This report summarizes an internship conducted by two students at Atlas Engineering Limited, a foundry company in Karachi, Pakistan. The goal of the internship project was to analyze and address shrinkage issues in the bore of a Drive plate casting. The report provides background on the company, describes the casting and melting processes used to produce the Drive plate, and identifies shrinkage as a common defect that causes rejection. It presents the objective to conduct root cause analysis and implement countermeasures to prevent/control shrinkage in the Drive plate bore.
Five Steps to Optimize Casting and Eliminate DefectsDesign World
Traditionally, engineers had a hard time predicting defects with their cast designs. With simulation, engineers can now predict defects from porosity and cold shots to air pockets.
Watch the webinar: http://www.designworldonline.com/optimize-casting-and-eliminate-defects/#_
Sand casting is ideal for an array of products, ranging from gears and pulleys on the small side to pump components and transmission cases on the large end. Learn more about Avalon Precision Metalsmiths' sand casting capabilities.
Metals tend to corrode very fast. To prevent corrosion various methods are used. Once such method is galvanization. Hot Dip Galvanizing is used to prevent machines from corroding. You can read along the document and get more details regarding the process.
A PROJECT REPORT ON
“Eliminating corner gap in sc mould at LD2 SNC”.
During the internship the following research is evaluated and being verified by the authorized TATA steel employee.
A Review on Optimization of the Process Parameters in Friction Stir Welding o...IJAEMSJORNAL
This study is describing a simple and systematic methodology for optimizing the Process parameters of friction stir welding (FSW) of (AA6105 and AA6082) aluminium alloy using Taguchi technique. The main focus of this review paper is to discuss FSW principle, process parameter and mechanical properties. The current study focuses on the friction stir welding of wrought aluminium alloys 6082 and aluminium alloy 6105 that are commonly used in the structural and automotive industries. Apart from this paper FSW process has been done on various aluminium alloys but dissimilar friction stir welding of these two materials are not reported in their research. A systematic study has been performed on the joint properties on the dissimilar welding of the selected materials and their relationships between various parameters.
Five Steps to Optimize Casting and Eliminate DefectsDesign World
Traditionally, engineers had a hard time predicting defects with their cast designs. With simulation, engineers can now predict defects from porosity and cold shots to air pockets.
Watch the webinar: http://www.designworldonline.com/optimize-casting-and-eliminate-defects/#_
Sand casting is ideal for an array of products, ranging from gears and pulleys on the small side to pump components and transmission cases on the large end. Learn more about Avalon Precision Metalsmiths' sand casting capabilities.
Metals tend to corrode very fast. To prevent corrosion various methods are used. Once such method is galvanization. Hot Dip Galvanizing is used to prevent machines from corroding. You can read along the document and get more details regarding the process.
A PROJECT REPORT ON
“Eliminating corner gap in sc mould at LD2 SNC”.
During the internship the following research is evaluated and being verified by the authorized TATA steel employee.
A Review on Optimization of the Process Parameters in Friction Stir Welding o...IJAEMSJORNAL
This study is describing a simple and systematic methodology for optimizing the Process parameters of friction stir welding (FSW) of (AA6105 and AA6082) aluminium alloy using Taguchi technique. The main focus of this review paper is to discuss FSW principle, process parameter and mechanical properties. The current study focuses on the friction stir welding of wrought aluminium alloys 6082 and aluminium alloy 6105 that are commonly used in the structural and automotive industries. Apart from this paper FSW process has been done on various aluminium alloys but dissimilar friction stir welding of these two materials are not reported in their research. A systematic study has been performed on the joint properties on the dissimilar welding of the selected materials and their relationships between various parameters.
Classification of manufacturing processAkhtar Kamal
Classification of manufacturing process...
Process for changing Physical properties of work piece.
Casting process
Primary metal working processes.
Shearing and Forming processes.
Joining processes.
Machining processes.
Surface finishing processes.
Continuous Casting: Get more from your CasterRakesh Niranjan
“Even
the best can be bettered.” It perfectly applies
to Continuous casting. Industry leaders always work on this concept of “there is a better way” and don’t settle for less. One of the
thought processes is how to get more from the investments on continuous casters
by optimization of the operations. This thought process is vital in the current tough
market conditions. Evolution of manufacturing processes through perfect application
of technology provides the
right platform to optimized manufacturing operations.
Avalon Precision Metalsmiths offers off-shore casting services in China for customers seeking high-quality precision metal castings at the most cost-effective price.
High-pressure die casting, sand casting and permanent mold casting are processes Avalon only offers through its casting partners in China. Avalon provides investment casting services at three U.S. production facilities and abroad.
Working with pre-qualified Chinese suppliers, Avalon provides complete turnkey metal casting and total supply chain management services
billet, rod, or tube are continuous cast, defined
as the continuous solidification and withdrawal
of product from an open-ended shaping mold.
Methods include both vertical and horizontal
casting, depending on product size, shape, and
volume. Casting vertically has certain inherent
technical advantages. The symmetry of cooling
promotes a uniform and predictable solidification
growth pattern and uniform axial loading
on the freshly solidified shell as it is withdrawn
from the mold. In tube or hollow section casting,
the vertical process has particular merit.
The disadvantages of vertical casting are
mostly logistic: difficulty in handling long
lengths of section; cut-off can be more difficult
to engineer and control; and it is generally a
semicontinuous operation. Horizontal casting
requires lower capital investment, is compatible
with lower production rates, and is a continuous
operation.
This article briefly reviews the history and
methods of copper alloy continuous casting;
the information is drawn from the very detailed
and extensive coverage of the subject in Ref 1
and the numerous publications of equipment
supply companies such as Rautomead, SMS
Meer, and so on
Steelmaking, Shaping, Treating and Processing, Steel and Steel Products (Fast...Ajjay Kumar Gupta
Steel is one of the most important and widely used products in the world. Currently, the steel industry is undergoing a process of change. As a result of ongoing technical and economic developments, the production and use of electric arc furnace steel is, beneath the steel production in a blast furnace, becoming increasingly important, continuously gaining share of world-wide steel production over the past 30 years.
See more
http://goo.gl/ldGTjh
http://goo.gl/xr564q
http://goo.gl/BPpZ3V
http://www.entrepreneurindia.co/
Tags
Bolt and Nut Manufacturing Technology, Business guidance for steel production industry, Business plan for steel rolling mill, Casting, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot Rolling Mill, Hot rolling mill process, Hot Rolling mill, Hot Rolling of Plate, Sheet and Strip, Hot Seamless Tube Rolling Processes, Hot Strip Mill, How is Steel Produced?, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Iron and Steel making by-Products, Manufacturing of Steel, Manufacturing Process for Steel products, Metal Fasteners Manufacturing, Mill Automation for Pipe and Tubing Production, Modern Rolling Plant, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Production of Welded Pipe, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Rod and Bar Rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling of Flat Products & others, Rolling of Steel, Bars and Rods, Rolling process, Seamless Tubes manufacturing, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel production Business, Starting Steel Mini Mill, Start-up Business Plan for steel products manufacturing, Startup Project for steel making business, Steel and hot rolling Business, Steel and Steel Products, Steel Based Profitable Projects, Steel Based Small Scale Industries Projects, Steel business opportunities, Steel Making, Steel making and Refining, Steel Making Products and Processes, Steel making Projects, Steel making technology, Steel manufacture, Steel mill process, Steel Production, Steel Production Process and Products, Steel Products Business, Steel Products for the Building Trade, Steel products manufacturing process, Steel rerolling mill feasibility start up, Steel rolling Industry in India, Steel rolling machine factory, Steel Rolling Technology, Steelmaking Processes, Steelmaking, Shaping, Treating and Processing, Types of rolling mills, Varnishing and Printing of Packaging Steels
Castings - Aluminum Gravity die casting Processroshnipatel829
"Aluminium die casting processes are hush-hush as Ingot casting or Mould casting.
During the willingly style, head of the line or slight aluminium is appoint
into rolling ore (slab), extrusion alloy (billet) and wire waive ingot which
are as a consequence transformed in semi- and satisfied products... www.alphametalind.com"
STUDIES ON ALUMINIUM-SILICON EUTECTIC ALLOY CASTING AND DESIGN APPROACH OF IT...IAEME Publication
LM-6 alloy, an eutectic alloy of Aluminium and Silicon is widely used in automobile industries and aircraft industries due to its high strength to weight ratio, high wear resistance, corrosion resistance etc. In this project work, to improve the mechanical properties of LM-6 alloy such as tensile strength, hardness and percentage elongation, modification treatment is carried out along with grain refinement, fluxing and degassing. Modification is a treatment of metal in molten condition which leads to the formation of fine grain structure improves the mechanical properties of the metal.
Classification of manufacturing processAkhtar Kamal
Classification of manufacturing process...
Process for changing Physical properties of work piece.
Casting process
Primary metal working processes.
Shearing and Forming processes.
Joining processes.
Machining processes.
Surface finishing processes.
Continuous Casting: Get more from your CasterRakesh Niranjan
“Even
the best can be bettered.” It perfectly applies
to Continuous casting. Industry leaders always work on this concept of “there is a better way” and don’t settle for less. One of the
thought processes is how to get more from the investments on continuous casters
by optimization of the operations. This thought process is vital in the current tough
market conditions. Evolution of manufacturing processes through perfect application
of technology provides the
right platform to optimized manufacturing operations.
Avalon Precision Metalsmiths offers off-shore casting services in China for customers seeking high-quality precision metal castings at the most cost-effective price.
High-pressure die casting, sand casting and permanent mold casting are processes Avalon only offers through its casting partners in China. Avalon provides investment casting services at three U.S. production facilities and abroad.
Working with pre-qualified Chinese suppliers, Avalon provides complete turnkey metal casting and total supply chain management services
billet, rod, or tube are continuous cast, defined
as the continuous solidification and withdrawal
of product from an open-ended shaping mold.
Methods include both vertical and horizontal
casting, depending on product size, shape, and
volume. Casting vertically has certain inherent
technical advantages. The symmetry of cooling
promotes a uniform and predictable solidification
growth pattern and uniform axial loading
on the freshly solidified shell as it is withdrawn
from the mold. In tube or hollow section casting,
the vertical process has particular merit.
The disadvantages of vertical casting are
mostly logistic: difficulty in handling long
lengths of section; cut-off can be more difficult
to engineer and control; and it is generally a
semicontinuous operation. Horizontal casting
requires lower capital investment, is compatible
with lower production rates, and is a continuous
operation.
This article briefly reviews the history and
methods of copper alloy continuous casting;
the information is drawn from the very detailed
and extensive coverage of the subject in Ref 1
and the numerous publications of equipment
supply companies such as Rautomead, SMS
Meer, and so on
Steelmaking, Shaping, Treating and Processing, Steel and Steel Products (Fast...Ajjay Kumar Gupta
Steel is one of the most important and widely used products in the world. Currently, the steel industry is undergoing a process of change. As a result of ongoing technical and economic developments, the production and use of electric arc furnace steel is, beneath the steel production in a blast furnace, becoming increasingly important, continuously gaining share of world-wide steel production over the past 30 years.
See more
http://goo.gl/ldGTjh
http://goo.gl/xr564q
http://goo.gl/BPpZ3V
http://www.entrepreneurindia.co/
Tags
Bolt and Nut Manufacturing Technology, Business guidance for steel production industry, Business plan for steel rolling mill, Casting, Fusion welding processes, Great Opportunity for Startup, Hot rolled steel properties, Hot Rolling Mill, Hot rolling mill process, Hot Rolling mill, Hot Rolling of Plate, Sheet and Strip, Hot Seamless Tube Rolling Processes, Hot Strip Mill, How is Steel Produced?, How to Start a Steel Production Business, How to start a successful steel rolling business, How to start steel mill industry, How to Start Steel rolling Industry in India, How to start steel rolling mill, Iron and Steel making by-Products, Manufacturing of Steel, Manufacturing Process for Steel products, Metal Fasteners Manufacturing, Mill Automation for Pipe and Tubing Production, Modern Rolling Plant, Most Profitable Steel Business Ideas, New small scale ideas in Steel rolling industry, Opportunity Steel Rolling Mill, Plate Mill, Production of Welded Pipe, Profitable small and cottage scale industries, Progress and Prospect of Rolling Technology, Rod and Bar Rolling, Rolling Metalworking, Rolling Mill for Steel Bars, Rolling of Flat Products & others, Rolling of Steel, Bars and Rods, Rolling process, Seamless Tubes manufacturing, Setting up and opening your steel rolling Business, Small scale Commercial steel rolling business, Small Scale Steel rolling Projects, Start a Rolling Mill Industry, Start steel rolling mill in India, Starting a Steel production Business, Starting Steel Mini Mill, Start-up Business Plan for steel products manufacturing, Startup Project for steel making business, Steel and hot rolling Business, Steel and Steel Products, Steel Based Profitable Projects, Steel Based Small Scale Industries Projects, Steel business opportunities, Steel Making, Steel making and Refining, Steel Making Products and Processes, Steel making Projects, Steel making technology, Steel manufacture, Steel mill process, Steel Production, Steel Production Process and Products, Steel Products Business, Steel Products for the Building Trade, Steel products manufacturing process, Steel rerolling mill feasibility start up, Steel rolling Industry in India, Steel rolling machine factory, Steel Rolling Technology, Steelmaking Processes, Steelmaking, Shaping, Treating and Processing, Types of rolling mills, Varnishing and Printing of Packaging Steels
Castings - Aluminum Gravity die casting Processroshnipatel829
"Aluminium die casting processes are hush-hush as Ingot casting or Mould casting.
During the willingly style, head of the line or slight aluminium is appoint
into rolling ore (slab), extrusion alloy (billet) and wire waive ingot which
are as a consequence transformed in semi- and satisfied products... www.alphametalind.com"
STUDIES ON ALUMINIUM-SILICON EUTECTIC ALLOY CASTING AND DESIGN APPROACH OF IT...IAEME Publication
LM-6 alloy, an eutectic alloy of Aluminium and Silicon is widely used in automobile industries and aircraft industries due to its high strength to weight ratio, high wear resistance, corrosion resistance etc. In this project work, to improve the mechanical properties of LM-6 alloy such as tensile strength, hardness and percentage elongation, modification treatment is carried out along with grain refinement, fluxing and degassing. Modification is a treatment of metal in molten condition which leads to the formation of fine grain structure improves the mechanical properties of the metal.
Steelcast limited industrial training reportaman1312
Steelcast limited is an India-based company. The company is engaged in the business of steel casting . Its product include carbon steel , low alloy steel , high alloy steel , hadfield manganese steel , and other grade of wear and abrasion resistant steel casting produced by sand molding and shell moulding process . The Company caters to industries , such as earthmoving equipment manufacturing , heavy electrical equipment manufacturing , mining , minerals processing equipment manufacturers , valve manufacturers and general engineering equipment manufacturers.
seminar presentation for topic engine block with engine parts and casting of blocks and schematic diagram with brief description about different parts and also with moualding process of the different parts
The abrasive particulates on the cutting wheel influence the quality of cut. The surface finish, and the temperature raise during the cutting processes is governed by various parameters such as size of the particulates, its shape, roundness of edges at the particulates and strength of the bond between particulates and resins. The composite parting-off wheel is superior to that of commercial counterparts. A composite parting-off wheel was fabricated using powder metallurgy technique. The composite powders were prepared using an ingeniously designed and developed horizontal axis ball mill. The parting-wheel was able to cut metals bars such as aluminium, copper and mild steel with relative ease. It was found out that the mechanical properties such as compressive strength, hardness and tensile strength was better than conventional abrasive wheels. The cutting ratio was superior to the abrasive wheels and CZT was lower in comparison
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
'Iron seemeth a simple metal but in its nature are many mysteries’. Many, but not all,of these mysteries have been solved over the past three hundred years using the combined skill of the foundryman and the knowledge of the scientist to provide today's design engineer with a family of casting alloys that offer a virtually unique combination of low cost and engineering versatility.
The various combinations of low cost with castability , strength,
Machinability , hardness, wear resistance ,corrosion resistance, thermal conductivity and damping are unequalled among all casting alloys and It makes Cast Iron most widely used metal in engineering purpose .
1. ATLAS ENGINEERING LIMITED
Internship Report
Group members:
Haris Haider (MY-008-T.E)
Abdul Aziz (MY-009-T.E)
NED University of Engineering & Technology
2. Internship Report
1
PREFACE
This report is about the work we have done during our winter internship from 5th
December 2014 to 25th
December 2014 in cast iron foundry of Atlas Engineering Limited. Situated at Landhi, National Highway,
Karachi.
The primary goal of this report is to present the work done regarding our project titled as:
“To conduct root cause analysis and countermeasures to prevent/control shrinkage in bore of Drive
plate CD-70 casting”
The report is based on practical knowledge, assignment and task that we have completed. It also include
company brief introduction.
3. Internship Report
2
AKNOWLEDGEMENT
First of all we are grateful to Almighty Allah for giving us opportunity to work in such a
pleasant environment and get this far in our project despite many problem and hurdles. It
is the indulgence to acknowledge our deep gratitude to management of Atlas Engineering
Limited for its advices and helping us with all knowledge and resources and also
providing whatever we asked for our need.
We are thankful of the staff and workers of Atlas Engineering Limited who fully
supported and cooperated us to increase our foundry knowledge and enhance our skills.
We put forward our special thanks to the following personnel:
Mr. Sikander {Production Manager (Cast iron Product)}
Mr. Qismat Ali {Assistant Manager (Cast iron Foundry)}
Mr. Minhaj {Production Engineer (Cast iron Foundry)}
Mr. M.Siddiqui (Supervisor, Hand moulding section)
4. Internship Report
3
Table of Contents
S.no Contents Page no.
1 About company 4
2 Cast iron 5
3 Theoretically aspect of project 6
4 Introduction 6
5 Casting process 7
6 Effect of composition on properties 9
7 Shrinkage 9
8 causes 10
9 Preventions 10
10 Experimental aspect of project 13
11 Experiment no. 1 13
12 Experiment no.2 14
13 Experiment no.3 15
14 Experiment no.4 16
15 Suggestions & recommendations 17
5. Internship Report
4
About Company
Atlas Engineering Limited:
Atlas Engineering Limited (formerly Allwin Engineering Industries Limited) was established in 1951 as a
partnership firm. It became a private limited company in 1963, and was converted into a public limited
company in July 15, 1966. Shirazi Investment (Private) Limited is its holding Company.
Atlas Engineering is one of the largest and oldest manufacturers of automotive parts and components in
the private sector in Pakistan
Atlas Engineering has state-of-the-art facilities to produce Cast Iron process pig iron and aluminum alloys
through various stages into high precision automotive components and has full access to technical know-
how and back-up of world renowned manufacturers like Honda Foundry, FCC and Shindengen Electric
Company, Japan.
The Company manufactures motorcycle pistons, cylinders, Aluminum Components, radiator assemblies
and radiator cores and a host of fully-machined cast iron parts. Various excellence awards have been
achieved for its quality.
The facilities at Atlas Engineering have been extended and modernized steadily over the last decade,
including CNCs, and semiautomatic machining lines are being added. Further expansion of facilities for
manufacturing piston and allied products are being undertaken. The production facilities are backed by
well-equipped quality assurance system, design and applied research facilities.
Atlas Engineering policy and operations are guided by the management approach of Atlas Group,
Organization development through self-development
6. Internship Report
5
Cast Iron.:
Cast iron is iron or a ferrous alloy which has been heated until it liquefies, and is then poured into a
mould to solidify. It is usually made from pig iron. The alloy constituents affect its color when
fractured: white cast iron has carbide impurities which allow cracks to pass straight through Grey cast
iron has graphite flakes which deflect a passing crack and initiate countless new cracks as the material
breaks.
Gray Cast Iron:
Gray iron, or grey cast iron, is a type of cast iron that has a graphitic microstructure. It is named after the
gray color of the fracture it forms, which is due to the presence of graphite.[1]
It is the most common cast
iron and thA typical chemical composition to obtain a graphitic microstructure is 2.5 to 4.0% carbon and
1 to 3% silicon by weight. Graphite may occupy 6 to 10% of the volume of grey iron. Silicon is important
to making grey iron as opposed to white cast iron, because silicon is a graphite stabilizing element in cast
iron, which means it helps the alloy produce graphite instead of iron carbides; at 3% silicon almost no
carbon is held in chemical combination with the iron. Another factor affecting graphitization is the
solidification rate; the slower the rate, the greater the time for the carbon to diffuse and accumulate into
graphite. A moderate cooling rate forms a more pearlitic matrix, while a fast cooling rate forms a
more ferritic matrix. To achieve a fully ferritic matrix the alloy must be annealed.[1][4]
Rapid cooling
partly or completely suppresses graphitization and leads to the formation of cementite, which is
called white iron.[5]
The presence of graphite flakes makes the Grey Iron easily machinable as they tend
to crack easily across the graphite flakes most widely used cast material based on weight.
Properties of Gray Iron
Graphite morphology and matrix characteristics affect the physical and mechanical properties of gray cast
iron. Large graphite flakes produce good dampening capacity, dimensional stability, resistance to
thermal shock and ease of machining. While on the other hand, small flakes result in higher tensile
strength, high modulus of elasticity, and smooth machined surfaces
Mechanical Properties can also be controlled through heat treatment of the gray cast iron. For example, as
quenched gray cast iron is brittle. If tempering is accomplished after quenching, the strength and
toughness can be improved, but hardness decreases. The tensile strength after tempering can be from 35-
45% greater than the as-cast strength and the toughness can approach the as-cast level
7. Internship Report
6
Theoretically Aspects of project
Introduction:
In current scenario the foundry industry is experiencing tremendous changes because of global
competition. Increasing demands and requirements to be produced in time and at very competitive price.
It is necessary to set new objectives and strategies in order to increase actual competitiveness.
Atlas Engineering Limited uses the Molasses Moulding Process for making mould and also shell mould.
An Economical and less skill requiring process and also this casting produces good surface finish and
excellent mechanical properties. However, along with this casting defects causing rejection before and
after machining operations continue to be a concern for variety of reasons.There are many casting defects
that can occurs in castings i.e “Slag/sand inclusion, Misrun, Blowhole, Extra metals, Miss-matching etc.
One of most important reason which is faced by cast iron foundry of AEL is shrinkage in particular part
“Drive Plate”. This is common problem faced by any of foundry. This kind of defects is non recoverable
and that’s why becoming the most important concern in cast iron foundry.
Main Problem:
Shrinkage in thicker section of the Drive Plate after machining.
Project Objective:
“To conduct root cause analysis and countermeasures to prevent/control shrinkage in bore of Drive plate
CD-70 casting”
8. Internship Report
7
Casting Process:
Molding Process:
Drive plate is casted by sand casting process. In which AEL uses Hand molding method by using silica
sand with a binder of molasses.
Hand Molding Method of Sand Casting
Sand casting production mainly include hand molding and machine molding method. The operation of
hand molding is more simple and flexible, but the production rate is low, so it is suitable for small batch,
amount production.
Hand Molding (Manual Moulding) Methods
1. Whole pattern, two cases molding
When the largest cross section of casting parts is located on the top position, then this position could be
used as the parting surface, and the pattern could be made as a whole part as the following diagram.
The whole pattern is in the sand mold, so it can avoid mismatch of mold cases, and can guarantee the
high dimensional accuracy.
2. Two parts molding
9. Internship Report
8
The patterns could be designed as two separated parts, and could be assembled with stop bolts as
following.
This molding method is simple and has very wide application. However, if the sand mold cases (sand
boxes) could not be fixed accurately, then mismatch will happen, and it will affect the accuracy of
castings. Moreover, the parting line will affect the surface quality too.
Melting Process.
AEL uses Induction furnace for melting and producing gray iron . AEL uses two induction furnaces at a
time which provide mass production requirements.
Induction furnace:
An induction furnace is an electrical furnace in which the heat is applied
by induction heating of metal. The induction furnace was first invented in 1877 in Italy. The first use of
the furnace was in 1927 in Britain. It wasn't until World War II, when the need for aluminum casting
grew significantly, that the induction furnace went into wider usage. In induction heating, a current
passes through a coil that surrounds the piece to be heated. The electric current frequency to be used
depends on the mass of the piece being heated. The induction coil (or induction heads for specific load
shapes) must be water cooled to protect them from overheating themselves. Although induction heating
usually uses less electricity than resistance heating, some of that gain may be lost due to the cost of the
cooling water and the heat that it carries down the drain. Induction heating is easily adapted to heating
only localized areas of each piece and to mass-production methods. Similar application of modern
production design techniques with rapid impingement heating using gas flames has been very successful
in hardening of gear teeth, heating of flat spring for vehicles, and a few other high production
applications.
Capacity of Induction furnace:
1.5 ton
10. Internship Report
9
Raw materials For Drive Plate:
Pig iron,
Steel scrap,
Shop returns, ferroalloys, re-carburizer.
Casting Temperature:
1450 – 1330o
C
Effect of composition on properties:
Carbon: During solidification, Carbon precipitates to Graphite, which offsets shrinkage. Amount
necessary to achieve this: %C + 1/7%Si ≥ 3.9% Also, Carbon contents greater than this amount
decrease fatigue strength.
Silicon: Graphitizing agent. Increasing amount of Silicon also increases amount of Ferrite. Increases
strength and hardness of this Ferrite and reduces impact resistance. Also, provides high temperature
oxidation resistance. For applications of high temperature, such as turbocharger housings, Silicon
contents of between 3.75% and 4.25% are required.
Manganese: Acts as a Pearlite stabilizer and increases strength, but decreases ductility and
machinability.
Nickel: Increases strength by promoting formation of fine Pearlite. Increases hardenibility.
Copper: Used to form Pearlite upon solidification with high strength and good toughness and
machinability.
Molybdenum: Used to stabilize structures at high temperatures
Shrinkage:
Cavity caused by liquid contraction. They are generally very irregular and have rough, dendrite-type
walls. They are usually found in interiors, in the thickness changing elements of the part, or in the inside
of extra-large zones, sometimes in the form of a surface depression in varying sizes.
GENERAL CHARACTERISTICS OF SHRINKAGE
They appear in the form of open cavities on the outside surface of a part, or closed cavities on the inside
of a part. The interior surfaces may be smooth (primary shrinkage) or have a dendritic morphology
(micro-shrinkage or secondary shrinkage). In certain eutectic alloys, primary shrinkages may appear with
dendritic interior surfaces.
11. Internship Report
10
Given that it is a contraction defect, it is normally formed in final solidification zones (the part’s thermal
centres). This defect is formed in final solidification zones, which correspond to the part’s thermal centre.
They may appear in zones with interior angles, often revealed during machining operations, close to
cores, sprues, etc., due to the difficulty of heat evacuation, a phenomenon which slows down the liquid
metal solidification process.
Their occurrence depends on the alloy’s liquid-solid contraction. In the case of graphite casting,
spheroidal is more prone to secondary shrinkage (as far as micro or macro defects are concerned) than
laminar, due to their different solidification patterns.
CAUSES
Technically, shrinkages are produced in the phase in which liquid becomes solid, due to the severe
contraction that the metal has to undergo in process. So the geometrically extra-large zones, as they cool
down at a slower rate than the rest of the part, provide material to the zones that cool faster, generating
dendritic caverns (shrinkages) in the interior. The causes behind the appearance of shrinkages are:
Unsuitably designed part to be cast, as well as inadequate casting methods.
The main cause is the contraction that the metal undergoes between the semi-solid
state and final solidification. The lower the metal’s tendency to contract, the lower
the risk of this defect appearing.
In graphite casting, an expansion is produced due to the formation of graphite at the
heart of the metallic material. This phenomenon can cause swelling inside the
moulds and increase the parts’ volume.
The feeding difficulties that are produced as the solid fraction increases must also be
taken into account: diameter and/or incorrect design of the risers, use of metal entry
points with thin sections, which solidify quickly, incorrectly designed parts
(ISOLATED EXTRA-LARGE SECTIONS), etc.
The use of high casting temperatures (which increase the mould’s instability due to
the intense heat, slowing down the solidification period) or excessively low
temperatures (with a fast solidification of entry points or necks, even in the risers)
Preventions
The preventive action to be taken to stop shrinkages from appearing is as follows:
Suitable and adequate metal composition, inoculation treatment. Efficient feeding of the
part. Use of an appropriate casting temperature.
Modification of the design to obtain more uniform sections of metal. If necessary, use
coolers for the thicker sections. Level out the cooling speed of the extra-large zones by
homogenizing the thicknesses, preventing the generation of extra-large zones. To do so,
you must always design the part to be obtained, endeavoring to ensure that the changes in
sections are progressive, avoiding any abrupt section changes. Prevent the formation of
extra-large sections, or at least limit abrupt section changes, by joining sections. Some
examples of this are shown below.
13. Internship Report
12
Before machining of pattern:
After Machining of pattern: Groove of 1mm
In the pattern’s manufacture, keep the machining ridges constant at a minimum of 5 mm
and up to a maximum of 15 mm. In this way, mortices, holes and, in general, deep
machining or machining in extra-large zones, must always be made on the pattern and
never be left blind to be obtained at a later date in the part that has been cast by
machining.
In this way, in the mortices of extra-large zones on the patterns, coolers will be included
inside the mortices or holes, known as controlled cooling. For this practice to be
implemented, the pattern must first have clearances in these zones to be able to house
the coolers. This is a common practice in iron and steel casting companies, and it is also
recognised in technical/scientific fields.
Diameter =
40 mm
Bore size=
12.5 mm
No Groove
Diameter =42mm
Bore size =
11.5mm
14. Internship Report
13
Experimental Aspect of Project
Experiment no. 1
Objective:
To determine the causes of shrinkage by comparing respecting positions of drive plate.
Principle:
If the shrinkage defect occur at same position of gating system in all moulds then the shrinkage is due to
faulty gating design.
If the shrinkage defect position follows zig zag or irregular position in all mould,then the shrinkage is
considered due to disturbance of metal composition.
Procedure:
We take 4 mold of drive plate for observation.We do casting of these mold and allow them to solidify
slowly.
Observation
Position of
drive plate
Mould 1 Mould 2 Mould 3 Mould 4
1 ok ok ok ok
2 ok shrinkage ok ok
3 ok ok ok ok
4 shrinkage ok Shrinkage shrinkage
5 ok ok ok ok
6 ok Shrinkage ok Shrinkage
1st
Pair 2nd
Pair 3rd
Pair
Rejected Piece/Total Piece 1/8 3/8 2/8
% Rejction 12.5 37.5 25
Result:
The above table shows that the shrinkage is due the metal composition disturbance as well as location of
pattern with respect to gating also play a role.
15. Internship Report
14
Experiment no.2
Objective:
Designing the gating system(modified gating system) that’s supports the well distribution of the melt
with same flow rate, avoiding the turbulence.
Principle:
If the parts are filled with the same flow rate at the same time, it will reduce the tendency of shrinkage.
Procedure:
The parts are arrange in form of circle having center pouring
Observation
No. of Parts 6
Accepted parts 4
Rejected parts 2
% of rejection 33
Result:
2 pieces rejected out of 6 pieces
Reason:
Distance between gate and riser is too far.
Disadvantage:
Pouring in inadequate manner
16. Internship Report
15
Experiment no. 3
Objective:
To determine the effect of pouring Temperature
Principle:
The use of high casting temperatures (which increase the mould’s instability due to the intense heat,
slowing down the solidification period) or excessively low temperatures (with a fast solidification of
entry points or necks, even in the risers)
Procedure:
We take initial 2 moulds and last 2 mould of casting to observing the temperature effect.
Temperature range:
1450-1330o
C (less chance of shrinkage in these range)
Observation
Initial 2 molds at 1460oC Last 2 molds at 1300oC
Nos of parts 12 12
Rejected parts 2 2
% of rejections 16.67 16.67
Results:
Too low and too high temperature can cause shrinkage .
17. Internship Report
16
Experiment no. 4
Objective:
To determine effect of over inoculation.
Procedure:
We take melt from furnace and pour it it into test ladle for study
Observation
Quantity Normal Inoculation High inoculation High
inoculation
100 2.8 kg/ladle 3.0 kg/ladle 3.2kg/ladle
%Rejection 2.0% 8.0% 14%
Result:
High inoculation increase shrinkage
18. Internship Report
17
Experiment no. 5
Objective:
To compare the shrinkage in different gating design system.
Procedure:
We do casting for following gating design.
1.) 2.)
3.) 4.)
Observation:
Quantity Gating Design % Rejection
60 Design no.1 18%
50 Design no.2 (5 parts) 14%
60 Design no.3 16%
60 Design no.4 6%
Result:
Gating design no. 4 having good capability of supporting disturb condition
19. Internship Report
18
Suggestion & Recommendations.
Good Control of composition specially carbon and silicon (can reduce shrinkage drastically)
Use the casting software such as magmasoft to determine the whole casting to solidification
process before practical
Proper inspection of mould
Conclusion:
There is no one factor that contribute in the defect but it is the combine effect of all factors that is given
below.
Gating design
Composition
Temperature
Inoculant & Inoculation
Pouring rate
Molding material & strength
But the gating design plays a major role that can support the factors.