2. Sieve the sand properly and pour it into the Muller mixer with
help of Charger(Bucket)
3. Add Bentonite Powder and Water in Sand as shown in table.
NEW SAND
(KG)
BENTONITE
(KG)
WATER
(LIT.)
200 30 8
100 15 4
OLD SAND
(KG)
BENTONITE
(KG)
WATER
(LIT.)
200 10 6
100 5 4
4. Mix the sand properly up to 5-7 min. and take it out from
outlet in trolley and pass it through sammum ariater for
fine sand.
5. 1) Place the pattern on machine
2) Put guide pins and fix it by
nut tightly
6. 3)Add parting paste (yellow color) at
parting line of pattern .
4) Put ejector pin on m/c
7. 5) Put empty mould box and do
proper setting of ejector pin .
6) Add parting agent on pattern
8. 1) Place the mold box on match plate properly and make
ejectors pin setting.
9. 2) Sieve the prepared sand for the facing of the component and fill the box
with filling sand vibrate once and then backfill it and press it after placing
wooden ply on it.
10. 3) Eject prepared mold box and clean it with air gun and put core in it if
required.
11. 4) Prepare upper mold as directed above but we have to drill riser by drill
m/c and clean riser also with the help of air gun.
5) Insert the closing pins and align lower and upper mold with the help
of closing pins on conveyer.
12. Start the furnace (electric or oil fired) wait till it get warm and then fill the
crucible by 60-40% of ingot and Scrap Alloy.
13. Wait for melt total
alloy in crucible after
melting it measure the
temp.
If it is near to pouring
temp. Add titanium
boron tablet and red flux
in it because of which all
impurities in the form of
dross will float on melt.
14. Coat the ladle before using and remove all the dross.
Do degassing up to 10min with the help of impeller, & after that take it out
and clean it.
15. Add modification powder(blue) and stir it properly and remove final
floating dross to clean the melt.
16. Warm the casting ladle before casting, remove oxide layer before pouring
and pour in mold box at an optimum speed.
17. 1) Melting cost.
Melt wt- 140 kg
Melting Time – 3.5 hrs
Weight of casting in Box – 4.9 kg
Weight of casting after grinding – 0.80 kg
Boxes poured in one Heat – 27
2) Core
No of cores /hour - 30
No of Persons – 2
Time required for1 core to prepare – 2.5 min
18. 3) Sand Preparation
Time required for 27 boxes – 3 hours
No of Persons – 2
Time required to make sand for 1 box – 7 min
4)Moulding
No of Boxes / hour – 11
No of Persons – 4
Time required for 1 Box – 5.5 min
19. 5) Melt Treatment
Melting Time – 3 hrs
Time for degassing and cleaning of melt – 30 min
Ingredient – Titanium boron tablet & red flux.
Weight – 600 gm & 1 kg respectively.
Wight of Feedol powder – 3 kg
6) Pouring
Pouring time for 1 Box – 40-50 sec
Pouring time for 27 boxes - 20 min
No of Person - 1
20. 7) Knock Out
Time required for knocking out of one twin casting – 3 min
No of twin castings knock ed out / hour – 20
No of person – 1
8) Cutting
Time required for cutting 1 twin casting - 2 min
No of cutting twin castings / hour – 30
No of person – 1
9) Grinding
Time required for grinding of 1 component – 3 min
No of pieces grinded / hour – 20
No of person - 1
21. 10) Final grinding
Time required for final grinding of 1 piece – 1.2 min
No of pieces finally grinded / hour – 42
No of person – 1
11) Shot Blasting
No of components shot blasted / hour – 200
12) Plant capacity
No of moulds poured / day- 80
23. Actual Time Required for making 1 screw down valve
(3105)
1) core - 4 min
2) Sand - 7 min
3) Mould box – 5 min
4) Melt Treatment & Pouring – 1 min
5) Knockout – 3 min
6) Grinding – 3 min
7) Final Grinding – 1 min
Total - 24 min
24. 1) Core sand – Rs 5/kg
For 1 core 1.5 kg sand required.
Hence, Cost= Rs 7.5
2) Bentonite – Rs 5/ kg
For 1 component 0.5 kg required.
Hence ,Cost= Rs 2.5
3) Hardener - Rs 105/ kg
For 1 core 12 gm hardner required.
Hence ,Cost= Rs 1.26
