1. INTERNSHIP REPORT
On
BRAKES INDIA FOUNDRY DIVISION, SHOLINGHUR
Done by
K CHANDRASHEKHAR
FINAL YEAR, B.E. (MECH)
SSN COLLEGE OF ENGINEERING, CHENNAI
[JUNE 2015]

2. ii
ACKNOWLEDGEMENT
We express our sincere gratitude to Mr. J Srinivasan, Senior General Manager –
HR and Mr. Umashankar, Deputy Manager- HR & Personnel for providing us with
the opportunity to undergo an internship program at the prestigious factory.
We extend our heartfelt gratitude to all the Senior Executives and Managers
who guided us in the learning process. We also thank all the supervisors who took
time off their schedule to explain the processes to us.

3. iii
CHAPTER DETAILS
CHAPTER TOPIC PAGE
NUMBER
1 ABOUT THE COMPANY 1
2 PATTERN AND DIE SHOP 3
3 PERMANENT MOULD FOUNDRY 8
4 NEW PRODUCT DEVELOPMENT 25
5 CORE SHOP 29
6 PROJECTS AND UTILITIES 36
7 ISO 14001 – EMS – IMS 42
8 STORES 47
9 QUALITY ASSURANCE 50
10 A, C, D & E LINE 54
11 SAND FOUNDRY INSPECTION 71
12 KUNKEL WAGNER LINE 77
13 WAREHOUSE 79

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DETAILED TOPIC INDEX
SERIAL
NUMBER
TOPICS PAGE
NUMBER
1 ABOUT THE COMPANY 1
1.1 QUALITY POLICY 1
1.2 COMPANY VISION 2
2 PATTERN AND DIE SHOP 3
2.1 INTRODUCTION 3
2.2 DIVISIONS 3
2.2.1 DESIGN AND TOOLING 3
2.2.2 TOOLING MANUFACTURING 5
2.2.3 DEVELOPMENT 6
2.3 MAJOR COMPONENTS 7
3 PERMANENT MOULD FOUNDRY 8
3.1 INTRODUCTION 8
3.2 RAW MATERIALS 8
3.3 CUPOLA FURNACE 10
3.3.1 PREPARATION OF CUPOLA 11
3.3.2 MELTING 11
3.3.3 CHARGING 13
3.3.4 RECUPERATOR 14
3.3.5 FLUE GASES 14
3.4 HOT METAL RESERVOIR 14
3.5 POURING 15
3.6 DIE CAST 15
3.7 HEAT TREATMENT 17
3.7.1 ANNEALING 18
3.7.2 NORMALIZING 18
3.8 SURFACE TREATMENT 18
3.8.1 SHOT BLASTING 19

5. v
3.8.2 FETTLING 19
3.9 INSPECTION 19
3.9.1 ON SITE 20
3.9.2 OFF SITE 20
3.9.2.1 MAGNETIC PENETRATION
INSPECTION
20
3.9.3 LABORATORY 21
3.10 MAINTENANCE 21
3.10.1 WET SCRUBBER 23
3.11 PMF VS AUTOMATED PROCESS 23
4 NEW PRODUCT DEVELOPMENT 25
4.1 INTRODUCTION 25
4.2 INITIAL SAMPLE INSPECTION ROOM 26
4.3 STANDARDS 26
4.4 3D TEST AND CMM ANALYSIS 27
5 CORE SHOP 29
5.1 INTRODUCTION 29
5.2 COLD BOX 30
5.2.1 PROCESS PARAMETERS 30
5.3 CORE SHELL 31
5.3.1 PROCESS PARAMETERS 32
5.4 SANDS USED 33
5.5 COMPONENTS WHICH REQUIRE A CORE 33
5.6 PAINTING 34
5.7 CORE DEFECTS 34
5.8 CORE ASSEMBLY 35
5.9 QUALITY INSPECTION – FIRST STOP
INSPECTION
35
6 PROJECTS AND UTILITIES 36
6.1 INTRODUCTION 36

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6.2 PROJECTS 36
6.3 UTILITIES 37
6.3.1 POWER SUPPLY 37
6.3.1.1 BACKUP POWER 38
6.3.2 COMPRESSED AIR 38
6.3.3 WATER 39
6.3.4 TELEPHONE AND MOBILE SERVICE 40
6.4 CTR FIRE PROTECTOR SYSTEM 40
7 ISO 14001 – EMS – IMS 42
7.1 INTRODUCTION 42
7.2 BASIC PRINCIPLE 43
7.2.1 PLAN 43
7.2.2 DO 44
7.2.3 CHECK 45
7.2.4 ACT 45
7.3 INTEGRATED MANAGEMENT SYSTEM 46
8 STORES 47
8.1 INTRODUCTION 47
8.1.1 RAW MATERIALS 47
8.1.2 CONSUMABLES 47
8.1.3 SPARES 48
8.2 STORAGE 48
8.3 PROCEDURE 48
9 QUALITY ASSURANCE 50
9.1 INTRODUCTION 50
9.2 HISTORY 50
9.3 ISO/TS 16949 51
9.4 QUALITY MAINTENANCE 52
10 A,C,D & E LINE 54
10.1 INTRODUCTION 54

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10.2 PROCESS FLOW 54
10.3 PRODUCTION SYSTEM 58
10.4 RAW MATERIAL AND ADDITIVIESS 59
10.4.1 SAND 60
10.4.2 BENTONITE 60
10.4.3 COAL DUST 61
10.5 SUPPLY MECHANISM 62
10.5.1 SAND MULTI CONTROLLER (SMC) 62
10.6 DISAMATIC MOULD MACHINE 63
10.7 MELTING AND POURING 66
10.7.1 CHARGING 67
10.8 MAGNESIUM TREATMENT 67
10.9 SAND LAB 68
10.10 PROCSS CONTROL 68
10.11 E LINE 69
10.11.1 INTRODUCTION 69
10.11.2 MELTING 69
10.11.3 HOLDING FURNACE 70
10.11.4 TUN DISH AND POURING 70
10.12 MISCELLANEOUS PROCESS 70
11 SAND FOUNDRY INSPECTION 71
11.1 INTRODUCTION 71
11.2 PROCESSES INVOLVED 71
11.2.1 ONLINE SHOT BLASTING 71
11.2.2 FETTLING 72
11.2.3 OFFLINE SHOT BLASTING 72
11.2.4 VISUAL INSPECTION 73
11.2.5 OIL INSPECTION 73
11.3 CUSTOMER SPECIFIC REQUIREMENT 73
11.4 NON DESTRUCTIVE TEST 74

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11.4.1 NVH TEST 74
11.4.2 ULTRASONIC TESTING 74
11.4.3 MAGNETIC PARTICLE INSPECTION 75
11.4.4 ENDOSCOPIC TESTING 75
11.4.5 DIMENSIONAL ANALYSIS 76
12 KUNKEL WAGNER LINE 77
12.1 INTRODUCTION 77
12.2 PROCESS 77
12.3 GRADE 78
13 WAREHOUSE 79
13.1 INTRODUTION 79
13.2 CAPTIVE TRANSFER 79
13.3 EXCISE DUTY 79
13.4 HANDLING 80

9. 1
CHAPTER 1
ABOUT THE COMPANY
In 1981, Brakes India established a Foundry Division at Sholinghur to manufacture
Permanent Mould Grey Iron castings with an installed capacity of 5,000 MTPA,
which was subsequently increased to 12,000 MTPA.
In 1992, the Foundry Division installed a DISAMATIC High pressure moulding
line with a capacity of 6,000 MTPA to produce Grey and Ductile Iron Sand
castings. In 1996, a second DISAMATIC moulding line with a capacity of 15,000
MTPA was installed. In 2002, a third DISAMATIC moulding line with a capacity
of 18,000 MTPA was installed. A fourth DISAMATIC with 26,000 MTPA
capacity was installed in 2005. State of the art manufacturing plant was set up at
Salalah, Sultanate of Oman during M0arch 2008 to meet the International
customers‟ requirement. This new plant had started its‟ commercial production
from April 2008 with 18,000 MTPA capacity. Dunes Oman has expanded its
capacity to 36,000 MTPA by adding one more line with a capacity of 18,000
MTPA
1.1 QUALITY POLICY
Every company has its own quality policy. The main purpose of this is to
improve the 3 factors interlinked together which will lead to the development of

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the company. They are: Quality, Cost, and Delivery. The quality policy of Brakes
India, Foundry division is “Brakes India limited, foundry division shall achieve
customer satisfaction by delivering products and services of the right quality at
competitive prices and at the right time. We are committed to meeting customers‟
expectations in total by complying with the requirements and continually
improving the effectiveness of the quality management system through total
employee involvement.”
1.2 COMPANY VISION
We shall achieve customer satisfaction by providing products and services of
high quality at globally competitive prices. We shall be a leading player in our
chosen area of operations in the light of engineering industry. We shall improve
the quality of life of our employees and fulfil their reasonable aspirations. By
creating an atmosphere of trust and care, we shall work as a cohesive team always
encouraging higher standards of performance. We shall provide an adequate return
to our stock holders and facilitate growth of the organization. We recognize our
vendors as our partners in progress. We shall give them a fair deal and nurture a
healthy relationship. We shall conduct ourselves as responsible corporate citizen
known for integrity and ethics.

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CHAPTER 2
PATTERN AND DIE SHOP
2.1 INTRODUCTION
The pattern and die shop is the basis for all foundry operations. Casting of
metal involves pouring of the molten metal into a die or in the case of a permanent
mould foundry, or into the sand moulding in the case of sand foundry. These are
made in the pattern and die shop. It also involves making of core mask, core box
etc. These are usually made of steel block from grey iron.
2.2 DIVISIONS
It consists of three main divisions, namely
i) Design and tooling
ii) Tooling manufacturing
iii) Development
2.2.1 DESIGN AND TOOLING
Design of the product is the first step in the process of making a pattern/die.
Design is done using ProE, Modeling CATIA, and at times CREO is also used.

12. 4
The requisition for the required casting is given by the customer to the marketing
division. The marketing division forwards the request to the design department. If
the design department is ready for undertaking a job, they respond positively. Then
the design of the required component is sent to the design department through the
marketing department. Then, the design is analyzed thoroughly and a feasibility
check is done and a report is prepared for the same. A meeting is conducted to
discuss about the feasibility. If feasible, the response is given to the marketing
division and the marketing division responds to the customer. If feasible with
minor changes in design, the request for small changes is sent from the design
department to the marketing division.
The marketing division then conducts a meeting with the customer and
makes sure the customer agrees to the changes made in the design. If not feasible,
the customer is told that it is not possible to continue. After the feasibility check
and report, the customer is linked directly to the design department. From now, the
design department directly clarifies with the customer if there are any issues.
Generally, dimensions and tolerances are decided according to the current stage of
production techniques and technology available. Once everything is ready, a
request for machining the die/pattern is sent to the machining department.
Prioritization of jobs is done at this stage.

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Briefly the different components designed and tooled here are
i. Die for Permanent mould foundry
ii. Pattern for Sand foundry
iii. Core mask for DISA machine
iv. Core box for core shop
2.2.2 TOOLING MANUFACTURING
The machining department starts to manufacture the die/pattern as soon as
the machines are ready and available for operation. The machining room consists
mainly of single spindle 5 axisDeckelMaho Universal CNC, single spindle 3 axis
Makino CNC, twin spindle 3 axis Parpas CNC, drilling m/c‟s and CNC lathes.The
software used for NC is generally for 5 axis CNC is Hypermill and for 3 axis CNC
is Tebbis. The CNC used usually contains ATC for changing the tool. It varies
from 18-20 for 3 axis CNC and about 30 – 32 for 5 axis CNC.The coolant used for
the CNCs is neat oil instead of water based oils. The advantage of using neat oil is
that, it does not require frequent changing. The change frequency for neat oil is 1
year approximately. The job does not rust easily as there is no moisture content in
the coolant. An important factor is that neat oil does not cause any environmental
problems.

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The tool used in lathes, CNCs is high strength carbide tip tools grinded at
high accuracy in the bench shop. For drilling machines, high speed steel tool bits
are used. The collets used for holding the tool are from Morris tooling, Schunk, or
Showa.All machines used in the machining department are calibrated once in 6
months and at any time if required. The die is manufactured using a steel block of
SG iron. The manufacturing of a die usually takes 4-5 days. Each and every die has
a unique number and each cavity in the die has a unique number so that tracing the
source of the cast is easy.
2.2.3 DEVELOPMENT
The bench shop contains conventional machines like lathe, radial drilling
machine, grinding wheel, honing tool, universal milling machine etc. The bench
shop is where the machined die/pattern is finished using grinding, honing, and a
polishing is done. The burrs obtained during the machining are removed using
suitable machines. Vertical radial drilling machines are used to make holes on the
die. The main purpose of making holes is to provide cooling effects. When the hot
molten metal is poured in the die, air passes through these holes and cooling is
done. Also, the holes act as a passage for the gases produced to escape without
disturbing the molten metal. In the absence of these holes, blowholes will be

15. 7
formed. The tools are obtained from Kenna Metals, ABI tools Ltd etc. In the case
of a repair or, the service department is called.
The gating system is done here at the machine shop. In the case of sand
foundry, runners and risers are made using aluminum or made of wood and stuck
together using a bonding agent like mseal. In the case of permanent mound
foundry, the runners and risers are integrated into the die when machining is done.
2.3 MAJOR COMPONENTS
The dies contain pattern of brakes, suspension, chassis components,
refrigerator compressor body, steering knuckles etc.

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CHAPTER 3
PERMANENT MOULD FOUNDRY
3.1 INTRODUCTION
The permanent mould foundry is the oldest foundry division in TVS. It was
started in 1981. The permanent mould foundry makes use of a hot blast cupola
furnace for production of molten metal. The molten metal is then poured into the
die casts and removed as it cools. The castings are then heat treated if necessary.
The castings are then inspected, quality checked and then sent to the warehouse.
3.2 RAW MATERIALS
 Pig iron (RINL - SAIL, LANCO, SESA)
 Steel scrap
 Foundry returns (own scrap)
 Coke (high and low ash)
 Limestone
 Charging materials

17. 9
Fig 3.1
PMF overall process
MARKETING
WARE HOUSE
INSPECTION
Defects Testing
FINISHING
Shot blasting
HEAT TREATMENT
Annealing Normalising
SORTING
Manual
CASTING
Die casting
MELTING
Cupola furnace

18. 10
3.3 CUPOLA FURNACE
A cupola or cupola furnace is a melting device used in foundries that can be
used to melt cast iron, Ni-resist iron and some bronzes. The cupola can be made
almost any practical size. The size of a cupola is expressed in diameters and can
range from 0.5 to 4.0 m. The overall shape is cylindrical and the equipment is
arranged vertically, usually supported by four legs. The overall look is similar to a
large smokestack.
The bottom of the cylinder is fitted with doors which swing down and out to
drop bottom. The top where gases escape can be open or fitted with a cap to
prevent rain from entering the cupola. To control emissions a cupola may be fitted
with a cap that is designed to pull the gases into a device to cool the gases and
remove particulate matter.
The shell of the cupola, is made of steel, has refractory brick and sand
patching material lining it. The bottom is lined in a similar manner but often a clay
and sand mixture (bod) may be used, as this lining is temporary. Finely divided
coal can be mixed with the clay lining so when heated the coal decomposes and the
bod becomes slightly friable, easing the opening up of the tap holes. The bottom
lining is compressed or rammed against the bottom doors. Some cupolas are fitted

19. 11
with cooling jackets to keep the sides cool and with oxygen injection to make the
coke fire burn hotter.
3.3.1 PREPARATION OF CUPOLA
Cupola furnace has to be prepared before each production day. The cupola is
made up of stainless steel. The cupolas outer lining is made up of 23-34% alumina,
50-60% silicon dioxide called refractory fire clay brick lining for about 1.5m thick.
Inside the fire clay lining, an acid lining is made manually. Selection of the lining
is important, it may be acid, basic or neutral. Depending on the need and inspecting
the molten metal coming from the furnace, a suitable lining is chosen. A person
enters the furnace through a two part door. He then applies the sand lining which
contains silica, graphite, and moisture. The sand lining is rammed by using a
pneumatic rammer. The bottom of the cupola is also lined using the sand and fire
clay bricks with some coke. The top of the cupola usually contains caps to prevent
the heat from escaping and preventing rain from entering the cupola. There are
provisions for the flue gases to escape.
3.3.2 MELTING
There are two hot blast cupola furnace used in the permanent mount foundry
division. Only one of the cupola is used in a day for melting the metal. The other

20. 12
cupola furnace is checked, and maintenance work is done. Initially the furnace is
filled with layers of coke and ignited with torches. When the coke is ignited, air is
introduced to the coke bed through ports in the sides called tuyeres. When the coke
is very hot, solid pieces of metal are charged into the furnace through an opening
in the top. The metal is alternated with additional layers of fresh coke. Limestone
is added to act as a flux. As the heat rises within the stack the metal is melted. It
drips down through the coke bed to collect in a pool at the bottom, just above the
bottom doors. During the melting process a thermodynamic reaction takes place
between the fuel and the blast air. The carbon in the coke combines with the
oxygen in the air to form carbon monoxide. The carbon monoxide further burns to
form carbon dioxide. Some of the carbon is picked up by the falling droplets of
molten metal which raises the carbon content of the iron. The molten metal which
drips collects at the bottom of the furnace.
Using a siphon, lined with terawool or glasswool to prevent heat loss is used
to bring out the molten metal. Limestone powder is added at this point to regulate
the sulfur content. Steel scrap is also added directly to reduce the amount of silicon
in the molt. Slag (CaOSiO3) formed due to the reaction of calcium oxide (CaO)
with silicon (Si) floats at the top and is removed similarly. Formation of CaO is
due to heating of CaCO3.

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Rough Chemical composition:
CHEMICAL PERCENTAGE
Total carbon 3.55 – 3.65
Silicon 2.35 – 2.65
Carbon equivalent 4.35 – 4.47
Phosphorous 0.4 – 0.45
Manganese 0.4 – 0.5
Sulfur 0.06 – 0.08
Titanium 0.005 – 0.01
3.3.3 CHARGING
Charging materials used are ferrosilicates, ferromanganese,
ferrophosphorous and rarely ferrotitanium. Charging is done in regular intervals
with proper calculations for the amount of weight of charge material to be added.
Charging can be done from 200 grams to 800 kilograms depending on the need.
Charging is a simultaneous process. It runs parallel to analyzing the chemical
composition of the molten metal coming out of the furnace. It can be said as a
corrective action for small deviations in the molten metal coming out of the
furnace.

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3.3.4 RECUPERATOR
A recuperator is a special purpose counter-flowenergy recoveryheat
exchanger positioned within the supply and exhaust air streams of an air handling
system, or in the exhaust gases of an industrial process, in order to recover the
waste heat. Cold air at about 30 degree Celsius exchanges heat from hot blast 500
degree Celsius air. By doing so, the hot air is recirculated into the cupola for
ignition and burning purpose.
3.3.5 FLUE GASES
The flue gas formed is mainly Carbon monoxide (CO). It is a poisonous gas
and hence the top area of the furnace is restricted. Carbon on reaction with oxygen
gives carbon dioxide and carbon monoxide.
3.4 HOT METAL RESERVOIR
Molten metal is taken out from the cupola by providing gates in the sand
lining. The molten metal is stored in a hot metal reservoir, usually abbreviated as
HMR. The molten metal is at temperatures of 1300-1500 degree Celsius. Due to
heat loses, the HMR stores molten metal at lower temperatures of 1000-1100
degree Celsius. The HMR is also made up of sand lined stain less steel. Depending

23. 15
on which cupola is used, the HMR operator changes side. Both side of the HMR
contains a wheel to tilt it. The HMR stores up to 2.5tonnes of molten metal.
3.5 POURING
Pouring of the molten metal from the HMR is done manually by an operator.
He rotates a wheel which tilts the HMR and pours the molten metal into a ladle.
The ladle is also made of sand lined stain less steel. A person known as bull ladle
carries the molten metal to the carousels. Usually, 3 – 4 and at times 5 bull ladle
operators work depending on the frequency of molten metal requirement.
3.6 DIE CAST
There are 7 carousels each containing 12 unique water cooled dies. Each die
contains from 1 to a maximum of 16 patterns. It varies depending on the size of the
casting required. The die is also made up of grey iron.
Given below is the general flow of process:
Cupola HMR Bull ladle Pouring
Acetylene
flame
Soot
formation
(parting
agent)
20 - 25
seconds
Knockout

24. 16
The molten metal from the bull ladle is transferred to a local ladle at each
carousel. A dedicated person pours metal into the die as it closes pneumatically.
One half of the die remains stationary while the other moves with the help of
compressed air.
The revolution period of each carousel vary depending on the number of
pattern in each die and the volume of molten metal consumed. The time period
varies from 4 to 7 ½ minutes.To describe the cycle, let us begin with opening of
the die, and formation of acetylene carbon soot on the die. The dies are opened and
passed through an acetylene burner arrangement. This burner coats the dies with a
layer of soot. The importance of this layer is that, since both the die and the casting
are of the same material, the die will melt when exposed to elevated casting
temperature. The layer of soot acts as a thermal barrier. This also helps in
preheating the dies. Less carbon soot leads to shrinkage of the casting, while
excess leads to lap. Correct level of soot is ensured by a person as soon as it comes
out of the burner chamber. The person has access to various brushes. He finely
scrubs off excess soot formed and spreads the formed soot evenly all over the die.
At this stage, the die closes and a person pours the molten metal till it rises
and appears over the riser. The die remains closed for about 20 – 25 seconds before
it opens again. Rapid cooling occurs and partial gray iron appearance is obtained.

25. 17
A person now with the help of a crow bar knocks out the casing from the dies on a
metal conveyor. The conveyor runs slowly, which aids in cooling. The end of the
conveyor is a large steel container. The castings fall on the container. The
containers are changed if it becomes full. If there are defects obtained which are
identified visually by the operator, they are immediately separated. 12 castings are
selected and inspected in regular intervals for defects.
If improper rise of molten metal is observed, a person with the help of a
blower, blows compressed air over the dies before it enters the burner. This helps
to clean the die from residues from the previous operation cycle. At times, a hand
grinder tool is used to grind away the residual cast stuck on the die. The operators
at any time, can stop the rotation with dedicated controls. The valves used are
solenoid actuated valves.
3.7 HEAT TREATMENT
There are a variety of heat treatment processes like annealing, carburizing,
quenching, normalizing, precipitation hardening, case hardening, tempering etc.
We focus mainly on annealing and normalizing as per customer requirements.

26. 18
3.7.1 ANNEALING
Annealing is a heat treatment process whereby a metal is heated to a specific
temperature, in our case up to 850 degree Celsius and then allowed to cool slowly.
There are 70 trolleys which moves once in 4 minutes, which adds up to about 5
hours in total.This softens the metal which means it can be cut and shaped more
easily. It also helps obtain a more homogenous crystal microstructure. It also helps
relieve internal residue stresses.
3.7.2 NORMALIZING
Normalizing is similar to annealing but the cooling is rather more controlled
and slow in air. Normalizing usually takes longer, about 8 hours compared to the 5
hour annealing process.
3.8 SURFACE TREATMENT
Surface treatment may refer to polishing or smoothening the top surface of
the metal for aesthetic and anti-corrosiveness. Major surface treatment process are
done by subcontractors but preliminary shot blasting is done here.

27. 19
3.8.1 SHOT BLASTING
Shot blasting is done in almost every industry. Shot blasting involves
impinging of very high velocity steel balls of small diameter on the metal from
almost every direction for certain period of time. The time period varies from 20
minutes to 40 minutes depending on the size of the cast.
3.8.2 FETTLING
The complete process of cleaning the casting is called fettling. It involves
the removal of cores, gates, runners, risers and chipping of any unnecessary fin
projections on the surface of the casting. There are various fettling processes which
are not being discussed in detail here as they are carried out by the sub-contractors.
3.9 INSPECTION
There are dedicated inspection units in the factory but there is a local
inspection unit inside PMF. This is referred to as onsite inspection. The onsite
inspection may be a dedicated inspection area or may be inculcated within the
process.

28. 20
3.9.1 ON SITE
The molten metal from the cupola is inspected every 15 minutes. The molt is
poured in to a suyash sand made frustum shaped cup which contains a lining of
tungsten and tellurium. This sends an electrical signal to the inspection room
nearby. The panels in the room displays the amount of carbon, carbon equivalent
and silicon. Deviations in values are corrected immediately by changing the
charging quantity or by adding limestone or by adding scrap material.
3.9.2 OFF SITE
Wet energy samples are done 2 times a day. Spectrometer test is done every
hour to check the various constituents. Visual inspection is done thoroughly to
detect defects. The main off site inspection involves Magnetic penetration
inspection (MPI).
3.9.2.1 MAGNETIC PENETRATION INSPECTION
Magnetic penetration inspection is a testing method in which the casting is
dipped into a rust protective oil like Protech castor oil. Then the cast is electrically
magnetized and placed below a UV lamp. If there are cracks inside the casting, on
magnetization it forms more number of poles and hence the UV light highlights the

29. 21
difference of oil pattern formed. Then the casting is demagnetized and sent for
dispatch. Furthermore, painting or plating may be done.
3.9.3 LABORATORY
In the laboratory, brinell hardness testing, microstructure observation by
laser spectroscopy, tensile testing and torsion testing, carbon testing etc are done
and reported.
3.10 MAINTENANCE
The maintenance team takes care of any problem occurring inside the PMF
shop. The maintenance team has stock of critical components which are necessary
for the production. In case of a failure, they change the component immediately.
Maintenance or change of a component is done when,
1. Complaints are made
2. Out of experience, i.e a component which is expected to breakdown is
changed beforehand.

30. 22
Maintenance can be broadly classified as
1. Corrective action: In the event of a failure, corrective actions are taken. For
example, when the pneumatic system of the die fails, the troubleshooting is
done to detect the area of failure and is rectified accordingly.
2. Preventive action: By experience, a good workman will be able to detect the
possibility of a failure. These kinds of diagnosis and steps taken to prevent is
known as preventive action.
3. Time based maintenance: Certain machines fail after a certain period of time
due to continuous operation. The maintenance work is scheduled in advance
and a date sheet is prepared.
There is a schedule stating when a maintenance activity has to be performed. To
quote one, the main blower (1 and 2) for the die casting unit, the recubertor,
cooling air and hot metal reservoir blower are greased and mounted once in a week
and evaluated for faults. The cooling water is checked on daily basis. The conveyor
systems are checked at the end of the days shift. Spare parts for important
mechanisms are available on demand.

31. 23
3.10.1 WET SCRUBBER
The flue gases produced from the cupola furnace is to be treated before
letting into the atmosphere. The gases are passed through series of columns to
break into simpler compounds and later passed through water to make it harmless.
As a result, pH value of the water rises, this water is reused. The pH value has to
be monitored and pH booster INDION 1150 is administered to maintain the pH
value in between 5.5 – 6.5.
3.11 PMF VS AUTOMATED PROCESS
 Tensile strength of casting is 12N/mm2
approximately which makes it easy
for machining.
 In case of a discrepancy, the die setting can be changed immediately but the
same cannot be done for an automated process. (DISA & KW).
 Cost per cast is less compared to induction furnace.
 Easy to weld.
 Lesser solidification shrinkage
 Silicon promotes corrosion resistance and good fluidity to molten form.

32. 24
 Very good damping capacity leading to withstand high pressure and helps
absorb energy. This is due to graphite content which acts as self-lubricants in
the micro structure.
 Tool life is not affected adversely.

33. 25
CHAPTER 4
NEW PRODUCT TESTING
4.1 INTRODUCTION
New product testing is a department in which the new products are tested in
detail before sending it for bulk manufacturing. The new product testing focuses
mainly on dimensional and metallurgical aspects. The flow chart given below
highlights the process of new product development.
Fig 4.1
Process chart of NPD
Feasibility check / Recheck
Plan and define a program
Product design and development
Process and product validation
Bulk production

34. 26
The new product testing (NPT) is divided into three categories.
1. Initial sample inspection (ISI)
2. Standards
3. 3D laser test and CMM analysis
4.2 INITIAL SAMPLE INSPECTION ROOM
The initial sample room (ISIR) contains about 3000 fixtures and gauges to
hold different types of casting on the measuring table. It may be a marking fixture
or a clamping fixture. A casting is checked dimensionally here. If the dimensions
are within the tolerance limits, they are marked OK. Otherwise a PMR is
generated. PMR is expanded as pattern modification report. In the PMR, the details
regarding each and every deviation and the possible reason for the cause is
highlighted and sent to the PND department.
4.3 STANDARDS
The standards room is where all the measurement and metrological
equipment are stored. Major equipment provider is INSIZE, who provides vernier
calipers, height gauges, v blocks, sine bars, spirit level etc. The equipment are
calibrated as per a calibration calendar. The calibration for equipment are mostly

35. 27
done once in 6 months or depending on the wear of the instrument. A calibration
frequency card is given to the user which indicates the date of previous calibration
to the date of next calibration. The units used are metric units as per ISO
regulations.
4.4 3D TEST AND CMM ANALYSIS
3D laser testing is done for casted components to obtain the complete profile
of the equipment. The equipment is imported and is highly useful. Manufacturer
support is given for calibration of foreign equipment. The casting is scanned with
the help of VX element software. The 3D scanner uses GeoMagic Qualify for
dimensioning and GeoMagic studio for obtaining the diagram of the casted
component. This process is called reverse engineering as instead of verifying the
casing with the diagram, a diagram is drawn from the casting. 3D scanning takes
about 15 minutes – 30 minutes for a casting depending on its size.
CMM expanded as coordinate measuring machine is an old method of
analysis of components. The castings are held on the measuring table using fixtures
and magnetic chucks etc. The software used here is Metris Solution‟s CAMIO 6.3,
now CAMIO 7 is available. With the help of the software, the object is fed to the
CMM, its location etc. Now the critical faces of the casting are checked using the

36. 28
PLP, plane line and point method. The CMM has a ruby tipped stylus which is
either of 6mm diameter or 4mm diameter. The selection of diameter of the stylus
depends on the size of the casting and the accuracy needed. The stylus fits on the
probe head magnetically. The probe head and the stylus are of opposite polarity to
ensure maximum attraction between them. Furthermore; The CMM can support
upto 725kg of casting on the table.

37. 29
CHAPTER 5
CORE SHOP
5.1 INTRODUCTION
Core making is similar to a casting process, but in this case, the casting is
made of sand. The core is generally made up of
i. Raw silica sand, 50% new, 50% recycled sand
ii. Binders
a. Actuator 0.6% - Phenolic formaldehyde (l)
b. Resin 0.65% - Phenolic reagent (l)
c. Catalyst 0.15% – Amine (l) → Amine (g)
The core shop has two main types of core making,
i. Cold box
ii. Core shell
950 tonnes of cores are produced monthly.

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5.2 COLD BOX
In this process, a sand bunker is set at ground level into which new sand is
poured in. From the sand bunker, sand is transferred to a sand hopper located at the
top of the mixer. In level with the mixer, there are two containers each containing a
resin and an actuator. Particular proportion of the sand, actuator, and resin are sent
to the mixer. From the mixer, by using an automated trolley, the sand is sent to the
available two machines. Here, with the help of compressed air, the sand is shot at 6
bar pressure inside the die. After shooting the sand, amine gas at temperature of
100 to 105 degree Celsius is passed through the pattern which solidifies the sand.
The bed movement is hydraulic whereas the movement of the dies is pneumatic.
The purpose of having two machines is to manufacture different cores. The
machine used is made by SPAN, Pune. The control machine used for cold box,
inlet and mixing are by SIMENS. COMPACX machine is available, which is
similar to the cold box machine, but in this there are two sets of dies on each side.
They are shot alternatively which increases production yield.
5.2.1 PROCESS PARAMETERS
In cold box, since there is no high temperature application between the dies,
the main process parameter is the pressure at which the sand is shot. If the pressure

39. 31
is too high, sand particles are concentrated at the bottom compared to the top,
which leads to variable properties across the core.
American foundry sand (AFS) number tells us about the grain size. Greater
the AFS number, lesser will the grain size. The cost of greater AFS numbered
sands are higher compared to the lower numbered sands, which limits the usage of
the latter. These sands are generally resin coated.
5.3 CORE SHELL
Core shell is different when compared to cold box. The main difference is
that core shell operates horizontally whereas cold box operates vertically. The core
shell uses ready mixed sand. The sand is shot when the dies are closed.
Temperature ranging from 200 to 400 degree Celsius will be applied across the
dies by using a heating unit. The heating unit consists of heating rods which passes
through the dies.
Core shell makes uses of thermal reclaim sand. That is, sand is reused.

40. 32
The advantages of using thermal reclaim sand is that it provides greater
strength compared to new sand, lesser blow holes are formed, and lesser casting
defects are obtained.
5.3.1 PROCESS PARAMETERS
In the case of core shell, the main criteria is the AFS number, the
temperature at which the dies are maintained and the pressure of shoot. The resin
percentage should not be too high, it is recommended that the resin percentage
Shell core sand
rejected
Rejected sand
collected
Treated with resins
Heat treatment 500
- 700 degree Celsius
Passed through a
roller for separation

41. 33
should be less than 2.3%. The reason behind this is that the resin when exposed to
high temperature will form blow holes, as gases are liberated
The time for which the dies remain closed is from 80 -100 seconds. This
influences the quality of the core obtained. Too high temperature weakens the sand
shell layer. Too low temperature doesn‟t give enough strength to the core. The
upper and lower dies are maintained at different temperature.
Shell thickness plays a major role; the desired value of shell thickness
is 6 – 7 mm. If the shell thickness is very less, it tends to break easily.
5.4 SANDS USED
i. Mangalore minerals private limited (AFS 80 – 90)
ii. ADVAN India limited
iii. NOVA Thermosys, NOVA regular (AFS 50 – 55)
iv. NOVA Thermosys, NOVA turbo (AFS 60 – 65)
v. RECOSAN, Hyderabad, (for small and complicated cores).
5.5 COMPONENTS WHICH REQUIRE A CORE
i. Bearing housing
ii. Brake housing

42. 34
iii. Caliper housing
iv. Torque plates etc
5.6 PAINTING
After the cores are made, some of them are painted. The main reason behind
applying a paint coating is to prevent the sand from coming in contact with the
metal when metal at very high temperature comes into contact. If there is no layer
of pain applied, the sand may fuse along with the metal leading to defects. There
are three different types of paint used.
i. Aluminum silicate base Rheotec 471
ii. Graphite base Rheotec 204p
iii. Zircon base Rheotec 310
Paints may be mixed in different proportions with one another. Water is used
for mixing.
5.7 CORE DEFECTS
i. Scaling: Residual sand in core shell process sticks on to the die during
next injection, there is a hallow formed on core. This is not an issue as
extra metal is formed.

43. 35
ii. Scoring: Excess volume of core due to defects in pattern. This cannot be
rectified as there are hallows formed in the cast.
iii. Air pocket: Air is trapped inside the core which makes it very weak.
Small forces will make the core to develop cracks.
5.8 CORE ASSEMBLY
Core assembly is done by simple processes like nailing, bolts, drills,
screws, and glue. Generally, glue is avoided as it easily melts at high
temperature.
5.9 QUALITY INSPECTION / FIRST STOP INSPECTION
First stop inspection contains simple inspection steps like hardness
testing and dimensional verification by using a vernier caliper. For cold box,
scratch hardness is tested. The desired range is 60 – 80 BHN. For core shell,
the shell thickness is checked. The shell thickness should be in the range of 6
– 7 mm.

44. 36
CHAPTER 6
PROJECTS AND UTILITIES
6.1 INTRODUCTION
The projects and utilities department supplies the required utilities for the
factory. The term utilities may refer to the set of services provided by these
organizations consumed by the employees of the company. These include
electricity, natural gas, acetylene gas, water for drinking, soft water, filter water
and demineralized water etc..
Maintenance work throughout the factory is also concentrated upon, tool
room maintenance, energy management system which focuses on efficient use of
energy, backup power system; PLC check for sand foundry is also done.
6.2 PROJECTS
The term projects may refer to making modifications to existing plant
operations for improvement, or rectifying a flow. Also, it may also relate to
erecting a unit from scratch. Sand foundry plant was opened in Oman, Dubai. A
numerous number of modifications have been done to existing units. Listing out
the number of projects goes beyond the scope of this report.

45. 37
6.3 UTILITIES
6.3.1 POWER SUPPLY
The factory uses power generated from a 8MW wind powered plant in
Tirunelveli and buys the rest from TNEB. The total consumption of unit 1 and 2
amounts to 12 million units per month but out of that, 10 million units is recovered.
The remaining 2 million units is paid for. There is 5 power based slots now, there
restrictions on the power consumptions have been lifted allowing the factory to
function at full operation throughout the day.
Utilities
Power supply
Compressed air
Water
Telephone
Safe work
atmosphere

46. 38
110 kVA input supply is stepped down to 11 kV by a 11 grid oil cooled
transformer. This power is given to dedicated transformers for each induction
furnace. This transformer steps down voltage from 11 kV to 440 V. It may vary as
per requirement.
6.3.1.1 BACKUP POWER
A 16 cylinder Cumins, Detroit diesel engine is used to generate 625 kV.
There is also a 1500 kV generator. These two generators run simultaneously. To
match the load output, a synchronizing unit is used to give a constant output of 300
A. The diesel consumption may be from 125 L/hr to 475 L/hr depending on the
load. The generators are maintained by annual maintenance contract, AMC.
6.3.2 COMPRESSED AIR
Compressed air is required for most of the operations. Most of the machines
require compressed air at different pressure for operation. Some machines use both
hydraulic and pneumatic systems. The capacity of the compressors is specified in
cubic feet per minute. Sand foundry 1 and 2 is supplied with a 1000 cubic feet per
minute screw compressor. 800 cubic feet per minute compressor is also available
for auxiliary support. A variable flow displacement single stage 350 cubic feet per
minute is available. The compressor outlet varies from 6 – 7 bar, 50 degree

47. 39
Celsius. Unloading occurs when the pressure reaches 7.5 bar. If the pressure drops
below 6 bar, the VFD starts. The depression in oil pressure Dp is set at
approximately 0.13 bar. Oil filter elements are used to prevent the oil from
disturbing the operation of the screws. The element outlet is about 99 degree
Celsius.
6.3.3 WATER
Water is one of the most essential components for survival, as well as for
industrial processes. The utilization of water is critical, as wastage has to be
avoided. The water is reused by water treatment operations.
There are two ground water tanks, each of capacity 235 kL, with a depth of 8
feet. There are two overhead tanks at a height of 80 feet, which stores 120 kL in
the case of filter water and 40 kL in the case of soft water. Filter water is used for
domestic purpose, soft water is critical for cooling purposes, if there exists
dissolved salts in the water used for cooling, it will corrode the furnace walls. The
soft water is of the pH range 6.8 – 7.5. Total dissolved salts, TDS content is less
than or equal to 10 ppm. Distilled water is prepared from cation anion exchanger
bed, by passing through activated carbon sieve. HCl and NaOH regenerator tanks

48. 40
are fixed for regeneration of the carbon sieve. Then it is passed to a cooling tower
through a cooling panel.
6.3.4 TELEPHONE AND MOBILE SERVICES
Telephone lines are laid and maintained. Intercom service is available within
the factory. Each department can be contacted with a dedicated number. A
Vodafone booster tower is in range to support wireless communication and to
enable transfer of data packets. Calling and billing software is used to create bills.
Software designed network, SDN is provided by BSNL. Maintenance of these
services is also undertaken by projects and utilities.
6.4 CTR FIRE PROTECTOR SYSTEM
The CTR fire protection system installed in TVS, BIF is the first ever to be
installed in the TVS group. It can be installed both indoors and outdoors. The fire
protector is installed outdoor but the control panels are installed indoor. The fire
protection system contains nitrogen tanks which store liquid nitrogen. The CTR
system has pipes passing to the inside of the transformer. The system has
complicated electronics involved. In case of a possible fire, the CTR triggers the
liquid nitrogen to enter the transformer oil tank which causes the oil to freeze
preventing the fire. This is really safe but with a false alarm, the whole transformer

49. 41
arrangement has to be changed leading to loss in time and production. The
possibility of a false alarm is very less.

50. 42
CHAPTER 7
ISO 14001 – EMS - IMS
7.1 INTRODUCTION
ISO 14000 is a family of standards related to environmental management
that exists to help organizations (a) minimize how their operations (processes, etc.)
negatively affect the environment (i.e., cause adverse changes to air, water, or
land); (b) comply with applicable laws, regulations, and other environmentally
oriented requirements, and (c) continually improve in the above.
ISO 14000 is similar to ISO 9000 quality management in that both pertain to
the process of how a product is produced, rather than to the product itself. As with
ISO 9000, certification is performed by third-party organizations rather than being
awarded by ISO directly. The ISO 19011 audit standard applies when auditing for
both 9000 and 14000 compliance at once.
The requirements of ISO 14001 are an integral part of the European Union„s
Eco-Management and Audit Scheme (EMAS). EMAS„s structure and material
requirements are more demanding, mainly concerning performance improvement,
legal compliance, and reporting duties.

51. 43
7.2 BASIC PRINCIPLE
These are based on the well-known Plan-Do-Check-Act cycle. It start from
planning, and take any direction.
Fig 7.1
ISO 14001 basic principle
7.2.1 PLAN
Prior to implementing ISO 14001, an initial review or gap analysis of the
organization‟s processes and products is recommended, to assist in identifying all
elements of the current operation and, if possible, future operations that may
interact with the environment termed "environmental aspects". Environmental
Plan
Do
Check
Act

52. 44
aspects can include both direct, such as those used during manufacturing, and
indirect, such as raw materials. This review assists the organization in establishing
their environmental objectives, goals, and targets, which should ideally be
measurable; helps with the development of control and management procedures
and processes; and serves to highlight any relevant legal requirement, which can
then be built into the policy.
7.2.2 DO
During this stage, the organization identifies the resources required and
works out those members of the organization responsible for the EMS‟
implementation and control. This includes establishing procedures and processes,
although only one documented procedure is specified related to operational
control. Other procedures are required to foster better management control over
elements such as documentation control, emergency preparedness and response,
and the education of employees, to ensure that they can competently implement the
necessary processes and record results. Communication and participation across all
levels of the organization, especially top management, is a vital part of the
implementation phase, with the effectiveness of the EMS being dependent on
active involvement from all employees.

53. 45
7.2.3 CHECK
During the 'check' stage, performance is monitored and periodically
measured to ensure that the organization‟s environmental targets and objectives are
being met. In addition, internal audits are conducted at planned intervals to
ascertain whether the EMS meets the user's expectations and whether the processes
and procedures are being adequately maintained and monitored.
7.2.4 ACT
After the checking stage, a management review is conducted to ensure that
the objectives of the EMS are being met, the extent to which they are being met,
and that communications are being appropriately managed; and to evaluate
changing circumstances, such as legal requirements, in order to make
recommendations for further improvement of the system. These recommendations
are incorporated through continual improvement: plans are renewed or new plans
are made, and the EMS moves forward.

54. 46
7.3 INTEGRATED MANAGEMENT SYSTEM
The integrated management system (IMS) combines all components of
business into one system for better management. Quality, Environmental, and
Safety management systems are often combined and managed as an IMS.
Fig 7.1
Integrated management system
IMS
Product
Environment
Health
Quality

55. 47
CHAPTER 8
STORES
8.1 INTRODUCTION
The stores is where the raw materials, consumables, spares and service
related materials are piled up. With the help of a SAP, structure application
program, the necessary data are managed.
8.1.1 RAW MATERIALS
Raw materials include bentonite, coal dust, pig iron, ferrolites, coal, steel
scrap, new sand etc. The raw materials are always kept in stock. When required by
the department, as per production requirements the store supplies the correct
amount of raw materials. If the raw materials are required more in quantity, the
respective department makes a request and collects the materials.
8.1.2 CONSUMABLES
Consumables are goods that are fast moving, used up, wasted or forms a part
of the manufacturing process. Consumables include coolant oil, hydraulic oil, filter
element, belts, m seal, glues, tapes, etc.

56. 48
8.1.3 SPARES
Spare parts of critical components are always kept in the store. In the case of
a component failure, the spare is used. When the spare is used, restock of the
spares is done. This ensures that the production does not stop.
8.2 STORAGE
Storage is done on the FIFO, first in first out principle. The materials which
are most frequently asked for are kept in the front and the least used materials are
stacked at the end.
8.3 PROCEDURE
When a new material has to enter the factory, gate entry is generated and the
material reaches the central lab. The central lab inspects the materials and readies
an inspection report. If the materials don‟t match the requirements, a request is sent
to the supplier demanding for a change. If the materials pass the quality check,
they are unloaded and sent to the store. Then a good received note is sent to the
sender. Perpetual verification of raw materials is done to check the accuracy of the
materials. Once in 6 months, a 100% raw material physical stock verification is
done. In case the stock has to be disposed, it is done through a tender with Murray

57. 49
and Co., Chennai. During the day 1, inspection of the materials is done. During the
day 2, the tender is verified and passed. The day 3 is when the bidding happens and
the stock is sold to the maximum bid. Storage of hazardous materials follow the
pollution control protocol. The inventory management procedure talks about
positive recall. For urgent production, any of the listed material may be released
without inspection or verification. These materials are recorded in the positive
recall register for later reference. The castings produced from these raw materials
are inspected and are either accepted or rejected. This increases the possibility of
having an accepted casting rather than not having gone for production due to delay
in inspection of raw materials.

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CHAPTER 9
QUALITY ASSURANCE
9.1 INTRODUCTION
Quality assurance (QA) is a way of preventing mistakes or defects in
manufactured products and avoiding problems when delivering solutions or
services to customers; which ISO 9000 defines as "part of quality management
focused on providing confidence that quality requirements will be fulfilled.” It is
the systematic measurement, comparison with a standard, monitoring of processes
and an associated feedback loop that confers error prevention. This can be
contrasted with quality control, which is focused on process output.
9.2 HISTORY
The standard initially followed at all companies was ISO 9001. ISO 9001
will give the organization the quality systems that will provide the foundation to
better customer satisfaction, staff motivation, and continual improvement. But over
the years many other institutions like schools, hospitals etc. started getting the ISO
9001 standard which eventually reduced the value of this certificate. Now
companies like Ford, GM and DC in the US formed a new standard QS 9000 in
addition to the ISO 9001. This standard was introduced in 1994. All suppliers to

59. 51
the US were needed to implement this system. Following this companies like
BMW, Audi, and Rolls Royce in Germany introduced a standard called VDA
which was to be followed by all suppliers to Germany. Similarly Renault in France
introduced AVSQ standard and ANFIA standard was introduced in Italy. This lead
to a lot of confusion and it was not possible to get certified by all these standards.
So all the major companies joined hands and formed a group called Automotive
Industries Action Group (AIAG). This group merged all the common factors of the
various standards and some additions were also done and a new standard was
formed called the ISO/ TS 16949. This was specific only to the automobile
industries and is being followed till date. It was first released in 1999 followed by a
2nd
release in 2002. The third and current release was in 2009. The main purpose of
quality assurance is to ensure these two standards are followed. Some other
standards which were followed are HSE 18001 and ISO 14001.
9.3 ISO/TS 16949
ISO/TS 16949 applies to the design/development, production and, when
relevant, installation and servicing of automotive-related products. The aim of the
standard is to improve the system and process quality to increase customer
satisfaction, to identify problems and risks in the production process and supply
chain, to eliminate their causes and to examine and take corrective and preventive
measures for their effectiveness.

60. 52
Clauses followed in TS 16949 are as follows:
1-3: Introduction and preface.
4: Quality Management System (general requirements, control of documents and
records)
5: Responsibility of the management.
6: Management of resources.
7: Product Realization.
8: Measurement, Analysis, and Improvement.
9.4 QUALITY MAINTENANCE
The following steps are followed in order to maintain the quality.
1. MRM- Management review meeting.
In this step a presentation is done to the top management by the shop floor
employees on how to improve or modify the quality assurance system. This
is done once every 3 months.
2. Internal audit
In this step, an inter-departmental audit takes place within the company. This
is also done once every 3 months.

61. 53
3. Process and product audit
In this step an assessment of the final product is done against the
requirements of the design record. This is done once every month.
4. Certification Process
In this step a Beuro Veritas Certification audit is done. This happens once
every three years. But a surveillance audit is done during the 2nd year and in
the 3rd
year recertification is done.
Fig 9.1
Hierarchy of company manual
Level 1 and 2 are maintained at the QA. The remaining two are maintained at each
department.
LEVEL-1: Company
mission,policy,vision
LEVEL-2: Procedure
manual for all units
LEVEL-3: Departmental
work instruction manual
LEVEL-4: Company
records

62. 54
CHAPTER 10
A, C, D & E LINE
10.1 INTRODUCTION
The A, C & D line is a sand foundry plant with three different lines. The
three lines are units purchased from DISA. DISA develops and manufactures a
complete range of metal casting production solutions for the ferrous and non-
ferrous foundry industries. A long-standing tradition of innovation, reliability and
commitment to providing its customers with competitive business value results in
DISA today enjoying the trust and loyalty of leading foundries all over the world.
10.2 PROCESS FLOW
The process flow is similar for the DISA lines. It works like a cycle. The raw
materials are stored in respective hoppers above the ground level. The raw material
is transferred to a weighing hopper where the required amount of sand and
additives are weighed. The charging is done by a separate unit in the case of A
line and D line but manually in the case of C line. The bas chemistry is confirmed.
The metal is transferred to the holder, and magnesium treatment is done. With the
DISAMATIC MOULDING M/c, the sand moulding is prepared by a sand shooting

63. 55
arrangement via a sand supply unit (SSU). The swing plate and the ram plate
makes the mould.

64. 56
Fig 10.1
DISA basic layout

65. 57
If the casting contains hallow part, a core masking unit sets the core inside
the mould. Within 7 – 9 minutes, the magnesium treated metal has to be poured. So
the metal is poured into the mould with a steam inoculation unit. The moulds are
transferred via an automatic mould conveyor (AMC) to the pouring unit. From
here with the help of the synchronized belt conveyor (SBC), the sand mould and
the casting reaches a vibrating conveyor. This leads to the DISA cooling drum. The
DISA cooling drum is where the sand and the casting gets separated to an extent.
The sand and the casting are rotated inside and are also cooled with water nozzles
spraying water near the inlet region. The casting moves forward along with the
sand. As the sand moves along with the casting, it provides friction for the
movement of the casting. On reaching the exit of the drum, the sand is sent out via
holes to sand return belt conveyor. Here there are over belt magnetic separators
(OBMS) to remove the small amount of casting particles like runner and riser
chips, the metal stuck on the sand etc. The sand is returned to the return sand
hopper. A sand multi controller checks the moisture content of the sand. If lesser
than required, the return sand is sprayed with water. If more than required is
present, the sand is rejected. The castings enter the online shot blasting unit. The
shot blasting unit may contain up to 6 impellers rotating at high speeds. Derisering
operation is done manually, casting, runner and riser are separated. Trimming,

66. 58
finishing and inspection are done. Then the final product is sent to the warehouse
for dispatch.
10.3 PRODUCTION SYSTEM
Fig 10.2
Sand foundry, Production system

67. 59
The production system in sand foundry is similar to the one for PMF. On
receiving of the order from the customer, the feasibility check etc are done. Design
and drawings of the moulding are done. The pattern for the die is designed and it is
machined in the PND. The core shop makes the required cores if cored item is
ordered. The pattern is screwed with aluminium runners and risers or with wood
for the initial moulds. M seal is used to make gates and finish the runner and risers.
The DISA moulding machine is fed with the required settings and the pattern on
ram plate, pattern on swing plate, and the core mask are fixed. Now pouring is
done and the remaining procedure is similar to what has been explained above.
There are dust collecting units and approximately 4 – 5 fume extractor for each
line.
10.4 RAW MATERIALS AND ADDITIVES
The main materials include
i. New sand
ii. Return sand
iii. Bentonite
iv. Coal dust

68. 60
10.4.1 SAND
Sand is the main raw material in the sand foundry. The properties of the sand
directly affects the quality of the casting. The sand is purchased from Mangalore,
Godur. The sea shore sand is taken, small particles are removed, and sand is
washed thoroughly and is sieved to get uniform shape. The structure of the sand is
very important. If there are very few micro pores, then the gases cannot escape
leading to cracks. If the sand is very porous, the cake breaks. Correct balance
between porosity and strength is required. New sand is used up to 5% only. The
remaining 95% is the return sand.
10.4.2 BENTONITE
Bentonite is an absorbent aluminium phyllosilicate, impure clay consisting
mostly of montmorillonite. There are different types of bentonite, each named after
the respective dominant element, such as potassium (K), sodium (Na), calcium
(Ca), and aluminium (Al). Experts debate a number of nomenclatorial problems
with the classification of bentonite clays. Bentonite usually forms from weathering
of volcanic ash, most often in the presence of water. However, the term bentonite,
as well as a similar clay called tonstein, has been used to describe clay beds of
uncertain origin. For industrial purposes, two main classes of bentonite exist:

69. 61
sodium and calcium bentonite. In stratigraphy and tephrochronology, completely
devitrified (weathered volcanic glass) ash-fall beds are commonly referred to as K-
bentonites when the dominant clay species is illite. Other common clay species that
are sometimes dominant, are montmorillonite and kaolinite. Kaolinite-dominated
clays are commonly referred to as tonsteins and are typically associated with coal.
The bentonite used for foundry process is (Na) and (Ca) activated bentonite.
Bentonite added is up to 2%.
10.4.3 COAL DUST
Coal dust is a fine powdered form of coal, which is created by the crushing,
grinding, or pulverizing of coal. Because of the brittle nature of coal, coal dust can
be created during mining, transportation, or by mechanically handling coal. Dust
extractors are provided to remove the dust produced when handling coal dust. The
coal dust added is very less. It amounts to a maximum of 1%.
Material Percentage added
Sand return 96.61%
New sand 1.18%
Bentonite 1.82%
Coal dust 0.37%
The above given composition is just a rough example. It does not refer to any particular process.

70. 62
10.5 SUPPLY MECHANISM
The raw materials, i.e the new sand and return sand are weighed and sent to
a mixer. The mixer contains a blender and a mixer with individual motors. The
mixer motor makes the cylinder rotate parallel to its axis. The blender motor makes
the blender rotate along a concentric path with a smaller radius and a higher radial
velocity, thus blending the mixture. With the help of a bond injection system,
additives are added to the mixer. The sand is supplied with a sand supplying unit
(SSU). It is a belt conveyor mechanism.
10.5.1 SAND MULTI CONTROLLER (SMC)
The sand multi controller is a small device attached to the mixer cylinder.
Each time the sand is sent to the mixer, a small quantity of sand is taken, rammed
and checked for the correct level of moisture with an electrode. If the moisture is
found to be lesser than required, with the help of a sprayed inside the mixer, water
is sprayed. If the moisture is more than the required amount, the sand is rejected.
This excess moisture is taken care of in the cooling drum.

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10.6 DISAMATIC MOULD MACHINE
The DISA DMM is where the cake is formed. To make one sand mould, the
moulding machine carries out a cycle consisting of six operations.
i. Operation 1: Filling the moulding chamber
 The moulding chamber is closed
 There is sufficient sand in the sand hopper
 The sand valve is closed
The sand shot value opens and compressed air from the air receiver blows
sand down into the moulding chamber. After the sand shot, the hopper is vented
through the exhaust valve.
ii. Operation 2: Squeezing the mould
Hydraulic fluid is led to the squeeze and swing plate cylinders so that
 The swing plate piston moves backward, puling the swing plate
against the moulding chamber, and keeps it in this position

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 The squeeze piston moves forward and pushes the squeeze plate into
the moulding chamber until the preset squeeze pressure of 12 – 15
kp/cm2
is reached.
iii. Operation 3: Stripping off the swing plate
The swing plate is vibrated so that it is stripped form the mould. At the same
time hydraulic fluid enters the annular area of the swing plate cylinder so
that the piston moves forward. As a result, the swing plate is stripped off the
mould and swings up to horizontal position. When the piston moves
forward, the fluid in the cylinder area is emptied into the accumulator. The
swing plate impression of the mould is blown off while the swing plate
swings up. The sand valve opens and the sand hopper starts filling. The
valve remains open until the sand level in the hopper is satisfied.
iv. Operation 4: Mould close-up and mould string transport
Fluid is led into the annular area of the accumulator. This makes the piston
move forward forcing the fluid from the accumulator into the cylinder area
of the squeeze cylinder. The fluid drives the squeeze piston forward so that
the squeeze plate pushes the mould out of the moulding chamber. The speed
is reduced just before the mould closes up with the mould string on the

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AMC. After close-up the squeeze plate continues its forward movement,
now in synchronism with the AMC. Together they convey the mould string
forward over a distance corresponding to the pitch of one mould.
v. Operation 5: Stripping off the squeeze plate
The squeeze plate is vibrated. At the same time fluid is led into the annular
area of the squeeze cylinder. This makes the squeeze piston move backward
so that the squeeze plate is pulled away from the mould and quickly returns
to its starting position in the moulding chamber. The piston moves
backwards forcing the fluid from the cylinder area of the squeeze cylinder
into the accumulator. The staring position of the squeeze plate is adjustable
so that it is possible to change thickness of the moulds.
vi. Operation 6: Closing the moulding chamber
Fluid is led into the annular area of the accumulator. This makes the piston
move forward forcing the fluid into the cylinder area of the swing plate
cylinder. As a result the swing plate piston is forced backward pulling the
swing plate down into vertical position so that it closes the moulding
chamber. When the swing plate swings down, the pattern plate impression of

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the mould is blown off and, if in-chamber spray is selected, the pattern plates
are sprayed with parting fluid. The next cycle can begin.
The core setting also has 6 operations which are similar to this 6 operation.
The core setting operation is done in the first 3 operations of the DMM.
10.7 MELTING AND POURING
Melting of metal is done by induction furnaces. The induction furnace used
are channel type induction furnaces. Pouring is done with the help of a pouring
bed. The bed moves in two axis. It is controlled hydraulically as well as
pneumatically. A steam inoculation unit is provided at the end of the pouring
nozzle. The pouring nozzle is acted by a graphite rod. A comparison of capacities
between the different lines are given below;
Parameter A & C line D line
Melting furnace capacity 6 tonne
2 x 4 tonne
6 tonne
Holding furnace capacity 12.5 tonne
20 tonne
60 tonne
Pouring tun dish capacity A – 1 tonne, C –
800Kg
1.2 tonne
Inlet ladle (Melting furnace –
holding furnace) capacity
5 tonne 5 tonne
Outlet ladle (Holding furnace –
pouring tun dish) capacity
0.7 tonne 0.7 tonne
Metal grade Grey iron, SG iron,
compacted iron
SG iron

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Capacity PMF
Hot metal reservoir (HMR) 2.5 tonne
Bull ladle 200kg
Pouring ladle 20kg
Metal grade Grey iron
10.7.1 CHARGING
Charging of the furnaces are done by
i) Own foundry return
ii) Steel scrap
iii)Pig iron
iv) Borings
v) Additives like carburiser, carbokast, Zirseed, ultraseed, Carbulux etc.
10.8 MAGNESIUM TREATMENT
Magnesium treatment of the metal is done to obtain SG iron. The
transformation of micro structure from grey iron to SG iron is very critical. Correct
amount of LAMAG alloy, with and without rare earth alloy of composition from
0.4% - 1.2% RE and covering steel is taken and fed into the empty outlet ladle. On
receiving metal from the holding furnace from another outlet ladle, the reaction
takes place. This metal has to be casted before 7 – 9 minutes or the structure
returns back to grey iron. The main alloy used for magnesium treatment is

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FeSiMg. To prevent the magnesium gases from escaping, a glasswool cover is
placed over the ladle. During pouring of the metal, fume extractor sucks away the
fumes produced.
10.9 SAND LAB
There are various tests done at the lab to determine the properties of the
sand. Some of these tests include determination of compressive strength, spalling
strength, wet tensile strength, amount of volatile matter, active clay percentage,
moisture content, compatibility test, permeability check and loss on ignition etc. In
case the quality of the sand is not as per requirement, it is rejected.
Spectrometer tests are also done. Upto 28 elements can be found with the
help of this spectrometer. The metal is casted into a small coin shape, grinded and
inspected under the spectrometer.
X ray inspection is done to check for internal shrinkage and internal cracks.
10.10 PROCESS CONTROL
The process control takes care of maintenance work of all the machines. It
ensures proper ratio of mix of sand, coal dust, bentonite and fines. The pouring
temperature has to be from 1390 degree Celsius to 1410 degree Celsius. The

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temperature for Mg treatment is from 1440 degree Celsius to 1510 degree Celsius.
If these temperatures are not maintained, the metal is returned to the furnace. The
temperature of the metal inside the pouring tun dish is obtained by the 13% BMD
tip. The Mg treatment temperature is obtained by using the Suyash cup. Visual
inspection is also done to detect visual defects. Critical dimensions are checked
using callipers and dial gauges.
10.11 E LINE
10.11.1 INTRODUCTION
The E line is also one among the DISA line. The main difference between
the E line and the other SF lines is that the E line DISA DMM is capable of
making sand cakes of the size 850x600. The machine used is DISA DMM 240C
which is the most advanced machine available in the factory. Also SAM-60 is used
instead of SAM-40 which is greater in capacity.
10.11.2 MELTING
The melting is done with the help of 3 melting furnace of capacity 5 tonnes
of which only 2 is in operation at a time. The ladles used for transferring the metal
from the melting furnace to the holding furnace is 7.5 tonnes and the ladle used for

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moving the metal from the holding furnace to the pouring tun dish is 1.7 tonnes.
The ladles are relined after 500 heats. Each heat refer to a single transfer of metal.
In a day, about 235 heats are done.
In terms of raw materials, the raw materials are foundry returns based on
SG-Sn, Sg-Cu, SiMo GJV, borings and steel scraps of 12x12x12 cubes.
10.11.3 HOLDING FURNACE
The holding furnace is of capacity 22 tonnes. There are 2 holding furnaces.
10.11.4 TUN DISH AND POURING
The tun dish is of capacity 3 tonnes, 1.3 – 1.7 tonnes in operation. It can
make up to 320 moulds per hour. Approximately 200 tonnes per day of metal is
poured and about 5000 moulds are done in a day.
10.12 MISCELLANEOUS PROCESS
After online shot blasting, hydraulic pressing to remove sharp edges,
trimming press to obtain accurate dimensions and robotic removal of fins are done.
This casting is then sent for fettling processes where finishing is done.

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CHAPTER 11
SAND FOUNDRY INSPECTION
11.1 INTRODUCTION
SF inspection is the stage at which all castings produced at all the lines are
inspected for the presence of defects. Different materials like SG iron, Grey iron
are inspected separately. After this step if the castings are found to be OK, they are
sent to the warehouse.
11.2 PROCESSES INVOLVED
The various checking or inspection processes are highlighted below.
11.2.1 ONLINE SHOT BLASTING
This step involves the removal of sand particles from the castings once it comes
from the conveyers. The runners and risers are cut using a wedge cutter and the
castings go into the online shot blasting machine via conveyers. Here small steel
shots are made to impact the casting and all the sand particles get removed from it.

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11.2.2 FETTLING
All processes involving the removal of fins, burrs and other surface irregularities
present in a casting come under this operation. This operation is done both
manually and automatically using robots. The manual methods involved are
1. Air grinding –Very small normally inaccessible areas are ground using this
method.
2. Cut off wheel – Small normally inaccessible areas are ground using this
method. The wheel has small thickness.
3. Wheel work – In this method normal sized wheels are used to grind easily
accessible areas on the castings.
11.2.3 OFFLINE SHOT BLASTING
This step involves the smooth surface finishing of the castings. The BMD shot
blasting machine is loaded with the castings. The door for loading is operated
pneumatically. Steel shots of size S-330 are allowed to strike the castings to
produce a smooth surface finish. There are 3 types of offline shot blasting
machines. They are Belt type, Hangar type, In operator type. There is a low shots
indicator light which will turn ON when the shots are low. This is due to low
current leading to low impeller speed. Shots circulation is less at this stage. It

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automatically increases when the current increases leading to increase in the
impeller speed. Housings are shot blasted in 15 min while rusted housings take
about 20 min. Bearings usually take about 25 min.
11.2.4 VISUAL INSPECTION
In this step a 100% visual inspection is done on the castings. All defects visible to
the naked eye are found and the rejected castings are sent to scrap. Some of those
defects are Porosities, Pinholes, Sand fusions, Core intrusions, Core crack etc.
11.2.5 OIL DIPPING
In this step the castings which are OK are allowed to pass through oil called Protec
oil. This oil is very expensive and unlike other oils it is hydrophilic. Water can be
mixed with this oil and used without fear of rusting of the castings. The castings
are then allowed to pass through a heater to dry them.
11.3 CUSTOMER SPECIFIC REQUIREMENTS
Customer Specific Requirements is a set of requirements provided by each
company which specifies what sort of oil they need the castings to be dipped into
and what types of testing should be done on the castings to inspect them.

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11.4 NON DESTRUCTIVE TESTING
Non Destructive Testing is the set of processes which are used to test the castings
for defects without any damage to them. Many processes like Ultrasonic testing,
Endoscopic testing, Dimensional inspection, Magnetic particle inspection and
Noise Vibration Harshness test(NVH), Dye Penetrate test, X ray testing come
under this process.
11.4.1 NOISE VIBRATION HARSHNESS TEST
In this test an electrical impact hammer is used to hit the casting at one point on the
casting and the sound is received by a mic which finds any defect in the casting
using software in the computer. The software used here is DirectSoft5. The
accepted level of bandwidth is ±3%. For example if the received value is 1000, the
upper and lower limits are 1030 and 970.
11.4.2 ULTRASONIC TESTING
In this test an oil grease coating is applied on the casting. A probe is placed on this
greased area and any defect in the casting is found out from the variation in the
graph of a device called Ultrasonic machine. A standard work piece is taken with
holes at different lengths made on its side. A Gate is placed at the required length

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and the device is calibrated according to that work piece. The castings are then
tested using the probe and the castings are approved if the reading is more than the
gate reading.
11.4.3 MAGNETIC PARTICLE INSPECTION
In this test cracks present in the castings can be found out. The castings are dipped
in oil and a current is passed through it making it magnetized. This casting is then
seen under ultraviolet light and any cracks if present can be found out. The castings
which do not have any cracks are sent through a magnetic flux device which
demagnetizes the casting. About 50 microns length of defects can be found.
11.4.4 ENDOSCOPIC TESTING
In this test an endoscope is used to find defects inside small places where the
defects cannot be seen by the naked eye. There are 2 types of endoscopes used.
The bigger endoscope is used to check for defects at the outer sides of the casting
whereas the little endoscope is used to penetrate smaller spaces where the bigger
one cannot penetrate.

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11.4.5 DIMENSIONAL INSPECTION
In this inspection different dimensions of the casting are compared with a standard
casting dimension using different devices like vernier height gauge, vernier caliper,
dial gauge etc...

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CHAPTER 12
KÜNKEL WAGNER LINE
12.1 INTRODUCTION
KW line is the oldest line available in TVS BIF. This line is different from
the DISA lines as KW is based on horizontal moulding. It consists of cope and
drag. Magnesium treatment is also done here similar to the DISA lines. The Mg
treatment is done in the ladle directly instead of using another ladle to bring the
metal in the case of A&C line. The yield is about 60% compared to the DISAs
40%. The production rate is comparatively slow, with approximately 100 moulds
per hour whereas the DISAs make 300 moulds per hour.
12.2 PROCESS
The process behind the KW line is based on the conventional horizontal
moulding. The cope and drag box are shot with sand along with the pattern and
rammed. This box is then sent to the melting line. The melting consists of three 3
tonne induction furnace. Only two of which is in operation at a time. Alternatively,
one acts as a holding furnace at 300kW power while the other acts as melting
furnace at 3000kW power. Compared to DISA, the production is only for 12 hours

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a day instead of the 24 hour production. Pouring is done with 2 pouring units
which can move along the line. This is similar to the DISA machines but the only
difference is in the capacities and the movement of the bed.
12.3 GRADE
The grades of metal produced here are Grey iron, SG iron, CG and GJV
SiMo. Complicated shapes and structures can be machined here at the KW line.

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CHAPTER 13
WAREHOUSE
13.1 INTRODUCTION
In general, the products which have been inspected, which have been
inspected and found okay after arrival from machining, painting from the sub-
contractors are ready for invoice printing. This is then packed using wooden
pallets, covered properly and sent to the warehouse for dispatch along with the
invoice. For any product to leave the company, an invoice is required.
13.2 CAPTIVE TRANSFER
For the final products to go within the company, like for example from
Brakes India foundry division to Brakes India which is located in the same city,
there is no need for any payment. The transfer can be made just with the invoice
printing.
13.3 EXCISE DUTY
For the finished products to be sent to companies within Tamil Nadu, excise
duty along with value added tax (VAT) has to be paid. For products to be sold

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outside Tamil Nadu, central sales tax along with VAT and excise duty has to be
paid.
13.4 HANDLING
The raw materials are carefully handled to prevent wastage, most of the raw
materials are being imported from outside India. Which involves a lot of cost. Duty
for materials incoming from outside India and duty for materials going outside the
factory are adjusted and brought to about 20% difference, which makes it cost
efficient. Billing is done inside the company when sending the goods. Accounting
is done at the customer end on receiving the goods. The pallets used are made of
reinforced wood. After the castings are delivered, they are emptied and washed. If
the customer sends back the foldable empty pallets within 6 months, the company
receives it without the need to pay any duty. This promotes the reuse of the pallets.
The records are maintained using a SAP program.
In case of any problem with delivery, the warehouse near the customer holds
a safety stock of 2 weeks. This is emptied in case of emergency and also this is
managed efficiently without having to hold the safety stock for long. Delay in
delivering is viewed seriously by the customer and is fined per hour depending on
the company.

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END OF REPORT