammer
2. by using cutting saw
3. Flame cutting
4. with abrasive cut off machine
1. By using chipping hammer
• It is particularly suited in case of grey iron castings and brittle materials. The gates and
risers can easily be broken by hitting the hammer.
2. with cutting saw
• These saws may be hand saw and power saw are used for cutting the ferrous like steel,
malleable iron and for nonferrous materials except aluminium.
• Mostly the hand saws are used for small and medium but when power and used for large
work.
3. with flame cutting
• This type of method is specially used for ferrous materials of large sized castings where the
risers and gates are very heavy.
• In this the gas cutting flames and arc cutting methods may be employed.

43. 4. with abrasive cut of machine
• These machines can work with all metals but are specially designed for hard metals which
cannot be saw or sheared & also where flame cutting and chipping is not feasible.
Removalof fins, rough spots and unwanted projections
• The casting surface after removal of the gates may still contain some rough surfaces left at
the time of removal of gates. They are needed to be cleaned thoroughly before the casting is
put to use.
• Sand that is fused with surface.
• Some fins and other projections on the surface near the parting line.
• The fins and other small projections attached with turbine housing may easily be chipped
off with the help of either hand tools or pneumatic tools.
• But for smoothing the rough cut gate edges either the pedestal or swing frame grinder is
used depends upon the size of castings.
INSPECTION DEPARTEMENT
This is the final process in industry where casted turbine housing component are cleaned and
additional impurities have been removed for dispatch to customer. There are several steps
involved –
1. Initially lot of turbine housing are collected
2. Provide shine to the component
3. Inspection of component
4. Packing of component

44. INSPECTION OF COMPONENT
There are two stages involved – stage 1 and stage 2
Stage 1
1. At first received fully fetted dressed and reshot blasted casting from fettling shop on
conveyer near the final inspection area.
2. Take first piece on inspection table check visually for properly fetted dressed, no over
ground on external surface of casting.
3. Check casting on riser pad whether grinded up to marked point or not.

45. 4. Check at tongue area for core cut or any defect by light source and mirror.
5. Check internal surface or any metal flash, excess core coating, excess metal in by light
source and mirror.
6. After putting inspection punch move forward for inspection at secondary stage. Note down
in job card.
7. Put cross mark and detect code on reject casting and keep it seperately in bin with red tape.
Stage 2
1. Working instruction for turbine housing with endoscopy machine.
2. At first recived the fully fetted dressed and reshot blasted casting from fettling departement
in endoscopy room.
3. Check internal surface or any metal flash, excess core coating, excess metal in by light
source and mirror.
4. See the image on display TV screen for any defect inside the involute.
5. If casting is ok then check casting by echometer for nodularity tester.
6. Keep ok casting after putting green blue double dot mark in separate bin with ok tag
carefully.
7. Put cross mark and detect code on reject casting and keep it separately in bin with red tape.