This document provides information about Prashant Castech (P) Ltd., an Indian foundry group that supplies electric motor castings. It details the company's capabilities including producing motor housings up to 560 frame size and 3 ton weight. The document describes the company's production process from pattern making to heat treatment and quality testing. It also provides specifications for raw materials and chemical composition for different cast iron grades produced by the foundry.

1. A TRAINING REPORT ON
CASTECH (P) LTD.
Address: Prashant Castech (P) Ltd.
Gondal Road
Near Hotel Krishna Park
Vavdi Road
Rajkot - 360 004

2. COMPANY PROFILE
• We are a family owned foundry group, based in India, and supplying
electric motor castings in , Finland, Germany, India, Italy and Mexico.
We started out, modestly, in 1967 as a supplier to local diesel engine
manufacturers and have now emerged as a 50,000 tons p.a. foundry,
supplying castings to world-class engineering companies. Our group
comprises of the following companies:

4. 1) Prashant Castings (P) Ltd.
2) Prashant Castech (P) Ltd.
3) Prashant Ferrex (P) Ltd.

5. • We have the capability to make electric motor housings upto frame
size 560 and weight per piece upto 3 tons.
We also make End shields, Bearing Covers, Terminal box covers, Fan
covers, pump parts, etc.
Please see below for a few photographs of our product range.

6. • Pattern
• Foundry
• Shot blasting
• Grinding
• Machining
• Laboratory Department

7. • PATTERN
• We are used a multi piece pattern
• PATTERAN MATERIAL:
• Aluminium pattern
• We offer various shapes and sizes for an extensive range of
aluminium pattern
• These are manufactured with customized solution to meet the
devise industry requirement

8. • These product are appreciated for its high quality and better abrasion
resistance
• Our range of aluminium pattern are ideal choice for long casting
production application and fabrication chemical and iron industry

9. • Resin and catalyst mixed with
sand in core making process
• Dust less sand required for
core making. Before chemical
mix in to sand.
• All dust are collect on to dust
collector. Than automatic
mixer mix resin and catalyst
with sand.

10. • A mould is a device used In casting
and moulding process to produce
internal cavities and re-entrant angles.
• They are most commonly used in sand
casting but are also used in injection
moulding.
• Mould are typically made out of sand
so that they can be out of the casting.

11. • For surface finishing and perfect
dimensions mould must be
painted.
• If colour mixed with thinner it can
taken.
• For process quick but if colour
mixed with water.
• It must be stay for 3 days for dry.

12. • Mould and centre core put on
surface plate for assembly.
• Mould centre core are assembly by
clamps and plates.

13. • Cupola is very commonly used furnace
in an iron foundry and consists of a
cylindrical shell of boiler plate.
• Cupola is employed for melting scrap
metal for the pig iron use in the
production of iron castings.
• Cupola is an economical furnace for the
production of different types of cast
irons.
• Cupola is mainly used for casting
process.

14. • CARBON
• SILICON
• MANGANESE
• SULPHUR
• COPPER
• CROMIUM
• PIG IRON
• M.S SCRAP
RAW MATERIAL FG-250 FG-200
PIG IRON 330 kg 540kg
M.S. SCRAP 480kg 375kg
STEEL SCRAP 180kg 84kg
SILICON 8kg 4kg
MANGANESE 4kg 2kg
LIME STONE 40kg 40kg

15. • Furnace is ready for the melting.
• When around 1400kg of liquid metal
prepared then a sample of liquid metal
taken for the C & Si, measurement.
• After getting the result of C & Si we add
Ferro alloys as per grade requirements.
• When liquid metal comes at top level then
add slag 30 for the slag remover.
• At last 1 ton of liquid metal is ready then
measures the temperature by pyrometer.
• Temperature is different as per grade
requirement.

16. ALLOYING ELEMENT FG-250 FG-200 FG-300
CARBON EQUIVALENT 3.60-3.90 % 3.90-4.10 % 3.40-3.80 %
CARBON 3.0-3.25 % 3.30-3.50 % 2.93-3.3 %
SILICON 1.5-1.80 % 1.60-2 % 1.4-1.6 %
MANGANESE 0.6-0.9 % 0.5-0.7 % 0.4-0.9 %
TEMPERATURE 1350-1400℃ 1250-1400℃ 1400℃

17. • This process is used clean.
• After cooling of casting past need to
remove sand on part surface. That’s why
shot blasting used for cleaning of part.
Small roller ball is used in shot blasting
process.
• Shot blasting machine through this roller on
part in specify speed and this roller remove
sand on the part and clean.
• We are used Air Blasting Technologies.

18. • After shot blasting need to grinding
is used to remove extra material
from part and make surface
finishing.

19. • Machining process is depended on
customer requirement.
• We provide semi machining
facilities for the boring and facing of
casting in machine shop. The casting
brought here from the grinding and
fettling shop are duly machined and
sent forward for final finishing.
• Any fuse sand in the pocket shall be
remove with the help of pneumatic
hand grinder.

20. • We have been issued ISO 9001:2008 certification
by TUV SUD Management Service GmbH and
accordingly a
• stringent quality control program is followed
which is implemented in the following phases:-
» Checking of raw materials
» Sand mixture analysis in our own fully equipped
laboratory by qualified personnel
» Checking of cores before they are placed in
moulds
» Inspection after shot-blasting process
» Final inspection of finished products

21. • Classifying chemical property composition
and mechanical property for material.
• We are used UTS MACHINE for tensile
strength.
• BRINNAL hardness tester machine .
• Chemical lab spectro machine for chemical
composition.

22.  The spectroscope is a stationary metal analyzer.

25. 1. The sample is excited by controlled spark/discharge.
2. The radiant energy of the selected analytical lines are converted to electrical
impulses by photomultiplier tube.
3. The concentrations of elements are calculated from analytical working curves
prepared by exposing standard samples of similar type.

26. A tensile test helps determining properties such as tensile strength,
elongation, reduction in area and modulus of elasticity.
In the tensile testing we have use standard test piece(as fig).

28. Tensile testing is also known as tension testing, is a fundamental
test in which a sample is subjected to a controlled tension until
failure.
Heat treated kb come from HT section.
KB send for machining and after check dimension(ex. Gauge
length.)
Test piece is put on UTM machine. first reading is know as YS %
second reading is know as UTS.
 after breaking tensile check strength, gauge length % reduce area.

30. The determination of the Rockwell hardness of a material involves the application
of a minor load followed by a major load.
The minor load establishes the zero position. The major load is applied, then
removed while still maintaining the minor load.
 The depth of penetration from the zero datum is measured from a dial, on which
a harder material gives a higher number.
That is, the penetration depth and hardness are inversely proportional.
The chief advantage of Rockwell hardness is its ability to display hardness values
directly