Small presentation as asked by an interviewer on -
- Why FRP?
- Describe the flow from generating an offer to certificate using Visio
- Resource Planning
- Description of Sand Moulding
Conventional processes- Explosive forming, electro-hydraulic
forming, magnetic pulse forming – Principles and process
parameters- Advantages- Limitations and Applications
Conventional processes- Explosive forming, electro-hydraulic
forming, magnetic pulse forming – Principles and process
parameters- Advantages- Limitations and Applications
It is a near net shape process in which casting and forging is done in single step.
It is Referred by many names such as “squeeze casting” , “pressure infiltration”, “liquid metal forging”, “extrusion casting”, “liquid pressing'', “pressure crystallization”.
its sheet metal working for non ferrous metal and alloy. its show all process like punching, deep drawing, etc which can employ in sheet metal working.its show how process done in short details.
Mumbai University
Mechanical engineering
SEM III
Material Technology
Module 1.4
Strain Hardening:
Definition importance of strain hardening, Dislocation theory of strain hardening, Effect of strain hardening on engineering behaviour of materials, Recrystallization Annealing: stages of recrystallization annealing and factors affecting it
Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained.
Strengthening Mechanisms of Metals and alloysDEVINDA MAHASEN
In this presentation, I have explained 4 types of strengthening processes of metals.
Grain-size reduction
Solid-solution alloying
Strain hardening (work hardening or cold working)
Annealing of deformed metals
It is a near net shape process in which casting and forging is done in single step.
It is Referred by many names such as “squeeze casting” , “pressure infiltration”, “liquid metal forging”, “extrusion casting”, “liquid pressing'', “pressure crystallization”.
its sheet metal working for non ferrous metal and alloy. its show all process like punching, deep drawing, etc which can employ in sheet metal working.its show how process done in short details.
Mumbai University
Mechanical engineering
SEM III
Material Technology
Module 1.4
Strain Hardening:
Definition importance of strain hardening, Dislocation theory of strain hardening, Effect of strain hardening on engineering behaviour of materials, Recrystallization Annealing: stages of recrystallization annealing and factors affecting it
Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained.
Strengthening Mechanisms of Metals and alloysDEVINDA MAHASEN
In this presentation, I have explained 4 types of strengthening processes of metals.
Grain-size reduction
Solid-solution alloying
Strain hardening (work hardening or cold working)
Annealing of deformed metals
A Design and Analysis of Two Plate Injection Mould Tool For Wi-Fi RouterTherm...EditorJST
This A Wi-Fi router is a device that performs the function of a wireless access point, it is used to provide
access to the internet or a private computer. It is the hardware device that provide basic infrastructure for a home
or small office network.Proposed to make a single impression semi-automatic family mould to design top and
bottom cover for Wi-Fi router to make it more aesthetic, to reduce material cost, better heat dissipation, and to
reduce the tooling cost, to make the product more competitive in the market.It is proposed select the suitable plastic
material, to modify the existing plastic product design and to develop a suitable two plate family mould of one
impression each using SIEMENS NX software. It is also proposed to make detailing of mould parts and its assembly
for manufacturing using SIEMENS NX software. The analysis was done in AUTODESK MOLDFLOW. The mould
cost, raw material cost and processing cost per component are to be estimated to find the cost per component and to
compare it with the existing component part.
Exploring Career Paths in Cybersecurity for Technical CommunicatorsBen Woelk, CISSP, CPTC
Brief overview of career options in cybersecurity for technical communicators. Includes discussion of my career path, certification options, NICE and NIST resources.
This comprehensive program covers essential aspects of performance marketing, growth strategies, and tactics, such as search engine optimization (SEO), pay-per-click (PPC) advertising, content marketing, social media marketing, and more
New Explore Careers and College Majors 2024.pdfDr. Mary Askew
Explore Careers and College Majors is a new online, interactive, self-guided career, major and college planning system.
The career system works on all devices!
For more Information, go to https://bit.ly/3SW5w8W
2. Reasons for the Indian foundry industry to use FRP
Workflow from creating an offer to generating a certificate
Resource planning
Sand molding – Steps & Components
Points to be covered
3. According to the recent World Census of Castings by Modern Castings(USA), India
Ranks as 2nd largest casting producer in the world.
Casting production
worldwide in 2017 (in million
metric tons)
Status of the foundry industry in India
4. There are approx 5000 units in the country
that are engaged in various types of metal
castings.
Major foundry clusters are located in Batala,
Jalandhar, Ludhiana, Agra, Pune, Kolhapur,
Sholapur, Rajkot, Mumbai, Ahmadabad,
Belgaum, Coimbatore, Chennai, Hyderabad,
Howrah, Kolkata, Indore, Chennai, Faridabad,
Gurugram e.t.c.
90% of the units are classified as
MSMEs.
Foundry units in India
5. The Indian foundry industry manufacturers metal cast components for
applications in Automobiles, Railways, Power, Agriculture, Machine Tools, Valves
& Compressors, Electrical Equipments, Diesel Engines etc.
Sector-wise share of foundry
6. 10%
90%
Foundry Industry
Others
Internal
86%
Export
14%
Government’s Revenue – Mar19’ Cumulative share in Foundry Industry’s revenue
Foundry industry account’s for approx 10% of the total government revenue of India
as in 2019 that scales to cumulative value of 1584.85 INR Billion.
Out of the cumulative share, 14% i.e. 219.84 INR Billion accounts for the export part.
Share of foundry industry in India’s revenue
7. FRP will help in overcoming the current problems like . .
Order delays
Miscommunications, material tracking issue, WIP tracking issue, etc.
Coordination issue and quality issue between customers and suppliers.
Cost secrecy, material and energy inefficiency and process insecurity in real time.
Current issues faced by foundry industry
8. Structured resource plan for every foundry stage.
Saves time, material, money and increases productivity by providing bottleneck
management.
Reduces miscommunication due to less paper work for daily report and audit
preparation.
Single point of information – the same data for everyone on daily basis.
Standardized reports with tamper proof data provides correct information and
enables us to make decision at the right time based on valid data.
Collaborative work in a client server infrastructure with live updates in the systems.
No buck pass as work in real time is being recorded 24*7.
Online trace of each and every process in industry 24*7.
Production status, advance actions and alertness in real time helps in achieving
target on time.
Reasons to use FRP
10. Summarizes the level of resources needed to complete a project.
Schematic tree structure of all the prerequisite of 3M – Man, Machine and Material.
Provides a base for planning, costing and scheduling.
Includes hidden charges such as freight charges, job work charges, etc.
Resource Plan
12. FRP provides a unique way to plan resources in a layered form, starting
from purchasing to dispatching.
Every layer of the resource plan is a plan on its own, where each layer
describes different master data.
Resource Plan’s Schematic
Resource planning in FRP
13. Sand casting or sand molding, is a metal casting process characterized by using sand
as the mold material.
Over 60% of the metal castings are produced via sand casting process.
Benefits – Inexpensive, reusability, withstand extremely high temperatures.
Two sets of castings
(Bronze and Aluminum) from
the sand mold
Sand Molding
14. Steps involved in sand molding prior to the cooling of casting –
Mold – Making:
First process is to create the mold for the casting. Sand mold is formed by packing
sand into each half of the mold. The sand is packed around the pattern, which is a
replica of the external shape of the casting. When the pattern is removed, the
cavity that will form the casting remains. Any internal features of the casting that
cannot be formed by the pattern are formed by separate cores which are made of
sand prior to the formation of the mold.
Cope & Drag (top and
bottom halves of a sand
mold), with cores in
place on the drag
Sand Molding - Steps
15. Pouring:
The molten metal is maintained at a set temperature in a furnace. After the mold
has been clamped, the molten metal can be ladled from its holding container in
the furnace and poured into the mold. The pouring can be performed manually or
by an automated machine. Enough molten metal must be poured to fill the entire
cavity and all channels in the mold. The filling time is very short in order to
prevent early solidification of any one part of the metal.
Molten metal in Sand Mold
Status of the Foundry Industry in India
16. Clamping :
Once the mold has been made, it must be prepared for the molten metal to be
poured. The surface of the mold cavity is first lubricated to facilitate the removal of
the casting. Then, the cores are positioned and the mold halves are closed and
securely clamped together. It is essential that the mold halves remain securely
closed to prevent the loss of any material.
A closed Sand Mold
Sand Molding - Steps
17. Pattern:
A skilled pattern maker builds the pattern of the object to be produced, using wood, metal
or plastic such as expanded polystyrene.
Pattern is usually slightly larger than the finished product and the difference is known as
contraction allowance.
Patterns have core prints that create registers within the molds into which sand cores are
placed.
Sand:
To create the mold, silica sand (SiO2) is used which is mixed with a type of binder to help
maintain the shape of the mold cavity.
Unique types of sand molds – Greensand mold, Skin-dried mold, Dry Sand mold, No-
bake mold.
Sand Molding - Components
18. Tools:
A multi-part molding box, the top and bottom halves of which are known
respectively as the cope and drag, is prepared to receive the pattern.
Cores are required to create the castings with holes and can be made up of
refractory materials.
Chaplets are the supports for the cores that are needed particularly when cores
are very big.
Chills are the metal plates that are placed to control the solidification structure of
the metal.
Sand Molding - Components