This document summarizes an industrial case study of centrifugal casting conducted at Kapilansh Dhatu Udyog Pvt. Ltd. in Nagpur. It describes the company and its production of cast iron pipes using centrifugal casting. The key processes are explained, including melting metal in cupola furnaces, spinning molten metal in molds, annealing, cleaning, testing and finishing pipes. Problems with raw material composition and cooling systems are discussed along with remedies. The importance of centrifugal casting for symmetrical parts is concluded.

1. INDUSTRIAL CASE STUDY
ON
CENTRIFUGAL CASTING
AT
“KAPILANSH DHATU UDYOG (P) LTD.” NAGPUR
Carried out by
Mr. Rupesh Nawlakhe
(ME11106)
Mr. Naved Khan
(ME11104)
Mr. Akash Khobragade
(ME11070)
Shri. P. S. Pachpor
(Head of Department)
Mr. Ashish Bramhnote
(ME11140)
Mr. Vijay Sewatkar
(ME11089)
Mr. Umesh Joshi
(MED11160)
Under the Guidance of
Shri. S. P. Chincholkar
Shri. N. N. Suraskar/ P.G. Pokley
(ICS Co-ordinator)

2. INTRODUCTION OF INDUSTRY
KAPILANSH DHATU UDYOG PVT. LTD. is pioneer in
manufacturing of centrifugally casted ‘KDUPL’ branded C.I.
pipes.
KAPILANSH is promoted by MOHATA family & managed by
a team of professionals from various fields.
‘KAPILANSH CENTRIFUGAL’ branded C.I. soil pipes &
fitting are used for municipal waste drainage & ventilation as
per 3989 (since 2004).
These pipes are used for water distribution ,oil , chemicals
conveying.
First industry to achieve 80mm pipes of 5500mm length.
BHEL,NTPC includes in the consumers list of this industry.

3. INTRODUCTION TO CASTING PROCESS
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Liquid metal is poured into a mould which contains hollow
cavity of desired shape.
Its allowed to solidify & ejected or broken out of the mould to
get the desired casting.
Used for making cylindrical shapes that’s not feasible by other
process.
Metal molds are more expensive but more dimensionally
stable & durable & used for repetitive production.

4. PROCESS FLOW CHART
CHARGING
MELTING
ANNEALING
DIPPING
CUTTING
SECTION
SPINNING
SCORING
HOT
PRESSURE TESTING
FINISHING
DISPATCH
COOLING TOWER
RAW MATERIALS:- Pig iron, Silicon, coke, limestone.

5. Cupola furnace
There are four cupola furnace in this industry.
FURNACE NO.
HEIGHT (FEET)
DIAMETER
(INCHES)
1
45
42
2
45
33
3
45
33
4
45
42

6. PROCESS FLOW OF KAPILANSH
1)CHARGING (MECHANICAL CHARGERING)
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Cupola furnace consist of vertical, cylindrical steel shell &
lined inside with brick lining.
Bottom of shell is provided with drop bottom door.
As soon as coke bed is ignited uniformly, alternate layer of
pig iron, coke, flux are charged from charging door.
Temperature inside the cupola is 1300˚C.

7. 2) MELTING
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Molten metal is drawn through a opening into ladle.
Slag is collected at bottom & taken out through slag opening.
Temperature of this molten metal falls to about 1200˚C when
it is feed to the spinning machine.
3) SPINNING
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They were having five spinning machine.
Molten metal from furnace is drawn into the spinning m/c.
Permanent mould is rotated at about 1400 rpm.
Molten metal solidify towards the inside mould wall due to
centrifugal force.
Water cooling jackets are provided for cooling of the mould.

8. 4) ANNEALING
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Used to reducing hardness & strength and increasing ductility
& machinability .
In this industry there are two annealing furnace having
horizontal & vertical placed burners.
Annealing Furnace has 3 zones:Heating zone :Temp is upto 9000 C. It removes stress .
Soaking zone :Oil is soaked from pipe.
Cooling zone :Pipes are cooled & it comes out at 1000C

9. 5) SCORING
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Here pipes are cleaned internally.
Excess metal & impurities are removed with the help of
scrubber.
It gives regular internal dimensions.
6) HOT DIPPING
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Pipes are dipped in tar to make them corrosion resistant &
give color.
7) PRESSURE TESTING
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To check quality of pipe manufactured.
Hydraulic testing m/c is used to check pressure limit of pipes
as per their standards.
If it found defective, pipe is rejected.

10. 8) CUTTING
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Pipes are cut as per required dimensions.
Waste pipes are reused in cupola.
9)FINISHING & DISPATCH SECTION
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Here quality & grade is marked as per the thickness of pipe,
its weight, etc.
Company logo & its mark is marked over it.
COOLING SYSTEM
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Water from spinning machine which is at 57˚C is drawn to
cooling chamber where it get cooled to 37˚C.

11. PROBLEMS
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Ignorance towards composition of raw materialsIdeally the composition is
Material
%
Pig iron
91-95.5
Silicon
1-3
Carbon (coke)
3-5.5
Lime stone
0.5
Security problem regarding hot dipping.
Cooling system problem.

12. REMIDIES
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Care must be taken while taking the composition of raw
materials.
Good quality of coal tar or any substitute can be prefered for
hot dipping.
Height of the cooling tower can be increases so that it will
help in cooling of water at faster rate.

13. CONCLUSION
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The importance of centrifugal casting process for producing
the symmetrical parts.
Cylinders and shapes with rotational symmetry are most
commonly cast by this technique.
Thin-walled cylinders are difficult to cast by other means, but
centrifugal casting is particularly suited to them.
It is also applied to the casting of disk and cylindrical shaped
objects such as railway carriage wheels or machine fittings
where the grain, flow, and balance are important to the
durability and utility of the finished product.
We observed and studied many processes for manufacturing
of cast iron pipes such as charging ,melting, spinning,
annealing, scoring, hot dipping, pressure testing, cutting,
finishing, cooling etc.

14. REFERENCES
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http://www.wikipidia.com>cupolafurnaceimages
(date-02-03-2014)