RICO is an engineering group that supplies precision machined aluminum and ferrous components to automotive OEMs globally. It has several joint venture companies producing items like clutch assemblies, brake products, and pumps. RICO has multiple facilities across India that do casting, machining, assembly, and R&D. The Dharuhera facility produces over 16 million die cast components annually for customers like Hero Moto and Maruti Suzuki. It uses electric arc furnaces, high pressure die casting machines, and machining centers to produce parts. Quality is ensured through various checks and the production process follows 5S methodology.
Myco Industries provides die casting and machining services using various metals. It has 7 main production processes: centrifugal casting, forging, gravity die casting, high pressure die casting, low pressure die casting, sand casting, and squeeze die casting. The document outlines the raw materials, descriptions, specifications for each process. It also discusses sales growth, purchasing procedures, statutory compliance, supply chain management, and crucial documentation used.
Process optimization of pressure die casting to eliminate defect using cae so...eSAT Journals
Abstract
Die Casting is the manufacturing process by which a liquid material is pressurized in to the mould, which contains a hallow
cavity of the desired shape, and then molten metal is allowed to solidify. The solidified part is known as casting which is ejected
or broken out to complete the process. Objective in this project is to develop tools, dies and gating system. Identify defects such as
gas defects, shrinkage cavities, and mould material defects, pouring material defects, metallurgical defects etc. and take measures
to reduce flaws by using CAE software. To reduce the amount airs entrapped in the mould by changing the gating system, runner
and overflow location and optimize the gating system and process parameters for best quality product and improved productivity.
Defects can be formed easily at critical location during pressure die casting of aluminium alloy part. It has defective effect on the
casting. Mould filling and solidification process of a part was simulated using Z-cast software.
Key Words: Casting, HPDC, Z-cast, CAE Software, Simulation.
The document discusses different types of metal casting processes. It describes gravity die casting and pressure die casting as two types of die casting processes. Gravity die casting involves pouring molten metal into an open steel mold, allowing it to cool and solidify, then tapping the mold to release the casting. Pressure die casting forces metal under high pressure into molds called dies. The document also discusses vacuum permanent mold casting and compares attributes of different casting processes like maximum size, tolerance, and economic quantity.
Hot chamber die casting machines are used for alloys with low melting temperatures like zinc, tin, or lead alloys. The molten metal is stored in a furnace attached to the machine. During injection, the molten metal is forced into the mold cavity under high pressure of 100-300 kp/cm2. This allows for a faster injection sequence than cold chamber machines and reduces burr formation and increases mold life.
Within 18 months of completion or 12 months of use, Hitachi Valve will repair or replace defective products free of charge if the failure is due to design or manufacturing issues. Exceptions include improper use, damage from foreign objects, unauthorized repairs, natural disasters, or other causes beyond Hitachi Valve's control. Malleable iron is suitable for valves due to its high yield point to tensile strength ratio, stable properties over a wide temperature range, and good castability and machinability. Graphite gaskets and packing provide maintenance-free sealing for valves.
Castings - Aluminum Gravity die casting Processroshnipatel829
"Aluminium die casting processes are hush-hush as Ingot casting or Mould casting.
During the willingly style, head of the line or slight aluminium is appoint
into rolling ore (slab), extrusion alloy (billet) and wire waive ingot which
are as a consequence transformed in semi- and satisfied products... www.alphametalind.com"
Five Steps to Optimize Casting and Eliminate DefectsDesign World
Traditionally, engineers had a hard time predicting defects with their cast designs. With simulation, engineers can now predict defects from porosity and cold shots to air pockets.
Watch the webinar: http://www.designworldonline.com/optimize-casting-and-eliminate-defects/#_
There are two main types of die casting: hot-chamber and cold-chamber. In hot-chamber die casting, molten metal is kept inside the die casting machine, while in cold-chamber die casting the molten metal is poured into the machine from outside. Both processes use pressure to force molten metal into a die cavity to create parts. Cold-chamber die casting is more economical for large production quantities, provides good accuracy and surface finish, and requires less floor space than hot-chamber die casting.
Myco Industries provides die casting and machining services using various metals. It has 7 main production processes: centrifugal casting, forging, gravity die casting, high pressure die casting, low pressure die casting, sand casting, and squeeze die casting. The document outlines the raw materials, descriptions, specifications for each process. It also discusses sales growth, purchasing procedures, statutory compliance, supply chain management, and crucial documentation used.
Process optimization of pressure die casting to eliminate defect using cae so...eSAT Journals
Abstract
Die Casting is the manufacturing process by which a liquid material is pressurized in to the mould, which contains a hallow
cavity of the desired shape, and then molten metal is allowed to solidify. The solidified part is known as casting which is ejected
or broken out to complete the process. Objective in this project is to develop tools, dies and gating system. Identify defects such as
gas defects, shrinkage cavities, and mould material defects, pouring material defects, metallurgical defects etc. and take measures
to reduce flaws by using CAE software. To reduce the amount airs entrapped in the mould by changing the gating system, runner
and overflow location and optimize the gating system and process parameters for best quality product and improved productivity.
Defects can be formed easily at critical location during pressure die casting of aluminium alloy part. It has defective effect on the
casting. Mould filling and solidification process of a part was simulated using Z-cast software.
Key Words: Casting, HPDC, Z-cast, CAE Software, Simulation.
The document discusses different types of metal casting processes. It describes gravity die casting and pressure die casting as two types of die casting processes. Gravity die casting involves pouring molten metal into an open steel mold, allowing it to cool and solidify, then tapping the mold to release the casting. Pressure die casting forces metal under high pressure into molds called dies. The document also discusses vacuum permanent mold casting and compares attributes of different casting processes like maximum size, tolerance, and economic quantity.
Hot chamber die casting machines are used for alloys with low melting temperatures like zinc, tin, or lead alloys. The molten metal is stored in a furnace attached to the machine. During injection, the molten metal is forced into the mold cavity under high pressure of 100-300 kp/cm2. This allows for a faster injection sequence than cold chamber machines and reduces burr formation and increases mold life.
Within 18 months of completion or 12 months of use, Hitachi Valve will repair or replace defective products free of charge if the failure is due to design or manufacturing issues. Exceptions include improper use, damage from foreign objects, unauthorized repairs, natural disasters, or other causes beyond Hitachi Valve's control. Malleable iron is suitable for valves due to its high yield point to tensile strength ratio, stable properties over a wide temperature range, and good castability and machinability. Graphite gaskets and packing provide maintenance-free sealing for valves.
Castings - Aluminum Gravity die casting Processroshnipatel829
"Aluminium die casting processes are hush-hush as Ingot casting or Mould casting.
During the willingly style, head of the line or slight aluminium is appoint
into rolling ore (slab), extrusion alloy (billet) and wire waive ingot which
are as a consequence transformed in semi- and satisfied products... www.alphametalind.com"
Five Steps to Optimize Casting and Eliminate DefectsDesign World
Traditionally, engineers had a hard time predicting defects with their cast designs. With simulation, engineers can now predict defects from porosity and cold shots to air pockets.
Watch the webinar: http://www.designworldonline.com/optimize-casting-and-eliminate-defects/#_
There are two main types of die casting: hot-chamber and cold-chamber. In hot-chamber die casting, molten metal is kept inside the die casting machine, while in cold-chamber die casting the molten metal is poured into the machine from outside. Both processes use pressure to force molten metal into a die cavity to create parts. Cold-chamber die casting is more economical for large production quantities, provides good accuracy and surface finish, and requires less floor space than hot-chamber die casting.
Raghunath V completed an industrial training at Salem Steel Plant from December 4-15, 2017. The report summarizes the processes and facilities within the plant's Hot Rolling Mill and Cold Rolling Mill. It describes the key units of each mill, including walking beam furnaces, roughing mills, annealing lines, and various rolling, cooling, and cutting equipment. The goal of the training was for Raghunath to understand the steel production processes firsthand at one of Steel Authority of India's special steels units known for stainless steel sheets and coils.
Steel Making and Rolling (Metalworking): Process & Applications, Rod and Bar...Ajjay Kumar Gupta
The steel industry has taken note of the continued growth in steel imports and a number of projects have been planned and are under implementation.In rolling mills, intermediate steel products are given their final shape and dimension in a series of shaping and finishing operations. Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop.
See more
http://goo.gl/lUUh86
http://goo.gl/fSIHG7
http://goo.gl/4os7IE
http://www.entrepreneurindia.co/
Tags
Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business, Steel and hot rolling Business, Steel Based Profitable Projects, Steel Based Small Scale Industries Projects, Steel business plan, Steel hot rolling process, Steel Industry in India, Steel making and rolling, Steel making Projects, Steel making technology, Steel Making, Steel manufacturing process, Steel mill process, Steel mill, Steel production process, Steel rerolling mill feasibility start up, Steel rolling Industry in India, Steel rolling machine factory, Steel rolling mill industry demand, Steel rolling mill industry overview, Steel rolling mill industry, Steel rolling mill market forecast, Steel rolling mill market growth, Steel rolling mill market, Steel rolling mill size, Steel rolling mill starts production, Steel rolling mill, Steel Rolling Technology, Steelmaking, Steelmaking Processes, Types of rolling mills
The document discusses two die casting processes: gravity die casting and high pressure die casting. Gravity die casting involves pouring molten metal into an open mold, allowing it to cool and solidify. The mold is then tapped to release the finished casting. Common products made through gravity die casting include toasters, lawnmowers, and car wheel rims. High pressure die casting forces molten metal into a closed mold under high pressure to form shapes. Common products include golf club heads, car engine blocks, and radiators. Both processes result in castings that exhibit ejector pin marks and sprue/runner marks.
Die Casting and its types By Raghav GuptaRaghav Gupta
This document provides an overview of different types of die casting processes and classifications of dies. It discusses the key aspects of various die casting methods including hot chamber die casting, cold chamber die casting, low pressure die casting, high pressure die casting, vacuum die casting, squeeze die casting, and gravity die casting. It also covers classifications of dies based on the number of impressions and materials poured, and provides examples of common applications for different metal alloys cast through die casting.
The document discusses automation in the die casting process. It begins by explaining die casting and its advantages over other casting processes. The scope for automation in die casting is wide due to factors like hazardous manual handling of hot materials and high pressures involved. The main types of die casting are hot chamber and cold chamber. Automation can be applied to various components of die casting machines like the injection system, clamping system, and ladle system. Recent developments in die casting include vacuum assisted die casting and active cooling channels to improve quality. Automating die casting provides benefits like time savings, higher accuracy and repeatability, and reduces hazardous manual work.
Investment casting processes, Steps and Applications by polayya chintadaPOLAYYA CHINTADA
This document provides an overview of the investment casting production technology course. It defines investment casting as a lost wax casting process where a wax or plastic pattern is used to create a ceramic mold, which is then filled with molten metal. The document outlines the key steps in investment casting including pattern making, assembly, shell building, dewaxing, metal casting pouring, knockout, and cutoff. Examples of applications for investment casting include parts for the aerospace, medical, and military industries due to its ability to produce complex and high-precision geometries. The course aims to provide insight into metal casting processes and gating systems.
The document summarizes a student's report on an industrial visit to Kalsi Metal Works Private Limited in Jalandhar, India. The student describes the various metal casting and machining processes used at the facility to produce submersible pumps and centrifugal pumps. Key processes mentioned include sand casting of cast iron, molding, finishing, and machining of pump components like impellers, shafts, casings, and seals. The student concludes that the visit helped apply their theoretical knowledge to a real-world manufacturing setting and gain a better understanding of the subject matter.
Gravity die casting involves melting an alloy of zinc and aluminum and pouring it into an open steel mold. The mold is then turned upside down and tapped to release the finished casting. Common items made through gravity die casting include toasters, lawnmowers, and car wheel rims.
Drawing,Wire Drawing &Tube drawing and Its Applications by polayya chintadaPOLAYYA CHINTADA
This document discusses production technology processes including rolling, extrusion, wire drawing, and tube drawing. It provides an overview of these metal forming processes, specifically focusing on drawing processes. Wire drawing involves reducing the diameter of thick wire by passing it through a series of dies. Tube drawing is similar but uses a mandrel to reduce the wall thickness and diameter of a tube. The document describes the different types of tube drawing based on whether a mandrel is used and how it is implemented. The objective is to explain these metal forming techniques and compare cold working versus hot working.
EFFECT OF CASTING PARAMETERS ON MACROSTRUCTURE OF STEELSurya Teja Botu
The document summarizes a student project conducted at Vizag Steel Plant investigating the effect of casting parameters on the macrostructure of steel. It was presented by five students and guided by P.V. Bhujanga Rao of Vizag Steel Plant. The project examined how melt temperature and casting speed influence steel structure and defect formation during continuous casting, and modeled temperature and melt flow in the caster sump. It provides background on Vizag Steel Plant and describes its raw material sources, production units including coke ovens, sinter plant, blast furnaces, and rolling mills.
Casting involves introducing molten metal into a mold cavity where it takes the shape of the cavity. Important factors include the solidification process and heat transfer during cooling. There are two main casting methods - ingot casting and continuous casting. Ingot casting produces ingots that are further processed, while continuous casting directly produces final products like steel slabs. Permanent molds are reused, while expendable molds like sand are only used once. Considerations in casting design include risers, draft angles, and machining/shrinkage allowances.
The document discusses die casting, which is a permanent mold casting process where metal alloys such as aluminum, magnesium, and copper are poured into metal molds to produce a large number of identical castings. There are two main types of die casting: gravity die casting where molten metal is poured by hand into molds, and pressure die casting where molten metal is injected into molds under high pressure. Pressure die casting provides smoother, more dimensionally accurate castings and is used to manufacture small castings in industries.
A PROJECT REPORT ON
“Eliminating corner gap in sc mould at LD2 SNC”.
During the internship the following research is evaluated and being verified by the authorized TATA steel employee.
This document provides an overview of the industrial training presentation given by Khagendra Kumar Dewangan at Bhilai Steel Plant. The training focused on two main plants: 1) Refractory Materials Plant-II which produces lime and dolomite bricks, and 2) Foundry & Pattern Shop which produces castings. The presentation covered the processes, departments, and safety procedures at each plant.
Vocational Training on Bhilai Steel PlantPiyush Verma
B.S.P a unit of steel Authority of India Ltd. Inagurated at 1959 by the President of India Dr. Rajendra Prasad with a production capacity of 1.0 million ton.
B.S.P is Indian sole procedure for rails and heavy steel plates and major producer of structural.
The plant is the sole suppliers of the country’s longest rail tracks of 260 meters. With annual production capacity of 3.153MT
This seminar report discusses shell molding, also known as shell mold casting. Some key points:
1) Shell molding uses a resin-covered sand to form molds for casting small to medium metal parts, providing better dimensional accuracy and productivity than sand casting.
2) The process involves creating a pattern, applying a heated sand-resin mixture to form a shell around the pattern, curing the shell, assembling two shell halves, and pouring molten metal to form the casting.
3) Shell molding allows casting of both ferrous and non-ferrous metals for parts requiring precision, such as gear housings and cylinder heads.
4) The sand used is finer
Bhilai Steel Plant is India's largest steel producing plant located in Durg, Chhattisgarh. It has a production capacity of over 4 million tons of steel per year. The plant uses a conventional steel making process involving twin hearth furnaces and ingot casting. Key components of the process include a mixer, stockyard, 4 furnaces, mould yard, and stripper yard. Hot metal, scrap, and fluxes are added to the furnaces and oxygen is blown in. Molten steel is tapped and alloying elements are added before casting ingots. The ingots are then heated and rolled into blooms in the blooming mill and further rolled into billets in the billet mill,
Glass products are made through a process involving raw material preparation and melting, shaping, and heat treatment. There are different shaping methods for discrete pieces like bottles and continuous processes for sheet glass. After shaping, glass undergoes annealing or tempering for heat treatment. Product design considerations include glass's transparency, strength in compression over tension, and brittleness.
Die casting process: Principles, applications and industrial useMayurjyotiNeog
The short presentation gives insights to some die casting process, its principles, applications and some industrial use. It also includes different die casting methods.
This document provides an overview of various permanent mold casting techniques, including basic permanent mold casting, slush casting, pressure casting, vacuum permanent mold casting, and low pressure casting. It describes the key steps in the permanent mold casting process, considerations for using permanent mold casting, and properties of castings produced via different permanent mold casting methods. The document is intended to cover learning objectives related to various permanent mold casting techniques and their applications in industry.
This document summarizes an internship project at Vihan Motors Muzaffarnagar focused on the process flow for body outer tool casting using zinc alloy ZAMAK-3. The key steps are: (1) ZAMAK-3 alloy is heated to 420-440°C and poured into a 130-ton hot chamber die casting machine; (2) The molten metal is injected under high pressure into the die; (3) The metal solidifies in the die cavity and cools to form the casted part; (4) The part is then ejected, degated to remove excess material, and undergoes secondary processes like buffing before dispatch to the paint shop. The document provides details
Raghunath V completed an industrial training at Salem Steel Plant from December 4-15, 2017. The report summarizes the processes and facilities within the plant's Hot Rolling Mill and Cold Rolling Mill. It describes the key units of each mill, including walking beam furnaces, roughing mills, annealing lines, and various rolling, cooling, and cutting equipment. The goal of the training was for Raghunath to understand the steel production processes firsthand at one of Steel Authority of India's special steels units known for stainless steel sheets and coils.
Steel Making and Rolling (Metalworking): Process & Applications, Rod and Bar...Ajjay Kumar Gupta
The steel industry has taken note of the continued growth in steel imports and a number of projects have been planned and are under implementation.In rolling mills, intermediate steel products are given their final shape and dimension in a series of shaping and finishing operations. Rolling of steel is one of the most important manufacturing processes for steel. It is usually the first step in the processing of steel after it is made and cast either in Ingot or continuous cast product in a steel melting shop.
See more
http://goo.gl/lUUh86
http://goo.gl/fSIHG7
http://goo.gl/4os7IE
http://www.entrepreneurindia.co/
Tags
Business guidance for steel rolling industry, Business Plan for a Startup Business, Business plan for steel rolling mill, Business start-up, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot rolling mill process, Hot Rolling Mill, Hot Rolling mill, Hot Strip Mill, How is Steel Produced, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Indian Steel Industry, Industrial steel rolling mill, Modern steel making technology, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Process & Applications, Process of steelmaking, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Project for startups, Rod and Bar Rolling, Rod and bar rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling process, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Small Start-up Business Project, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel Business, Starting a Steel rolling Business, Starting Steel Mini Mill, Start-up Business Plan for steel rolling, Startup Project for steel rolling business, Steel and hot rolling Business, Steel Based Profitable Projects, Steel Based Small Scale Industries Projects, Steel business plan, Steel hot rolling process, Steel Industry in India, Steel making and rolling, Steel making Projects, Steel making technology, Steel Making, Steel manufacturing process, Steel mill process, Steel mill, Steel production process, Steel rerolling mill feasibility start up, Steel rolling Industry in India, Steel rolling machine factory, Steel rolling mill industry demand, Steel rolling mill industry overview, Steel rolling mill industry, Steel rolling mill market forecast, Steel rolling mill market growth, Steel rolling mill market, Steel rolling mill size, Steel rolling mill starts production, Steel rolling mill, Steel Rolling Technology, Steelmaking, Steelmaking Processes, Types of rolling mills
The document discusses two die casting processes: gravity die casting and high pressure die casting. Gravity die casting involves pouring molten metal into an open mold, allowing it to cool and solidify. The mold is then tapped to release the finished casting. Common products made through gravity die casting include toasters, lawnmowers, and car wheel rims. High pressure die casting forces molten metal into a closed mold under high pressure to form shapes. Common products include golf club heads, car engine blocks, and radiators. Both processes result in castings that exhibit ejector pin marks and sprue/runner marks.
Die Casting and its types By Raghav GuptaRaghav Gupta
This document provides an overview of different types of die casting processes and classifications of dies. It discusses the key aspects of various die casting methods including hot chamber die casting, cold chamber die casting, low pressure die casting, high pressure die casting, vacuum die casting, squeeze die casting, and gravity die casting. It also covers classifications of dies based on the number of impressions and materials poured, and provides examples of common applications for different metal alloys cast through die casting.
The document discusses automation in the die casting process. It begins by explaining die casting and its advantages over other casting processes. The scope for automation in die casting is wide due to factors like hazardous manual handling of hot materials and high pressures involved. The main types of die casting are hot chamber and cold chamber. Automation can be applied to various components of die casting machines like the injection system, clamping system, and ladle system. Recent developments in die casting include vacuum assisted die casting and active cooling channels to improve quality. Automating die casting provides benefits like time savings, higher accuracy and repeatability, and reduces hazardous manual work.
Investment casting processes, Steps and Applications by polayya chintadaPOLAYYA CHINTADA
This document provides an overview of the investment casting production technology course. It defines investment casting as a lost wax casting process where a wax or plastic pattern is used to create a ceramic mold, which is then filled with molten metal. The document outlines the key steps in investment casting including pattern making, assembly, shell building, dewaxing, metal casting pouring, knockout, and cutoff. Examples of applications for investment casting include parts for the aerospace, medical, and military industries due to its ability to produce complex and high-precision geometries. The course aims to provide insight into metal casting processes and gating systems.
The document summarizes a student's report on an industrial visit to Kalsi Metal Works Private Limited in Jalandhar, India. The student describes the various metal casting and machining processes used at the facility to produce submersible pumps and centrifugal pumps. Key processes mentioned include sand casting of cast iron, molding, finishing, and machining of pump components like impellers, shafts, casings, and seals. The student concludes that the visit helped apply their theoretical knowledge to a real-world manufacturing setting and gain a better understanding of the subject matter.
Gravity die casting involves melting an alloy of zinc and aluminum and pouring it into an open steel mold. The mold is then turned upside down and tapped to release the finished casting. Common items made through gravity die casting include toasters, lawnmowers, and car wheel rims.
Drawing,Wire Drawing &Tube drawing and Its Applications by polayya chintadaPOLAYYA CHINTADA
This document discusses production technology processes including rolling, extrusion, wire drawing, and tube drawing. It provides an overview of these metal forming processes, specifically focusing on drawing processes. Wire drawing involves reducing the diameter of thick wire by passing it through a series of dies. Tube drawing is similar but uses a mandrel to reduce the wall thickness and diameter of a tube. The document describes the different types of tube drawing based on whether a mandrel is used and how it is implemented. The objective is to explain these metal forming techniques and compare cold working versus hot working.
EFFECT OF CASTING PARAMETERS ON MACROSTRUCTURE OF STEELSurya Teja Botu
The document summarizes a student project conducted at Vizag Steel Plant investigating the effect of casting parameters on the macrostructure of steel. It was presented by five students and guided by P.V. Bhujanga Rao of Vizag Steel Plant. The project examined how melt temperature and casting speed influence steel structure and defect formation during continuous casting, and modeled temperature and melt flow in the caster sump. It provides background on Vizag Steel Plant and describes its raw material sources, production units including coke ovens, sinter plant, blast furnaces, and rolling mills.
Casting involves introducing molten metal into a mold cavity where it takes the shape of the cavity. Important factors include the solidification process and heat transfer during cooling. There are two main casting methods - ingot casting and continuous casting. Ingot casting produces ingots that are further processed, while continuous casting directly produces final products like steel slabs. Permanent molds are reused, while expendable molds like sand are only used once. Considerations in casting design include risers, draft angles, and machining/shrinkage allowances.
The document discusses die casting, which is a permanent mold casting process where metal alloys such as aluminum, magnesium, and copper are poured into metal molds to produce a large number of identical castings. There are two main types of die casting: gravity die casting where molten metal is poured by hand into molds, and pressure die casting where molten metal is injected into molds under high pressure. Pressure die casting provides smoother, more dimensionally accurate castings and is used to manufacture small castings in industries.
A PROJECT REPORT ON
“Eliminating corner gap in sc mould at LD2 SNC”.
During the internship the following research is evaluated and being verified by the authorized TATA steel employee.
This document provides an overview of the industrial training presentation given by Khagendra Kumar Dewangan at Bhilai Steel Plant. The training focused on two main plants: 1) Refractory Materials Plant-II which produces lime and dolomite bricks, and 2) Foundry & Pattern Shop which produces castings. The presentation covered the processes, departments, and safety procedures at each plant.
Vocational Training on Bhilai Steel PlantPiyush Verma
B.S.P a unit of steel Authority of India Ltd. Inagurated at 1959 by the President of India Dr. Rajendra Prasad with a production capacity of 1.0 million ton.
B.S.P is Indian sole procedure for rails and heavy steel plates and major producer of structural.
The plant is the sole suppliers of the country’s longest rail tracks of 260 meters. With annual production capacity of 3.153MT
This seminar report discusses shell molding, also known as shell mold casting. Some key points:
1) Shell molding uses a resin-covered sand to form molds for casting small to medium metal parts, providing better dimensional accuracy and productivity than sand casting.
2) The process involves creating a pattern, applying a heated sand-resin mixture to form a shell around the pattern, curing the shell, assembling two shell halves, and pouring molten metal to form the casting.
3) Shell molding allows casting of both ferrous and non-ferrous metals for parts requiring precision, such as gear housings and cylinder heads.
4) The sand used is finer
Bhilai Steel Plant is India's largest steel producing plant located in Durg, Chhattisgarh. It has a production capacity of over 4 million tons of steel per year. The plant uses a conventional steel making process involving twin hearth furnaces and ingot casting. Key components of the process include a mixer, stockyard, 4 furnaces, mould yard, and stripper yard. Hot metal, scrap, and fluxes are added to the furnaces and oxygen is blown in. Molten steel is tapped and alloying elements are added before casting ingots. The ingots are then heated and rolled into blooms in the blooming mill and further rolled into billets in the billet mill,
Glass products are made through a process involving raw material preparation and melting, shaping, and heat treatment. There are different shaping methods for discrete pieces like bottles and continuous processes for sheet glass. After shaping, glass undergoes annealing or tempering for heat treatment. Product design considerations include glass's transparency, strength in compression over tension, and brittleness.
Die casting process: Principles, applications and industrial useMayurjyotiNeog
The short presentation gives insights to some die casting process, its principles, applications and some industrial use. It also includes different die casting methods.
This document provides an overview of various permanent mold casting techniques, including basic permanent mold casting, slush casting, pressure casting, vacuum permanent mold casting, and low pressure casting. It describes the key steps in the permanent mold casting process, considerations for using permanent mold casting, and properties of castings produced via different permanent mold casting methods. The document is intended to cover learning objectives related to various permanent mold casting techniques and their applications in industry.
This document summarizes an internship project at Vihan Motors Muzaffarnagar focused on the process flow for body outer tool casting using zinc alloy ZAMAK-3. The key steps are: (1) ZAMAK-3 alloy is heated to 420-440°C and poured into a 130-ton hot chamber die casting machine; (2) The molten metal is injected under high pressure into the die; (3) The metal solidifies in the die cavity and cools to form the casted part; (4) The part is then ejected, degated to remove excess material, and undergoes secondary processes like buffing before dispatch to the paint shop. The document provides details
Pressure die casting is a manufacturing process where molten metal is injected under high pressure into a steel mold cavity. This allows for the rapid solidification of net-shaped metal components with tight tolerances. There are two main types - high pressure die casting for parts requiring close tolerances, and low pressure die casting for larger, less critical parts. Pressure die casting allows for high-volume production of complex parts and good dimensional accuracy.
Development of Special Purpose of profile Machine, PVC Fittings and PVC Pipe ...Atharva Naik
This presentation contain information about Development of Special Purpose of profile Machine, PVC Fittings and PVC Pipe Machine. This PPT is nothing but our industrial experience as intern at Supreme Gold PVT LTD Nanded.
The document discusses various permanent mold casting processes including basic permanent mold casting, squeeze casting, die casting, centrifugal casting, slush casting, pressure casting, and semi-solid metal forming (thixocasting). Permanent mold casting involves reusing the same mold for multiple castings. The mold material depends on the alloy being cast. Die casting injects molten metal into a mold under high pressure using either a hot or cold chamber machine. Centrifugal casting involves pouring molten metal into a rotating mold to produce hollow tubular parts.
Assembly of the components (Crank shaft, Connecting rod, Gudgeon pin and Piston) by
using different manufacturing processes from the material generated as a scrap during
manufacturing of different products through various processes.
The introduction of the automatic transmission did this by offering a “no-muss, no-fuss” form of shifting.
The earliest automobiles offered only manual transmissions, which were similar in principle to today’s stick-shift vehicles.
These cars sported two forward gears and one reverse, coupled to the engine via a series of pedals.
But as cars grew larger and traffic got worse, engineers began searching for a way to have the car “automatically” shift from one gear to another.
Designers spent decades perfecting the modern automatic transmission.
Here we offer a brief introduction and overview of the history of the automatic transmission.
The document discusses various aspects of extrusion, a manufacturing process where a block of metal is forced to flow through a die opening. It describes different types of extrusion like hot and cold, direct and indirect, lubricated and hydrostatic. It also discusses defects in extrusion and the drawing process which is similar but uses a pulling force. The key information provided includes how extrusion allows shaping of solid and hollow metal sections, the operating principles and classifications of extrusion, and factors that affect the extrusion force.
Manufacturing of liquid propellant tankSai Malleswar
The document discusses the manufacturing process of liquid propellant tanks used in rockets. It describes the key design requirements, including withstanding pressure while being lightweight. The tanks are made of aluminum alloy and consist of domes, cylindrical shells, and other components joined by welding. The manufacturing processes for each component are detailed, including forging, drilling, welding, rolling, and hydroforming. The complete tank assembly process is also outlined.
The document discusses the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die to create solid or hollow shapes. There are different types of extrusion classified by direction (direct, indirect), operating temperature (hot, cold), and equipment (horizontal, vertical). Hot extrusion is done at high temperatures using lubrication while cold extrusion is done at room temperature. The document also discusses defects, drawing as a related process, and factors that affect extrusion forces.
This document summarizes the extrusion manufacturing process. Extrusion involves forcing a block of metal through a die opening to produce solid or hollow sections. It can be performed hot or cold, and produces parts through direct or indirect methods. Key advantages are producing complex shapes efficiently in small batches, though high costs and potential defects exist. The document also briefly outlines the related drawing process of pulling wire or tubing through a die to reduce its cross-section.
Forging is a metalworking process where a metal workpiece is shaped by applying compressive forces. It can produce parts that are stronger than those made by other metalworking processes. There are two main types of forging: open die forging between flat dies for larger objects, and closed die forging between shaped dies for smaller, more precise components. Common metals forged include carbon steels, aluminum, and titanium. The forging process involves heating metal, shaping it between dies using presses, trimming off excess flash, and often further processing like heat treating. Forgings are found in critical applications like engines and chassis where strength and reliability are important.
Shell moulding is a metal casting process that uses a resin-coated sand mixture to form an expendable mould around a reusable metal pattern. This allows for higher production rates compared to sand casting, with better dimensional accuracy and precision for small to medium parts. The process involves heating metal patterns, coating them with sand and resin to form shell halves, assembling the shells to create the mould cavity, pouring molten metal, cooling and solidification, then removing the casting. It is commonly used for automotive and engine components that require precision dimensions.
This document discusses various metal forming processes including forging, rolling, drawing, and extrusion. It provides details on hot working and cold working metals, types of forging machines and operations, flat and shape rolling, defects in rolled parts, principles of drawing rods, tubes and wires, and types of extrusion such as hot and cold extrusion. The key advantages and disadvantages of these metal forming techniques are also summarized.
This document provides information about Dawlance, a household appliance company in Pakistan. It includes:
1. Dawlance's mission is to promote reliability in everything they do for household appliances and their vision is to make Dawlance a global brand known for reliability and make Pakistan proud.
2. The document describes several departments visited during an internship at Dawlance, including production departments for sheet metal work, welding, painting, plastic molding, and assembly lines. It also discusses maintenance, quality control, and condenser manufacturing departments.
3. The intern expresses gratitude to Dawlance leadership for providing the opportunity and to supervisors for their advice and encouragement during the learning experience.
IIIE SECTION A MANUFACTURING TECHNOLOGY NOTES 8.die castingsBhaskar Nagarajan
This document summarizes the die casting process used to produce metal castings. It discusses:
- Die casting forces molten metal into a mold cavity under high pressure (1500-25400 psi).
- Common materials used are zinc, aluminum, magnesium, copper, lead, and tin alloys.
- There are four main steps: die preparation, filling, ejection, and shakeout to separate scrap.
- Different types of die casting machines (hot chamber, cold chamber, vacuum) are used depending on the material and required pressure.
Foundry Processes in Sand-Molded Casting of SteelIRJET Journal
The document summarizes the key steps involved in the sand-molten casting process for steel components. It discusses:
1) Pattern making to create an exact replica of the desired casting shape which is then used to form molds.
2) Core making to form solid sand cores within the mold to create hollow cavities in the casting.
3) Molding which involves dividing molds into two halves, adding sand mixtures, and placing cores to form the complete mold for pouring molten metal.
The document outlines several other important foundry processes like melting scrap metal, pouring into molds, allowing the metal to solidify, and provides details on each step to produce quality castings and avoid failures.
Bulk deformation processes are metal forming operations that cause significant shape change through plastic deformation of initially bulk metal parts like bars, billets, and slabs. The main bulk deformation processes are rolling, forging, extrusion, and drawing.
Rolling reduces the thickness of metal by passing it through opposing rolls. Forging shapes metal by compressing it between dies under impact or gradual pressure. Extrusion forces metal through a die opening to take on its cross-sectional shape. Drawing reduces the diameter of wires or bars by pulling them through a die. These processes are commonly done hot to facilitate greater plastic deformation.
This 3 sentence summary provides the key details about the industrial training report:
The report describes Akbar's 4 week industrial training at the foundry shop of Indo Farm Equipment Limited in Baddi, Himachal Pradesh. The training involved learning the various processes used in the foundry shop such as core making, mold making, melting metals, and finishing casted parts. Akbar gained hands-on experience working in the core shop and observing the other processes like molding, melting, pouring, and fettling during his training.
1. 1
ABOUT THE COMPANY
RICO is a world- class engineering group supplying a wide range of high precision fully
machined aluminum and ferrous components and assemblies to automotive OEMs across the
globe. RICO’s integrate services include design, tooling, casting, machining, assembly and R&D
across ferrous and aluminum products.
RICO GROUP OF INDUSTRIES
TABLE 1.1
COMPANY NAME PARTNERSHIP PRODUCTS
FCC RICO 50% FCC & 50% RICO Clutch assembly –two
wheelers and four wheelers
CONTINENTAL RICO 50% CONTINENTAL &
50% RICO
Hydraulic Brake products and
services
MAGNA Powertrain RICO 50% MAGNA Powertrain &
50% RICO
Oil pump and Water pump
RICO JINFEI 92.5% RICO & 7.5% JINFEI Aluminum Alloy Wheels-
Two Wheelers
RICO USA& UK 100% RICO Assembly, logistics,
Customer support
TABLE 1.2. RICO IN INDIA
COMPANY NAME LOCATION PRODUCTS/PROCESSES
DHARUHERA Dharuhera Aluminum Casting and
Machining
RICO GURGAON Gurgaon Aluminum /Ferrous Dies &
Moulds, R&D, CAD/CAM
CAE
RICO HARIDWAR Haridwar Aluminum Casting &
Machining
RICO BHIWADI-1 Bhiwadi Machining
RCL LUDHIANA Ludhiana Ferrous Casting & Machining
RCL MANESAR Manesar Aluminum Casting &
Machining
FCC RICO Manesar Manesar Clutch Assembly
FCC RICO Pune +RICO
Pune
Pune Machining
CONTINENTAL RICO Gurgaon Hydraulic Brakes
MAGNA RICO Dharuhera Oil and Water Pump
RICO JINFEI Manesar Aluminum Alloy Wheels
RICO Chennai Chennai Aluminum Casting and
Machining
2. 2
RICO AUTO INDUSTRIES –DHARUHERA
LOCATION:-
69 K.M STONE, DELHI- JAIPUR HIGHWAY,
DHARUHERA(H.R)
CERTIFICATION:
ISO9000-1994
QS-1998
ISO 1401-2002
OHSAS 18001-2002
CAPACITY :
Over 16 million high pressure die cast components are produced per annum.
FUTURE PLANS OF THE FIRM :
Reduce dependency on other industrial sector.
Searching for new customers
Expansion of the firm.
Investment in the other profitable industrial sectors.
PRODUCTS AT RICO DHARUHERA
Table 1.3
PRODUCTS CUSTOMER
Clutch Assembly(2 Wheeler) Hero-Moto Corp
Wheel Hub Assembly(2 Wheeler) Hero-Moto Corp
Brake Panel Assembly(2 Wheeler) Hero-Moto Corp
CUSTOMERS:-
Hero Moto Corp
Maruti Suzuki
Ford Motor Company
Volvo
Cummins
3. 3
5-S OF THE COMPANY :
SEIRI (SORTING)
SEITON (SYSTEMATISING)
SEISO (SHINING)
SEIKETSU (STANDARISATION)
SHITSAKE(SELF DISCIPLINE)
UTILITY :-
Maintenance department is responsible for the management and supply of electricity and
compressed air to different section of firm.
Power comes from HVPNL (HARYANA VIDYUT PARISHADH NIGAM LTD.) 1,30,000
Kw-h / day
Generated voltage – 11 KV
Compressor : 2200 CFM
Screw type compressor used.
Fig 1.
RICO DIES PRODUCTION SHOP :
RICO dies unit molds (machines) the dies required in the HPDC Shop.
It involves manufacturing of new dies and maintenance of old once.
4. 4
CAD/CAM DIVISION :
Function of this unit is product design, tool design, jig design, etc.
AUTOCAD software was used by the department for 2D layouts
Pro E and CATIA were used for 3D Design and Modelling
CNC Machines were coded through LAN system. Code is generated on CAM and uploaded in
CNC Machines through LAN system.
Fig 2. RICO Dharuhera
5. 5
MASTER PRODUCTION CHART :-
FLOW CHART 1.
RAW MATERIAL:-
ADC-12 & ADC-14 alloys
FURNANCE (MELTING):-
Electric Arc Furnace is used to melt the raw aluminum into liquid metal
An electric arc furnace (EAF) is a furnace that heats charged material by means of
an electric arc.
Alloys are melted in a furnace at 1000°C.
Raw Aluminum is brought to the furnace on conveyor belts.
When the Aluminum enters the red hot furnace maintained at 1000°C aluminum melts
This liquid Aluminum passed to molding machines through channels (pipes) which pour
the molten metal into a reservoir.
Each injection molding have a separate reservoir.
RAW MATERIAL
STORAGE
FURNANCE
(MELTING)
HIGH PRESSURE
DIE CASTING
HEAT
TREATMENT
MACHINING
ROW (TURNING,
DRILLING , etc.)
QUALITY UNIT
PAINT SHOP
PACKAGING AND
STORAGE
6. 6
Fig 3. Electric arc furnace
FOUNDARY SHOP
HIGH PRESSURE DIE CASTING:-
Here, the liquid metal is injected with high speed and high pressure into the metal
mold.
The basic equipment consists of two vertical platens.
The bolsters are placed on these platens and this holds the die halves.
Out of the two platens, one is fixed and the other movable. This helps the die to open
and close.
A specific amount of metal is poured into the shot sleeve and afterwards introduced
into the mold cavity. This is done using a hydraulically-driven piston.
After the metal has solidified, the die is opened and the casting eventually removed.
Fig 4. High Pressure Die Casting
7. 7
TYPES OF HIGH PRESSURE DIE CASTING PROCESS
Hot Chamber Process
Cold Chamber Process
Hot Chamber Process:-
The hot-chamber process is applicable only for zinc and other low melting
point alloys that does not affect and erode metal pots cylinders and plungers.
The molten metal for casting is placed in the holding furnace at the required
temperature adjacent to (sometimes as part of the machine itself) the machine.
The injection mechanism is placed within the holding furnace and most of its
part is in constant touch with the molten metal. When pressure is transmitted
by the injection piston, the metal is forced through the gooseneck into the die.
On the return stroke, the metal is drawn towards the gooseneck for the next
shot.
This process ensures minimum contact between air and the metal to be
injected. The tendency for entrainment of air in the metal during injection is
also minimized.
Fig. 5 Hot Chamber Die Casting
Cold Chamber Die Casting:-
The injection system is not submerged in molten metal.
Metal gets transferred by ladle, manually or automatically, to
the shot sleeve.
8. 8
The metal is pushed into the die by a hydraulically operated
plunger. This process minimizes the contact time between the
injector components and the molten metal.
The entrainment of air into the metal generally associated with
high-speed injection can cause gas porosity in the castings. In
the cold chamber machine, injection pressures over 10,000 psi
or 70,000 KPa is obtainable.
Fig 6 Cold Chamber Die Casting
RICO DIE CASTING (HPDC UNIT) :-
18 high pressure die casting machines in the HPDC SHOP
In HPDC machine two dies are used :
Fixed die ( cover die)
Movable die (ejector pins)
These machines have different locking force like 660 ton, 560 T, 400 T, 250 T, 200 T,
160 T, 135 T.
Dycote is used for cooling of the die.
The die is also cooled by water for efficient cooling of the casting. This increase dies life.
HPDC machine is controlled by three factors :
Accumulator pressure
Nitrogen pressure
Die opening time
Nitrogen pressure is produced with the help of nitrogen gas.
9. 9
Nitrogen gas pushes the piston accumulator and thus accumulator pressure is produced.
The time between closing the die for casting to the opening it, is called die opening time.
PROCESS:-
Spray the mold with lubricant and close it. This helps to maintain the inside temp. Of
the die and also allows easy removal of cast product.
The nitrogen gas increases the accumulator pressure and the molten metal is injected
into the shot sleeve.
The metal is injected at very high pressure which ensures the precise shape of cast
object.
After the mold fills completely, it is allowed to cool under high pressure.
Open the die and cast product is removed with the help of ejector pins.
COMPONENTS MADE IN HPDC SHOP :-
Outer clutch
Centre clutch
Friction disc
Lifter plate
Pressure plate
Front & rear hub
Front & rear brake panel
TYPES OF COOLING IN HPDC SHOP :-
SPOT COOLING: The cooling is done at particular spots only.
LINE COOLING: Continuous cooling is done. An entire region is cooled by this.
FUNCTION OF DYCOTE :-
( Filler + bonding agent + water )
The principal functions required of a coating for die casting are:
Control of the metal flow to ensure that it reaches all parts of the die at a
sufficient temperature to prevent the formation of seams, cold laps, etc.
Control of heat transfer to obtain better solidification and ensure that the castings
are properly fed.
Good surfaces, and therefore a reduction in finishing costs
Longer die life, therefore increased productivity and reduced maintenance and
cost.
10. 10
FACT :-
The layer of DYCOTE with a coarse surface, the contact between molten metal and
DYCOTE is significantly reduced, because the metal, due to its surface tension, is first
in contact with only the “peaks “of the layer, and only after a time, though this is
extremely short, does it penetrate into the "valleys", after which the air escapes through
the channels in the permeable coating. The result of this phenomenon is to reduce heat
loss to a minimum in the molten metal, which thus maintains its fluidity at the critical
moment to fill the die completely.
SELECTION OF DYCOTE COATING :
The section thickness of the casting. One of the main properties of a coating is its ability
to aid the filling of the die. When the casting concerned has a thin section then a coarse
DYCOTE with high insulation properties should be considered.
The surface finish requirement of a casting is very important but coatings which give
very good surface finish make it more difficult to fill the die because of the smooth
surface of the coating and because the insulation is not as good as with a coarser
coating. The balance of surface finish and insulation will therefore be a compromise.
FETTLING PROCESS :
First take O.K casting and start fettling.
Remove all outer flake.
After that face of parting line is cleaned with the help of rough file.
Clean of flake of ejection pin.
Clean slot hole.
After that check the casting and put it in trolley.
11. 11
Fig.7 Component after Fettling Process
CASTING DEFECTS:-
EXTERNAL DEFECTS:-
These defects can be seen on the surface or the edges of the casting. Use a
microscope to see the fine details
TABLE 2.1 EXTERNAL DEFECTS
CATEGORY DEFECT NAME
Gas Related Blisters
Exploded Blisters
Collapsed Blisters
Shrinkage Related Sinks
Filling Related Cold Flow
Short Fill
Laminations
Inclusions Flakes
Die Lube Marks
Surface Deposits
Gate breakout
Thermal- Mechanical Cracks
Hot Tearing
Die Related Soldering
Heat Checking
Die Erosion
Ejection Marks
12. 12
INTERNAL DEFECTS:-
Table 2.2 Internal Defects
CATEGORY DEFECT NAME
GAS RELATED Gas Porosity
Lubricant Entrapment
Hydrogen Porosity
SHRINKAGE RELATED Shrinkage Porosity
Leakers
Layer Porosity
Filling Related Cold Flow
Laminations
Joints
THERMAL CONTRACTION Cracks
Hot Tearing
EXCESS MATERIAL Flash
OUT OF TOLERANCE War page And Deformation
MACHINING SHOP :
COMPUTER NUMERICAL CONTROL MACHINE ( CNC) :-
There are 15 CNC machines in the machine shop. These machines are used to
perform different machining operations.
The CNC works a/c to the program written by the operator. CNC have two or more
programmable directions of motion called axis. An axis can be linear or rotary.
Common linear axis names are X, Y and Z.
Common rotary axis are A, B & C.
The axis of any CNC machine is required for the purpose of causing the motion
needed for the manufacturing process.
LATHE MACHINE :
There are five lathe machines in the tool room shop.
These all have self-centered chucks.
Operation performed by Lathe Machine are as follows:-
Facing
Boring
Drilling
Threading
Knurling
Parting
13. 13
Facing: to produce a flat surface at the end of the part and perpendicular to its
axis useful for parts that are assembled with other components. Face grooving
produces grooves for applications such as O-ring seats.
Boring: to enlarge a hole or cylindrical cavity made by a previous process or
to produce circular internal grooves
Drilling: to produce a hole which may be followed by boring to improve its
dimensional accuracy and surface finish.
Parting: also called cutting off, to cut a piece from the end of a part, as is
done in the production of slugs or blanks for additional processing into
discrete products.
Threading: to produce external or internal threads.
Knurling: to produce a regularly shaped roughness on cylindrical surfaces, as
in making knobs and handles
Fig 8 Operation in lathe
MILLING MACHINE:-
Milling includes a number of highly versatile machining operations taking place in a
variety of configurations with the use of a milling cutter-a multi-tooth
tool that produces a number of chips in one revolution.
Milling Machines are of three types :-
Column and Knee type Milling machine:-
14. 14
Used for general-purpose milling operations, column-and-knee-type machines
are the most common milling machines. The spindle on which the milling
cutter is mounted may be horizontal.
Fig 9 Milling Machine
Fig 10 Milling Machine
Bed-type Milling Machines. In bed-type machines, the worktable is mounted
directly on the Cutters bed, which replaces the knee and can move only
longitudinally
Fig 11 Bed Milling Machine
15. 15
DRILLING MACHINE:-
Drilling machines are used for drilling holes, tapping, reaming, and small-diameter
boring operations. The most common machine is the drill press, the major
components. The work piece is placed on an adjustable table, either by clamping it
directly into the slots and holes on the table or by using a vise, which in turn is
clamped to the table. The drill is lowered manually by a hand wheel or by power feed
at preset rates. Manual feeding requires some skill in judging the appropriate feed
rate.
Reaming is an operation used to (a) make an existing hole dimensionally more
accurate than can be achieved by drilling alone, and (b) improve its surface finish.
Fig. 11 Drilling Machine
GRINDING MACHINE
Grinding is used to finish work pieces that must show high surface quality (e.g.,
low surface roughness) and high accuracy of shape and dimension.
Fig 12 Grinding Machine
16. 16
ELECTRO DISCHARGE MACHING :
Electric discharge machining provides an effective manufacturing technique that
enables the production of parts made of special materials with complicated geometry
which is difficult to produce by conventional machining processes. Controlling the
process parameters to achieve the required dimensional accuracy and finish placed this
machining operation in a prominent position. From that reason, electric discharge
machining has found broad applications in industry. The absorbing interest for electric
discharge machines has resulted great improvements in EDM technology. Nowadays,
sophisticated electric discharge machines are available for most of machine shop
applications
Basically Electric Discharge Machining (EDM) is a process for eroding and removing material by
transient action of electric sparks on electrically conductive materials. This process is achieved by
applying consecutive spark discharges between charged work piece and electrode immersed in a
dielectric liquid and separated by a small gap. Usually, localized breakdown of the dielectric liquid
occurs where the local electrical field is highest. Each spark melts and even evaporates a small
amount of material from both electrode and work piece. Part of this material is removed by the
dielectric fluid and the remaining part solidifies rapidly on the surfaces of the electrodes. The net
result is that each discharge leaves a small crater on both work piece and electrode. Application of
consecutive pulses with high frequencies together with the forward movement of the tool electrode
towards the work piece, results with a form of a complementary shape of the electrode on the work
piece...
17. 17
PAINT SHOP :
The component is passed into degreasing tank. It is addition of pagancleanal-124
(200gm) and water (100 ltr). Temperature of the tank is 55-65 degree Celsius. It removes
oil, dust from the component.
Then it is rinsed in cold water tank to remove oil and dust.
It is then passed into achromatizing tank. Achrom chemical is coated on the component.
Passed into oven at 100-110 degree Celsius.
Second coat of paint is done on paint booth followed by the first.
After that clear coat (leather coat) is done on third paint booth.
Then it is passed into baking room at 140-150 degree Celsius.
18. 18
WORK DONE AT THE INDUSTRY
DESIGN OF CLUTCH HOUSING
COMPANY:-HERO Moto Corp
Clutch Housings is a mostly used part which holds the clutch disks of the vehicles.
Fig 13 Clutch Housing
DESIGN OF CLUTCH MASTER SPACER
Fig 14 Clutch Master Spacer
20. 20
PROJECT
DESIGN OF AUTOMATIC SEALING MACHINE
Fig 16 vertical vacuum sealing machine
About The Machine :-
Vacuum sealing machine at RICO, Dharuhera was manually operated. It was press
operated machine i.e. the engineer/technician have to press the pedal in order to seal the
package. Machine had two coils (heating coils) which melted the package and helped in
packing the machine
Firstly, the package containing the component was placed between the jaws as wells as
the heating coils.
Then the air inside the package was removed using the vacuum pump which removed all
the air present inside the package.
Then the jaws closes making the packaging air tight.
Then through some mechanism the heating coils pressed against each other melting the
packing material.
Heating coils were pressed for 2-3 seconds.
Then the jaws opens and the package was removed.
21. 21
Aim:-
To design 3D model of vacuum sealing machine considering the problems faced during
packing of the finished products.
To learn Pro E modelling software.
To make the machine automatic (pneumatic controlled).
Design Constraints :-
Dimensions of the machine.
Material used to make different parts.
Problems :-
The sealing machine used at RICO Dharuhera was vertical.
Person who was sealing the finished product have to hold the packet.
This led to errors such as partial vacuum, improper seal, time consumed was high.
Changes In Design:-
Orientation of machine was changed from horizontal to vertical.
Machine was designed horizontally so as to remove the effort required for lifting the
packet for a longer time.
Secondly to remove the effort of holding the package a small slab was incorporated into
the design which would help to support the weight to the package.
Problems such as partial vacuum was also eliminated as the vacuum system could create
vacuum in the package kept stationary on the slab and also there would be less
misalignment during packaging.
Space was provided for pneumatic valves and pipes.
22. 22
Fabrication of machine:-
The machine was made horizontal keeping the components in position.
Secondly extra sheet metal were added to close off the space so in order to prevent the
dust from entering the package.
Sheet metal were welded to the machine.
Pneumatic system was prepared to fit in the space.
Pedal now acted as a pneumatic actuator when pressed pneumatic pistons were actuated
and the jaws were closed.
Pneumatic solenoids were used to provide the required pressure of air.
Stand was made separately to support the machine alignment.
Then slab was added (made of sheet metal thick sheet) to the base of the machine to
support the package.
Fig 17 Horizontal Automated vacuum sealing machine
23. 23
CONCLUSION
Summer training undergone at RICO Auto Industries, Dharuhera (H.R) helped me develop new
skills such as learning Pro E software and basics of AutoCAD which is very essential from
industrial point of view. During this internship, I got a golden opportunity to interact with highly
skilled and knowledgeable employees of the company who not only explained me all the
machining process but also provided me with the essential knowledge of how each and every
machine worked and how was one different from the other. This internship not only made me
learn new things but also helped me in framing the clear picture of what we study during the
engineering course such as the entire process from designing to fabrication of the component,
factors that need to be considered to bring even slightest change to component, etc. The
vocational training is helping me throughout my studies as well as my engineering career.
24. 24
REFERENCES
Manufacturing Engineering and Technology (Fourth Edition) by Serope Kalpakjain and
Steven R.Schmid
Wikipedia (https://en.wikipedia.org)
http://www.themetalcasting.com/
http://www.ehow.com/
http://www.ricoauto.com/
RICO Corporate Presentation(2012)