This 3 sentence summary provides the key details about the industrial training report: The report describes Akbar's 4 week industrial training at the foundry shop of Indo Farm Equipment Limited in Baddi, Himachal Pradesh. The training involved learning the various processes used in the foundry shop such as core making, mold making, melting metals, and finishing casted parts. Akbar gained hands-on experience working in the core shop and observing the other processes like molding, melting, pouring, and fettling during his training.

1. INDUSTRIAL TRAINING REPORT
ON
FOUNDRY SHOP
AT
INDO FARM EQUIPMENT LIMITED
BADDI, DISTT. SOLAN
NAME:- AKBARNAME:- AKBAR
ROLL.NO.:- (MAU13UME004)ROLL.NO.:- (MAU13UME004)
COURSE:- B.TECHCOURSE:- B.TECH
BRANCH:- (MECHANICAL ENGINEERING)BRANCH:- (MECHANICAL ENGINEERING)
UNDER THE GUIDANCE OF :- MR. BIDYUT KUMAR PANDAUNDER THE GUIDANCE OF :- MR. BIDYUT KUMAR PANDA
UNIVERSITY :- MAHARAJAAGRASEN UNIVERSITYUNIVERSITY :- MAHARAJAAGRASEN UNIVERSITY
MAHARAJAAGRASEN INSTITUTE OF TECHNOLOGYMAHARAJAAGRASEN INSTITUTE OF TECHNOLOGY
MAHARAJAAGRASEN UNIVERSITY, HIMACHAL PRADESHMAHARAJAAGRASEN UNIVERSITY, HIMACHAL PRADESH
PLOT NO. 6 & 8, ATAL SHIKSHA KUNJ, ATAL NAGAR, VILL- KALUJHANDA, TEHSIL- BADDI,PLOT NO. 6 & 8, ATAL SHIKSHA KUNJ, ATAL NAGAR, VILL- KALUJHANDA, TEHSIL- BADDI,
DISTT-SOLAN (HP) 174 103, HIMACHAL PRADESH, INDIADISTT-SOLAN (HP) 174 103, HIMACHAL PRADESH, INDIA
(Training Period: From 29 June to 29 July)

2. INTRODUCTION OF INDO FARM
 Indo Farm Equipment Limited is an ISO certified company
located in Himachal Pradesh and is into manufacturing of
world-class tractors, cranes, engines, diesel gensets .
 Incorporated in 1994, it is promoted by Mr. R.S. Khadwalia,
who is the Chairman & Managing Director of the company
and has over two decades of experience in manufacturing and
marketing of various engineering products.
Fig. 1 View of Indo Farm

3.  Indo Farm commenced commercial production of tractors in
October 2000, with technology from Ursus, Poland, at its plant
located at Baddi in District Solan, Himachal Pradesh. Spread over
an area of 34 acres, the plant started with the production of a
single model. Within a decade of successful operations Indo Farm
grew to a company having models in the range of 30 HP, 38 HP,
42 HP, 48 HP, 50 HP, 52 HP, 55 HP, 60 HP, 65 HP, 75 HP and 90
HP with many variants.
 Plant spread over an area of 34 acres and additional 5 acres have
been used in our captive grey iron and SG iron Foundry.
 Installed Capacity of 12,000 tractors, 2,400 Cranes, 300 Harvester
Combines, 20,000 Engines & 6,000 Gensets per annum.
 Company has its own Foundry unit commissioned in 2006.
Ensures better product quality

4. FOUNDRY SHOP
 A Foundry is a factory that produces metal casting.
Metal are cast into shapes by melting them into liquid,
pouring the metal in a mould, and removing the mould
material or casting after the metal has solidified as it
cools.
 The most common metals processed are aluminium and
cast iron. However other metals, Such as bronze, brass,
steel, magnesium, and zinc are also used to produce
casting in foundries.
 In this process, parts of desired shapes and sizes can be
formed.

5. FOUNDRY PROCESSES
Fig. 2 Foundry Processes

6. WORKING PROCESSES IN FOUNDRY
The working process is done by following steps:
 Core Making
 Mould making
 Furnace
 Pouring
 Surface cleaning
 Finishing
Core Shop:-A core is a device used in casting and moulding processes to produce
internal cavities and reentrant angles. The core is normally a disposable item
that is destroyed to get it out of the piece. They are most commonly used in
sand casting, but are also used in injection moulding.

7. Mould making:-In the casting process a pattern is made in the shape of the desired
part. Simple designs can be made in a single piece or solid pattern. More complex
designs are made in two parts, called split patterns. A split pattern has a top or
upper section, called a cope, and a bottom or lower section called a drag. Cores are
used to create hollow areas in the mould that would otherwise be impossible to
achieve
Furnace:-Furnaces are used to melt the metal. Furnaces are refractory lined vessels
that contain the material to be melted and provide the energy to melt it.
Pouring:-In a foundry, molten metal is poured into moulds. Pouring can be
accomplished with gravity, or it may be assisted with a vacuum or pressurized gas.
Surface cleaning:-Sand or other moulding media may adhere to the casting. To
remove this surface is cleaned using a blasting process. The blasting media is
selected to develop the colour and reflectance of the cast surface.
Finishing:-The final step in the process usually involves grinding, sanding, or
machining the component in order to achieve the desired dimensional accuracies,
physical shape and surface finish .

8. CORE SHOP
 In my training session in INDO FARM first ten days I worked at
foundry plant in core shop.
 A core is a device used in casting and moulding processes to
produce internal cavities and reentrant angles.
 They are most commonly used in sand casting, but are also used in
injection moulding.
 There are many types of cores available.
 The selection of the correct type of core depends on production
quantity, production rate, required precision, required surface
finish, and the type of metal being used.
 In core shop core are made by machines and manually both ways.
There were two machines for core making one was a cold box
shooter machine and another one was a hot box processing
machine.

9. CORE SHOOTER MACHINE
 Core shooter is a machine used to produce cores of different shapes
required by end users.
 Previously cores are manufactured manually, that means in that
process the sand is rammed manually so that the process was very time
consuming and having demerits such as low strength, low surface
finish etc.
 The cores produced by using this machine may be hardened either by
heating the core box (shell type) or by pouring gases such as amine,
CO2 inside the core box (cold box type). So the hot box or cold box
methods are selected according to application of core.
Fig.3 Rear Transmission Core make by a cold
box core shooter machine

10. WORKING
 Preparation of sand - Initially silica sand is taken and in that 3% of
carbo-phane (Binder) is added by weight, the process of mixing is
carried out in Sand Muller. After that the prepared sand from
Muller is taken out and poured into the sand hopper.
 By switching on the butterfly valve manually the sand from sand
hopper is taken into the sand magazine. Once the sand magazine is
filled with sand, the butterfly valve switched off, in order to avoid
back splashing of sand.
 Now core box of required shape is mounted on work table. After
that the work table moved upward by pneumatic actuator to clamp
the core box against sand magazine.
 Now the sand from sand magazine is shoot in to the core box by
using shooting guns, the number of shoots taken according to the
shape core box size.

11.  Once the shooting of sand is completed, the work table along with
core box is taken downward by pneumatic actuator.
 Now, certain number of holes is made on the core box in order to
fill up the entire core box with CO2 gas. After pouring the CO2
the reaction will takes place and the grains of sand clustered and
core becomes hard.
 Finally core is removed from the core box.

12. MOULDING SHOP
 In the casting process a pattern is made in the shape of
the desired part.
 Simple designs can be made in a single piece or solid
pattern.
 More complex designs are made in two parts, called split
patterns. A split pattern has a top or upper section, called
a cope, and a bottom or lower section called a drag.
 Cores are used to create hollow areas in the mould that
would otherwise be impossible to achieve. Where the
cope and drag separates is called the parting line

13. BASIC PROCESS
There are six steps in this process:
1.Place a pattern in sand to create a mould.
2.Incorporate the pattern and sand in a gating system.
3.Remove the pattern.
4.Fill the mould cavity with molten metal.
5.Allow the metal to cool.
6.Break away the sand mould and remove the casting

14. COMPONENTS
1. Patterns
2. Tools
3. Moulding box and materials
4. Chills
5. Cores
6. Design requirements

15. MOULD MATERIALS
There are four main components for making a sand
casting mould:
1)Base sand,
2)A binder,
3)Additives,
4)and a parting compound

16. i. Base sand is the type used to make the mould or
core without any binder. Because it does not have a
binder it will not bond together and is not usable in
this state.
ii. Binders are added to a base sand to bond the sand
particle together (i.e. it is the glue that holds the
mould together).
iii. Additives are added to the moulding components to
improve: surface finish, dry strength, refractoriness,
and "cushioning properties

17. ARPA MOULDING MACHINE
DISA ARPA is a jolt squeeze moulding machine suitable
for smaller foundries requiring flexibility, good quality
production of short run castings.
With more than 1000 ARPA machines running across
the globe, DISA has further upgraded its moulding
machine. The new DISA ARPA resembles the market
benchmark in simultaneous jolt squeeze moulding
machines.

18. Fig 4 ARPA Moulding Machine
THE kEy fEATURES Of ARPA ARE :-
- High frequency, low amplitude
jolting with high dynamic squeeze
force for uniform and rigid
moulds
- Hydro-pneumatic swing in and out
and precisely guided pattern draw for
dame free stripping
- All parts accessible above floor level
for easy maintenance
- Covers a complete mould range from
500x600 to 1050x1400 mm

19. MELTING AND POURING Of METALS
 The next important step in the making of casting is the melting of
metal.
 In order to transfer the metal from the furnace into the moulds,
some type of pouring device, or ladle, must be used.
 The primary considerations are to maintain the metal at the proper
temperature for pouring and to ensure that only quality metal will
get into the moulds.
 The operations involved in melting of metal in oil fired
furnace/induction furnace and pouring of liquid metal into the
mould cavity will be shown during the demonstration.

20. INDUCTION fURNACES
 In INDO FARM foundry plant two induction furnaces is
used to melt the metal.
 The holding of this furnace is 10KW and high temp. of
the molten metal is 1550°C.
 An induction furnace is an electrical furnace in which the
heat is applied by induction heating of metal.
 Induction furnace capacities range from less than one
kilogram to one hundred tonnes capacity and are used to
melt iron and steel, copper, aluminium and precious
metals

21. OPERATION
1 - Melt
2 - water-cooled coil
3 - yokes
4 - crucible
1. Operating frequencies range from utility frequency (50 or 60 Hz)
to 400 kHz or higher,
2. Power supplies range from 10 kW to 42 MW, with melt sizes of
20 kg to 65 tonnes of metal respectively
Fig 5 Furnaces parts

22. REMOVAL AND FINISHING OF CASTINGS
After complete solidification, the castings are removed from
the mould. Most castings require some cleaning and
finishing operations, such as removal of cores, removal of
gates and risers, removal of fins and flash, cleaning of
surfaces, etc.

23. FETTLING SHOP
 General meaning of fettling:- Mostly used for the words related
to cleaning, polishing, and maintaining systems so that they will be
functional or will remain functional.
 The word itself is derived from a root word referring to
“condition,” as seen in the phrase “in fine fettle,” which is meant to
describe good condition, shape.
 Fettling is the means by which a crude casting is turned into a cost
effective quality component that meets all the standards required
by the customer

24. FETTLING PROCESS
 It involves the removal of the cores, gates, sprues, runners, risers
and chipping of any of unnecessary projections on the surface of
the castings. Fettling operations can be divided into different
stages
 FETTLING OPERATIONS: Knocking dry sand cores Removal of
gates & riser Removal of fins and unwanted projections.
 WITH CUTTING SAW: These saws may be hand saw and power
saw are used for cutting the ferrous like steel, melable iron and for
non-ferrous materials except aluminium.
 BY USING CHIPPING HAMMER: It is particularly suited in case
of grey iron castings and brittle materials. The gates and risers can
easily be broken by hitting the hammer.

25. With abrasive cut of machine : These machines can work with all
metals but are specially designed for hard metals which cannot be
saw or sheared & also where flame cutting and chipping is not
feasible
Fig 6 Abrasive cut of machine

26. Sand Casting