project report

AKBAR (MAU13UME004) Page 1
1. INTRODUCTION
1.1 Introduction of INDO FARM
INDO FARM in Baddi Himachal Pradesh, India in 1999, Indo Farm builds tractors in the 33
to 90hp range. The company is also manufacturing 9 to 18 ton cranes and 15 to 50 kv silent
generator sets. Ursus Poland is its technical partners. The company is exporting their products
to many countries and their manufacturing is fully computerized.
1.1.1 Company profile
Indo Farm Equipment Limited is an ISO certified company located in Himachal Pradesh and
is into manufacturing of world-class tractors, cranes, engines, and diesel gensets has now
recently launched Harvester Combine Agricom 1070 for wetland paddy harvesting.
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.
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.
Way back within a year of its operations, the company had successfully indigenized
the engine components, manufacturing and assembly processes, and accordingly stopped
import of engines and so much so, it commenced export of engine components to Poland in
May 2006 and engines to Ursus in May 2008. In 2008, the company diversified into
manufacturing and marketing of Pick-N-Carry cranes of 9 tonnes - 20 tonnes capacity and
has recently commenced production of mobile tower cranes too. Engines being the company's
core competence area, it is now making engines for generator sets that are exported overseas.
The company has its state-of-the-art foundry equipped with induction furnaces in
order to ensure still better quality as well as to ensure uninterrupted supply.

Indo Farm operates on a pan-India basis and this has made it a well-recognized brand,
associated with quality and dependability. The company operates through 15 regional offices
and a widespread 300 strong dealer network for sales and service.
1.1.2 Research & Development
Indo Farm is progressing fast because of its belief in the importance of research and
development. Design software like Auto CAD and ProE enable us to design and virtually
simulate the components and processes.
Some key achievements:-
a. Indigenisation of technology for manufacture of high-grade tractor engines,
obtained from Ursus, Poland
b. Development of indigenous engines in 3-cylinder and 4-cylinder range, used
in our 3 series tractor models
c. Design of re-entrant type combustion chamber in all engines for better
combustion through proper air fuel mixing resulting in low fuel consumption
d. Ring-carrier design in 3 series engines for increased piston life
e. Engines having sufficient back-up torque for deep cultivation and haulage of
heavy loads on steep gradients
f. Diesel filter-cum-water separator for removal of water from diesel for
enhanced life of Fuel Injection Pump
g. Design of Pick-N-Carry cranes of 9 tonnes-20 tonnes capacity.
h. Design of Engines for Genset Applications from 15 kVa to 50 kVA.
i. Design of Diesel Gensets of 15 kVA to 50 kVA.
j. Design of Harvester Combine.
1.1.3 Facilities
a. Plant spread over an area of 34 acres and additional 5 acres have been used in our
captive grey iron and SG iron Foundry.
b. Installed Capacity of 12,000 tractors, 2,400 Cranes, 300 Harvester Combines, 20,000
Engines & 6,000 Gensets per annum.

c. State-of-art Machine Shop having more than 150 modern machines, SPMs and latest
CNC machining centres for producing excellent quality components like Cylinder
heads, Blocks, Transmission housings, Gear boxes, Hydraulic housings, Axle tubes,
Differential Cages, Timing cases & covers, Fly wheel housings, etc.
d. Separate Research, Design, Development and Testing Department, instrumental in
developing tractors using latest technology for catering to the ever-changing farming
needs.
e. Company has its own Foundry unit commissioned in 2006. Ensures better product
quality.
f. Top management comprises of professionals with rich industry expiries
1.1.4 ORGANIZATIONAL SET UP OF INDO FARM
1. MANAGING DIRECTOR
2. EXECUTIVE DIRECTOR
3. VICE PRESIDENT ASSOCAITIVE VICE
4. PRESIDENT
5. GENERAL MANAGER DEPUTY GENERAL
6. MANAGER
7. SENIOR MANAGER CHIEF MANAGER
8. ASST MANAGER
9. ENGINEER SENIOR ENGINEER ASST ENGINEER
10. JUNIOR ENGINEER
1.2 Introduction of foundry plant
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. Schematic diagram of foundry shop is given in Figure 1.1 below.

Fig. 1.1 Processes of foundry shop
1.2.1 Working process in foundry:-
The working process is done by following steps:
 Core Making
 Mould making
 Furnace
 Pouring
 Heat treating
 Surface cleaning
 Finishing

OBJECTIVE
2.1 Objectives of Indo Farm
The main objective of Indo Farm Equipment Limited foundry plant is to develop &
continuously update & upgrade integrated information system on Foundry & make the
information available to Indo Farm Equipment Limited members & other interested users &
overseas companies in the interest of Indian Foundry industry. This can broadly be given as
below.
 To build up information system & periodically update for foundries
 To identify suitable sources of cast component, foundry materials equipment’s,
consultants etc.
 To generate information of special plant machinery & technology overseas in
developed countries.
 To maintain profiles of exporters in foundry & allied industry.
 To maintain Various Govt. Notifications, circulars etc. issued by Govt. from time to
time particularly with regard to export, import, excise, taxation etc.
 To reply to various queries received from Indo Farm members & other interested
users from time to time.
 To provide max possible information online

SCHEDULE OF ACTIVITY
29 –June to 09-July
3.1 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.
In my training session in INDO FARM first ten days I worked at foundry plant in core
shop. 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. In machines large types of core are but manually both small and large
types of core are made. Example:-
1. Rear transmission core (RT),
2. Front transmission core (FT),
3. Internal transmission core (IT),
4. Axial tube 65core (H.P),
5. Hydraulic housing core (1400 H.P),
6. Engine rear plate core,
7. Rear lever core,
8. Exhaust Manifold 3 bore core,
9. Exhaust Manifold 4 bore core,
10. Sensor Tube core etc.

3.1.1 Advantages and disadvantages
Cores are useful for features that cannot tolerate draft or to provide detail that cannot
otherwise be integrated into a core-less casting or mould.
The main disadvantage is the additional cost to incorporate cores.
3.1.2 Requirement
There are seven requirements for core:-
1. Green Strength: In the green condition there must be adequate strength for handling.
2. In the hardened state it must be strong enough to handle the forces of casting; therefore
the compression strength should be 100 to 300 psi (0.69 to 2.07 MPa).
3. Permeability must be very high to allow for the escape of gases.
4. Friability: As the casting or moulding cools the core must be weak enough to break down
as the material shrinks. Moreover, they must be easy to remove during shakeout.
5. Good refractoriness is required as the core is usually surrounded by hot metal during
casting or moulding.
6. A smooth surface finish.
7. Minimum generation of gases during metal pouring.
3.1.3 Types
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. For example, certain metals are sensitive to gases that are given off by
certain types of core sands; other metals have too low of a melting point to properly break
down the binder for removal during the shakeout.
3.1.3.1Green-sand cores
Green-sand cores are not a typical type of core in that it is part of the cope and drag, but still
form an internal feature. Their major disadvantage is their lack of strength, which makes

casting long narrow features difficult or impossible. Even for long features that can be cast it
still leave much material to be machined.
3.1.3.2Dry-sand cores
The simplest way to make dry-sand cores is in a dump core box, in which sand is packed into
the box and scraped level with the top. A wood or metal plate is then placed over the box, and
then the two are flipped over and the core segment falls out of the core box. The core
segment is then baked or hardened. Multiple core segments are then hot glued together or
attached by some other means. Any rough spots are filed or sanded down. Finally, the core is
lightly coated with graphite, silica, or mica to give a smoother surface finish and greater
resistance to heat. Single-piece cores do not need to be assembled because they are made in a
split core box. A split core box, like it sounds, is made of two halves and has at least one hole
for sand to be introduced. For simple cores that have constant cross-sections they can be
created on special core-producing extruders. The extrusions are then just cut to the proper
length and hardened. More complex single-piece cores can be made in a manner similar to
injection mouldings and die castings.
3.1.3.3Lost cores
Cores are used for complex injection mouldings in the fusible core injection moulding
process. First, a core is made from a fusible alloy or low melting temperature polymer. It is
then placed inside the injection mould's dies and the plastic is shot into the mould. The
moulding is then removed from the mould with the core still in it. Finally, the core is melted
or washed out of the moulding in a hot bath.
3.1.3.4Binders
Special binders are introduced into core sands to add strength. The oldest binder was
vegetable oil, however now synthetic oil is used, in conjunction with cereal or clay. The core
is then baked in a convection oven between 200 and 250°C (392 and 482°F). The heat causes
the binder to cross-link or polymerize. While this process is simple, the dimensional accuracy
is low.
Another type of binder process is called the hot-box process, which uses a thermoset
and catalyst for a binder. The sand with the binder is packed into a core box that is heated to

approximately 230°C (446°F) (which is where the name originated from). The binder that
touches the hot surface of the core box begins to cure within 10 to 30 seconds. Depending on
the type of binder it may require further baking to fully cure. Cores produced using this
method are sometimes referred to as "shell-core" because often, only the outside layer of the
core is hardened when in contact with the hot core box. When the core box is opened and the
core removed, the uncured sand inside the core is dumped out to be reused. This practice can
also be observed in some cold-box core making practices, though cold box shell-core making
is much less common.
In a similar vein, the cold-box process uses a binder that is hardened through the use
of special gases. The binder coated sand is packed into a core box and then sealed so that a
curing gas can be introduced. These gases are often toxic (i.e. amine gas) or odorous (i.e.
SO2), so special handling systems must be used. However, because high temperatures are not
required the core box can be made from metal, wood, or plastic. An added benefit is that
hollow core can be formed if the gas is introduced via holes in the core surface which cause
only the surface of the core to harden; the remaining sand is then just dumped out to be used
again. For example, a cold-box sand casting core binder is sodium silicate which hardens on
exposure to carbon dioxide
Special binders are used in air-set sands to produce core at room temperature. These
sands do not require a gas catalyst because organic binders and a curing catalyst are mixed
together in the sand which initiates the curing process. The only disadvantage with this is that
after the catalyst is mixed in there is a short time to use the sand. A third way to produce
room temperature cores is by shell moulding.
The term no-bake sands can refer to either the cold-box process or air-set process.
3.1.3.5 Other considerations
To increase the strength of cores internal wires and rods can be added. To enhance
collapsibility straw can be added to the middle of the core or a hollow core can be used. This
attribute is especially important for steel casting because a large amount of shrinkage is
present.

Except for very small cores, all cores require vent holes to release gases. These are
usually formed by using small wires to create holes from the surface of the mould to the core.
When this is not feasible cinder and coke can be added to the core to increase permeability.
3.1.4 Chaplets
As mentioned earlier, cores are usually supported by two core prints in the mould . However,
there are situations where a core only uses one core print so other means are required to
support the cantilevered end. These are usually supplied in the form of chaplets. These are
small metal supports that bridge the gap between the mould surface and the core, but because
of this become part of the casting. As such, the chaplets must be of the same or similar
material as the metal being cast. Moreover, their design must be optimized because if they are
too small they will completely melt and allow the core to move, but if they are too big then
their whole surface cannot melt and fuse with the poured metal. Their use should also be
minimized because they can cause casting defects or create a weak spot in the casting. It is
usually more critical to ensure the upper chaplets are stronger than the lower ones because the
core will want to float up in the molten metal. The different types of chaplet is shown in
Figure 3.1 below.
Fig.3.1 Different types of Chaplets
3.1.5 Core Making
The complete core making cycle is accomplished in the following four stages:
1-Preparation of Core sand
2-Core making

3-Core drying
4-Finishing
1. Preparation of Core Sand: In small foundries the core sand mixtures are still prepared
through hand operations. But these operation do not facilitate a homogeneous and efficient
mixing. The common means include the uses of either Roller Mills or Core Sand Mixers.
2. Core-making: For Core making by hand, the sand prepared as above is filled and rammed
in the Core Boxes. The prepared cores are placed on metal plates and fed into the drying
oven.
But in all modern foundries, which are mechanised to a large extent, machines are
used for core-making. The following types of machines are used in indo farm foundry shop.
a) Cold Box core shooter machine
b) Hot Box Core shooter machine
a) Cold Box 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. So in order to overcome such kinds of drawbacks and to
increase the productivity we have developed such a machine which takes less time to produce
number of cores. Generally there two main types of core shooters are available viz;
Horizontal Parting type, Vertical parting type. Currently in market there are various types of
core shooters are available, but most of them are vertical parting type. But they require extra
hydraulic power pack to clamp core box and it is very bulky. So we developed a horizontal
parting type core shooter, which does not require any extra hydraulic power pack and it does
not involve any operational complications. 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. Cold Box Core Shooter Machine shown in Figure 3.2 is
below.

Fig.3.2 Cold Box Core Shooter Machine
WORKING
i. 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.
ii. 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.
iii. 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.
iv. 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.
v. Once the shooting of sand is completed, the work table along with core box is taken
downward by pneumatic actuator.

vi. 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.
vii. Finally core is removed from the core box. . Rear Transmission Core Make on Cold Box
Machine Shown in Figure 3.3 is below.
Fig 3.3 Rear Transmission Core make on cold box machine
b) Hot Box Core shooter machine: In INDO FARM Hot Box Core Shooter Machine shown
in Figure 3.4 below.it is also used to make the cores. In this machine silica sand is used but
no binder and hardener is used. In this machine core is solidified with the help of heating
process. And In this machine not large type core are manufacture only small and medium
type cores are manufacture like Exhaust Manifold 3 Bore, Exhaust Manifold 4 Bar etc.
Process: In Hot Box Core Shooter Machine firstly silica sand is filled in the lower
tab and with the help of compressor sand is filled in the upper tab. After that die heater is
started and when the die is so hot then the sand is filled in the die and die is closed. After 4-5
minutes the core is formed and extracted out of die.

Fig. 3.4 Hot Box Core shooter machine
3. Core Drying:- After the cores have been prepared and suitably supported on plates or
dryers, they are sent to Ovens to drive out the moisture content and provide them the
desired hardness. The ovens used for this purpose are called Core Drying Ovens or
Core Baking Ovens.
4. Finishing:-After receiving them from ovens, the cores are properly finished by
rubbing or filing, etc., to bring them to correct dimensions, remove extra sand
projections from surfaces and provides a good surfaces finish. Then only they become
suitable for being placed in the moulds.
10- July to 19-July
3.2 Moulding Shop
There are, however, quite a few other work steps necessary before you can finally hold your
tailor-made casting in your hand. The basis for the outer part of your casting is determined in
the moulding shop - regardless of its final size: Our machines for different sized moulds
guarantee that your specifications are met to the full in our foundry.

With the fast development of the car and machine building industry the casting
consuming areas called for steady higher productivity. The basic process stages of the
mechanical moulding and casting process are similar to those described under the manual
sand casting process. The technical and mental development however was so rapid and
profound that the character of the sand casting process changed radically.
Sand casting, also known as sand moulded casting, is a metal casting process
characterized by using sand as the mould material. The term "sand casting" can also refer to
an object produced via the sand casting process. Sand castings are produced in specialized
factories called foundries. Over 70% of all metal castings are produced via a sand casting
process.
Sand casting is relatively cheap and sufficiently refractory even for steel foundry use.
In addition to the sand, a suitable bonding agent (usually clay) is mixed or occurs with the
sand. The mixture is moistened, typically with water, but sometimes with other substances, to
develop strength and plasticity of the clay and to make the aggregate suitable for moulding.
The sand is typically contained in a system of frames or mould boxes known as a flask. The
mould cavities and gate system are created by compacting the sand around models, or
patterns, or carved directly into the sand.
3.2.1 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.
3.2.2 Components
In Moulding Shop there are following component are used to complete the moulding process.
Like patterns, moulding box and material, chills, cores and design requirement.

3.2.2.1Patterns
When mould filled with the molten material on solidifying, forms a reproduction of the
pattern and is known as mould. It is slightly larger in size then casting.
In the process of casting, “A pattern is a replica of the object to cast, used to prepare
the cavity into which molten material will be poured during the casting process”. It is not an
exact replica of the casting desired.
Pattern-makers are able to produce suitable patterns using "Contraction rules" (these are
sometimes called "shrink allowance rulers" where the ruled markings are deliberately made
to a larger spacing according to the percentage of extra length needed). Different scaled rules
are used for different metals, because each metal and alloy contracts by an amount distinct
from all others.
Paths for the entrance of metal into the mould cavity constitute the runner system
and include the spruce, various feeders which maintain a good metal 'feed', and in-gates
which attach the runner system to the casting cavity. Gas and steam generated during casting
exit through the permeable sand or via risers which are added either in the pattern itself, or as
separate pieces
TYPES OF PATTERNS:
This depends on shape, size, method, number of casting etc. They are classified as:
a. Single Piece or Solid Pattern:
This is the simplest type of pattern, exactly like the desired casting. For making a mould, the
pattern is accommodated either in cope or drag. Used for producing a few large castings, for
example, stuffing box of steam engine. Single piece pattern is shown in Figure 3.5 below:
Fig. 3.5 Single Piece or Solid Pattern

b. Cope and Drag Pattern:
A cope and drag pattern is a split pattern having the cope and drag portions each mounted on
separate match plates. These patterns are used when in the production of large castings; the
complete mould scare too heavy and unwieldy to be handled by a single worker. Cope and
Drag pattern is shown in Figure 3.6 below.
Fig. 3.6 Cope and Drag Pattern
c. Gated Pattern:
A gated pattern is simply one or more loose patterns having attached gates and runners.
Because of their higher cost, these patterns are used for producing small castings in mass
production systems and on moulding machines. Gated pattern is shown in Figure 3.7 below:
Fig. 3.7 Gated Pattern

3.2.2.2Moulding box and materials
A multi-part moulding box (known as a casting flask, the top and bottom halves of which are
known respectively as the cope and drag) is prepared to receive the pattern. Moulding boxes
are made in segments that may be latched to each other and to end closures. For a simple
object—flat on one side—the lower portion of the box, closed at the bottom, will be filled
with a moulding sand. The sand is packed in through a vibratory process called ramming, and
in this case, periodically screened level. The surface of the sand may then be stabilized with a
sizing compound. The pattern is placed on the sand and another moulding box segment is
added. Additional sand is rammed over and around the pattern. Finally a cover is placed on
the box and it is turned and unlatched, so that the halves of the mould may be parted and the
pattern with its spruce and vent patterns removed. Additional sizing may be added and any
defects introduced by the removal of the pattern are corrected. The box is closed again. This
forms a "green" mould which must be dried to receive the hot metal. If the mould is not
sufficiently dried a steam explosion can occur that can throw molten metal about. In some
cases, the sand may be oiled instead of moistened, which makes possible casting without
waiting for the sand to dry. Sand may also be bonded by chemical binders, such as resins or
amine-hardened resins.
3.2.2.3Chills
To control the solidification structure of the metal, it is possible to place metal plates, chills,
in the mould. The associated rapid local cooling will form a finer-grained structure and may
form a somewhat harder metal at these locations. In ferrous castings, the effect is similar to
quenching metals in forge work. The inner diameter of an engine cylinder is made hard by a
chilling core. In other metals, chills may be used to promote directional solidification of the
casting. In controlling the way a casting freezes, it is possible to prevent internal voids or
porosity inside castings.
3.2.2.4Cores
To produce cavities within the casting such as for liquid cooling in engine blocks and
cylinder heads negative forms are used to produce cores. Usually sand-moulded, cores are
inserted into the casting box after removal of the pattern. Whenever possible, designs are
made that avoid the use of cores, due to the additional set-up time and thus greater cost.

With a completed mould at the appropriate moisture content, the box containing the
sand mould is then positioned for filling with molten metal typically iron, steel, bronze, brass,
aluminium, magnesium alloys, or various pot metal alloys, which often include lead, tin, and
zinc. After filling with liquid metal the box is set aside until the metal is sufficiently cool to
be strong. The sand is then removed revealing a rough casting that, in the case of iron or
steel, may still be glowing red. When casting with metals like iron or lead, which are
significantly heavier than the casting sand, the casting flask is often covered with a heavy
plate to prevent a problem known as floating the mould. Floating the mould occurs when the
pressure of the metal pushes the sand above the mould cavity out of shape, causing the
casting to fail.
After casting, the cores are broken up by rods or shot and removed from the casting.
The metal from the sprue and risers is cut from the rough casting. Various heat treatments
may be applied to relieve stresses from the initial cooling and to add hardness in the case of
steel or iron, by quenching in water or oil.
3.2.2.5Design requirements
The part to be made and its pattern must be designed to accommodate each stage of the
process, as it must be possible to remove the pattern without disturbing the moulding sand
and to have proper locations to receive and position the cores. A slight taper, known as draft,
must be used on surfaces perpendicular to the parting line, in order to be able to remove the
pattern from the mould. This requirement also applies to cores, as they must be removed from
the core box in which they are formed. The sprue and risers must be arranged to allow a
proper flow of metal and gasses within the mould in order to avoid an incomplete casting.
Should a piece of core or mould become dislodged it may be embedded in the final casting,
forming a sand pit, which may render the casting unusable. Gas pockets can cause internal
voids. These may be immediately visible or may only be revealed after extensive machining
has been performed. For critical applications, or where the cost of wasted effort is a factor,
non-destructive testing methods may be applied before further work is performed.
3.2.3 Processes
In general, we can distinguish between two methods of sand casting; the first one using
greensand and the second being the air set method.

3.2.3.1Green sand
These expendable moulds are made of wet sand that is used to make the mould's shape. The
name comes from the fact that wet sand is used in the moulding process. Green sand is not
green in colour, but "green" in the sense that it is used in a wet state (akin to green wood).
Unlike the name suggests, "green sand" is not a type of sand on its own, but is rather a
mixture of:
 Silica sand (SiO2), chromite sand (FeCr2O4), or zircon sand (ZrSiO4), 75 to 85%,
sometimes with a proportion of olivine, staurolite, or graphite.
 Bentonite (clay), 5 to 11%
 water, 2 to 4%
 inert sludge 3 to 5%
 Anthracite (0 to 1%)
There are many recipes for the proportion of clay, but they all strike different balances
between mould ability, surface finish, and ability of the hot molten metal to degas. The coal,
typically referred to in foundries as sea-coal, which is present at a ratio of less than 5%,
partially combusts in the presence of the molten metal leading to off gassing of organic
vapours. Green sand for non-ferrous metals does not use coal additives since the CO created
is not effective to prevent oxidation. Green sand for aluminium typically uses olivine sand (a
mixture of the minerals forsterite and fayalite which are made by crushing dunite rock). The
choice of sand has a lot to do with the temperature that the metal is poured. At the
temperatures that copper and iron are poured, the clay gets inactivated by the heat in that the
montmorillonite is converted to illite, which is a non-expanding clay. Most foundries do not
have the very expensive equipment to remove the burned out clay and substitute new clay, so
instead, those that pour iron typically work with silica sand that is inexpensive compared to
the other sands. As the clay is burned out, newly mixed sand is added and some of the old
sand is discarded or recycled into other uses. Silica is the least desirable of the sands since
metamorphic grains of silica sand have a tendency to explode to form sub-micron sized
particles when thermally shocked during pouring of the moulds. These particles enter the air
of the work area and can lead to silicosis in the workers. Iron foundries spend a considerable
effort on aggressive dust collection to capture this fine silica. The sand also has the
dimensional instability associated with the conversion of quartz from alpha quartz to beta

quartz at 1250 degrees F. Often additives such as wood flour are added to create a space for
the grains to expand without deforming the mould. Olivine, chromite, etc. are used because
they do not have a phase conversion that causes rapid expansion of the grains, as well as
offering greater density, which cools the metal faster and produces finer grain structures in
the metal. Since they are not metamorphic minerals, they do not have the polycrystals found
in silica, and subsequently do not form hazardous sub-micron sized particles.
3.2.3.2The "air set" method
The air set method uses dry sand bonded with materials other than clay, using a fast curing
adhesive. The latter may also be referred to as no bake mould casting. When these are used,
they are collectively called "air set" sand castings to distinguish them from "green sand"
castings. Two types of moulding sand are natural bonded (bank sand) and synthetic (lake
sand); the latter is generally preferred due to its more consistent composition.
With both methods, the sand mixture is packed around a pattern, forming a mould
cavity. If necessary, a temporary plug is placed in the sand and touching the pattern in order
to later form a channel into which the casting fluid can be poured. Air-set moulds are often
formed with the help of a casting flask having a top and bottom part, termed the cope and
drag. The sand mixture is tamped down as it is added around the pattern, and the final mould
assembly is sometimes vibrated to compact the sand and fill any unwanted voids in the
mould. Then the pattern is removed along with the channel plug, leaving the mould cavity.
The casting liquid (typically molten metal) is then poured into the mould cavity. After the
metal has solidified and cooled, the casting is separated from the sand mould. There is
typically no mould release agent, and the mould is generally destroyed in the removal
process.
The accuracy of the casting is limited by the type of sand and the moulding process.
Sand castings made from coarse green sand impart a rough texture to the surface, and this
makes them easy to identify. Castings made from fine green sand can shine as cast but are
limited by the depth to width ratio of pockets in the pattern. Air-set moulds can produce
castings with smoother surfaces than coarse green sand but this method is primarily chosen
when deep narrow pockets in the pattern are necessary, due to the expense of the plastic used
in the process. Air-set castings can typically be easily identified by the burnt colour on the
surface. The castings are typically shot blasted to remove that burnt colour. Surfaces can also

be later ground and polished, for example when making a large bell. After moulding, the
casting is covered with a residue of oxides, silicates and other compounds. This residue can
be removed by various means, such as grinding, or shot blasting.
During casting, some of the components of the sand mixture are lost in the thermal
casting process. Green sand can be reused after adjusting its composition to replenish the lost
moisture and additives. The pattern itself can be reused indefinitely to produce new sand
moulds. The sand moulding process has been used for many centuries to produce castings
manually. Since 1950, partially automated casting processes have been developed for
production lines.
3.2.3.3Cold box
Uses organic and inorganic binders that strength the mould by chemically adhering to the
sand. This type of mould gets its name from not being baked in an oven like other sand
mould types. This type of mould is more accurate dimensionally than green-sand moulds but
is more expensive. Thus it is used only in applications that necessitate it.
3.2.3.4No-bake moulds
No-bake moulds are expendable sand moulds, similar to typical sand moulds, except they
also contain a quick-setting liquid resin and catalyst. Rather than being rammed, the
moulding sand is poured into the flask and held until the resin solidifies, which occurs at
room temperature. This type of moulding also produces a better surface finish than other
types of sand moulds. Because no heat is involved it is called a cold-setting process.
Common flask materials that are used are wood, metal, and plastic. Common metals cast into
no-bake moulds are brass, iron (ferrous), and aluminium alloys.
3.2.3.5Fast mould making processes
With the fast development of the car and machine building industry the casting consuming
areas called for steady higher productivity. The basic process stages of the mechanical
moulding and casting process are similar to those described under the manual sand casting
process. The technical and mental development however was so rapid and profound that the
character of the sand casting process changed radically.

Mechanized sand moulding
The first mechanized moulding lines consisted of sand slingers and/or jolt-squeeze devices
that compacted the sand in the flasks. Subsequent mould handling was mechanical using
cranes, hoists and straps. After core setting the copes and drags were coupled using guide
pins and clamped for closer accuracy. The moulds were manually pushed off on a roller
conveyor for casting and cooling.
Automatic high pressure sand moulding lines
Increasing quality requirements made it necessary to increase the mould stability by applying
steadily higher squeeze pressure and modern compaction methods for the sand in the flasks.
In early fifties the high pressure moulding was developed and applied in mechanical and later
automatic flask lines. The first lines were using jolting and vibrations to pre-compact the sand
in the flasks and compressed air powered pistons to compact the moulds.
Horizontal sand flask moulding
In the first automatic horizontal flask lines the sand was shot or slung down on the pattern in
a flask and squeezed with hydraulic pressure of up to 140 bars. The subsequent mould
handling including turn-over, assembling, pushing-out on a conveyor were accomplished
either manually or automatically. In the late fifties hydraulically powered pistons or multi-
piston systems were used for the sand compaction in the flasks. This method produced much
more stable and accurate moulds than it was possible manually or pneumatically. In the late
sixties mould compaction by fast air pressure or gas pressure drop over the pre-compacted
sand mould was developed (sand-impulse and gas-impact).
Today there are many manufacturers of the automatic horizontal flask moulding lines.
The major disadvantages of these systems is high spare parts consumption due to multitude of
movable parts, need of storing, transporting and maintaining the flasks and productivity
limited to approximately 90–120 moulds per hour.

ARPA Moulding machine use in Indo Farm foundry plant
DISA ARPA
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 show in Figure 3.8 is below. The new DISA ARPA
resembles the market benchmark in simultaneous jolt squeeze moulding machines.
Fig. 3.8 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
3.2.4 Mould materials
There are four main components for making a sand casting mould: base sand, a binder,
additives, and a parting compound.
3.2.4.1Moulding sands
Moulding sands, also known as foundry sands, are defined by eight characteristics:
refractoriness, chemical inertness, permeability, surface finish, cohesiveness, flow ability,
collapsibility, and availability/cost.
Refractoriness: This refers to the sand's ability to withstand the temperature of the liquid
metal being cast without breaking down. For example some sands only need to withstand
650°C (1,202°F) if casting aluminium alloys, whereas steel needs sand that will withstand
1,500°C (2,730°F). Sand with too low a refractoriness will melt and fuse to the casting.
Chemical inertness: The sand must not react with the metal being cast. This is especially
important with highly reactive metals, such as magnesium and titanium.
Permeability: This refers to the sand's ability to exhaust gases. This is important because
during the pouring process many gases are produced, such as hydrogen, nitrogen, carbon
dioxide, and steam, which must leave the mould otherwise casting defects, such as blow
holes and gas holes, occur in the casting. Note that for each cubic centimetre (cc) of water
added to the mould 16,000 cc of steam is produced.
Surface finish: The size and shape of the sand particles defines the best surface finish
achievable, with finer particles producing a better finish. However, as the particles become
finer (and surface finish improves) the permeability becomes worse.
Cohesiveness (or bond): This is the ability of the sand to retain a given shape after the
pattern is removed.
Flow ability: The ability for the sand to flow into intricate details and tight corners without
special processes or equipment.

Collapsibility: This is the ability of the sand to be easily stripped off the casting after it has
solidified. Sands with poor collapsibility will adhere strongly to the casting. When casting
metals that contract a lot during cooling or with long freezing temperature ranges a sand with
poor collapsibility will cause cracking and hot tears in the casting. Special additives can be
used to improve collapsibility.
Availability/cost: The availability and cost of the sand is very important because for every
ton of metal poured, three to six tons of sand is required. Although sand can be screened and
reused, the particles eventually become too fine and require periodic replacement with fresh
sand.
In large castings it is economical to use two different sands, because the majority of
the sand will not be in contact with the casting, so it does not need any special properties. The
sand that is in contact with the casting is called facing sand, and is designed for the casting on
hand. This sand will be built up around the pattern to a thickness of 30 to 100 mm (1.2 to
3.9 in). The sand that fills in around the facing sand is called backing sand. This sand is
simply silica sand with only a small amount of binder and no special additives.
Types of base sands
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.
Silica sand
Silica (SiO2) sand is the sand found on a beach and is also the most commonly used sand. It is
made by either crushing sandstone or taken from natural occurring locations, such as beaches
and river beds. The fusion point of pure silica is 1,760°C (3,200°F), however the sands used
have a lower melting point due to impurities. For high melting point casting, such as steels, a
minimum of 98% pure silica sand must be used; however for lower melting point metals,
such as cast iron and non-ferrous metals, a lower purity sand can be used (between 94 and
98% pure).
Silica sand is the most commonly used sand because of its great abundance, and, thus,
low cost (therein being its greatest advantage). Its disadvantages are high thermal expansion,
which can cause casting defects with high melting point metals, and low thermal

conductivity, which can lead to unsound casting. It also cannot be used with certain basic
metal because it will chemically interact with the metal forming surface defect. Finally, it
causes silicosis in foundry workers.
Olivine sand
Olivine is a mixture of orthosilicates of iron and magnesium from the mineral dunite. Its main
advantage is that it is free from silica, therefore it can be used with basic metals, such as
manganese steels. Other advantages include a low thermal expansion, high thermal
conductivity, and high fusion point. Finally, it is safer to use than silica, therefore it is popular
in Europe.
Chromite sand
Chromite sand is a solid solution of spinels. Its advantages are a low percentage of silica, a
very high fusion point (1,850°C (3,360°F)), and a very high thermal conductivity. Its
disadvantage is its costliness; therefore it's only used with expensive alloy steel casting and to
make cores.
Zircon sand
Zircon sand is a compound of approximately two-thirds zircon oxide (Zr2O) and one-third
silica. It has the highest fusion point of all the base sands at 2,600 °C (4,710 °F), a very low
thermal expansion, and a high thermal conductivity. Because of these good properties it is
commonly used when casting alloy steels and other expensive alloys. It is also used as a
mould wash (a coating applied to the moulding cavity) to improve surface finish. However, it
is expensive and not readily available.
Chamotte sand
Chamotte is made by calcining clay (Al2O3-SiO2) above 1,100°C (2,010°F). Its fusion point
is 1,750°C (3,180°F) and has low thermal expansion. It is the second cheapest sand, however
it is still twice as expensive as silica. Its disadvantages are very coarse grains, which result in
a poor surface finish, and it is limited to dry sand moulding. Mould washes are used to
overcome the surface finish problem. This sand is usually used when casting large steel work
pieces.

3.2.4.2Binders
Binders are added to a base sand to bond the sand particle together (i.e. it is the glue that
holds the mould together).
Clay and water
A mixture of clay and water is the most commonly used binder. There are two types of clay
commonly used bentonite and kaolinite, with the former being the most common.
Oil
Oils, such as linseed oil, other vegetable oils and marine oils, used to be used as a binder,
however due to their increasing cost, they have been mostly phased out. The oil also required
careful baking at 100 to 200°C (212 to 392°F) to cure (if overheated the oil becomes brittle,
wasting the mould).
Resin
Resin binders are natural or synthetic high melting point gums. The two common types used
are urea formaldehyde (UF) and phenol formaldehyde (PF) resins. PF resins have a higher
heat resistance than UF resins and cost less. There are also cold-set resins, which use a
catalyst instead of a heat to cure the binder. Resin binders are quite popular because different
properties can be achieved by mixing with various additives. Other advantages include good
collapsibility, low gassing, and they leave a good surface finish on the casting.
MDI (methylene diphenyldiisocyanate) is also a commonly used binder resin in the
foundry core process.
Sodium silicate
Sodium silicate [Na2SiO3 or (Na2O)(SiO2)] is a high strength binder used with silica
moulding sand. To cure the binder carbon dioxide gas is used, which creates the following
reaction:

The advantage to this binder is that it can be used at room temperature and it's fast. The
disadvantage is that its high strength leads to shakeout difficulties and possibly hot tears in
the casting.
3.2.4.3Additives
Additives are added to the moulding components to improve: surface finish, dry strength,
refractoriness, and "cushioning properties".
Up to 5% of reducing agents, such as coal powder, pitch, creosote, and fuel oil, may
be added to the moulding material to prevent wetting (prevention of liquid metal sticking to
sand particles, thus leaving them on the casting surface), improve surface finish, decrease
metal penetration, and burn-on defects. These additives achieve this by creating gases at the
surface of the mould cavity, which prevent the liquid metal from adhering to the sand.
Reducing agents are not used with steel casting, because they can carburize the metal during
casting.
Up to 3% of "cushioning material", such as wood flour, saw dust, powdered husks,
peat, and straw, can be added to reduce scabbing, hot tear, and hot crack casting defects when
casting high temperature metals. These materials are beneficial because burn-off when the
metal is poured creating voids in the mould, which allow it to expand. They also increase
collapsibility and reduce shakeout time.
Up to 2% of cereal binders, such as dextrin, starch, sulphitelye, and molasses, can be
used to increase dry strength (the strength of the mould after curing) and improve surface
finish. Cereal binders also improve collapsibility and reduce shakeout time because they
burn-off when the metal is poured. The disadvantage to cereal binders is that they are
expensive.
Up to 2% of iron oxide powder can be used to prevent mould cracking and metal
penetration, essentially improving refractoriness. Silica flour (fine silica) and zircon flour
also improve refractoriness, especially in ferrous castings. The disadvantages to these
additives is that they greatly reduce permeability.

20- July to 29- July
3.3 Fettling Shop
Introduction 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. In context with the casting
process, fettling means the removal of unwanted metal, e.g. flashings, risers etc. It can
include processes like chipping, grinding, shot blasting etc.
3.3.1 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.
a. FETTLING OPERATIONS: Knocking dry sand cores Removal of gates & riser
Removal of fins and unwanted projections.
b. KNOCKING OF DRY SAND CORE: Knocking out of dry sand cores. Dry sand
cores may be removed by knocking with iron bar. For quick knocking pneumatic or
hydraulic devices are employed, this method is used for small, medium work. For
large castings the hydro blast process is mostly employed.
c. REMOVAL OF GATE AND RISER: With chipping hammer By using cutting saw
Flame cutting With abrasive cut off machine.
d. 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.
e. 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.

f. WITH FLAME CUTTING: This type of method is specially used for ferrous
materials of large sized castings where the risers and gates are very heavy. In this the
gas cutting flames and arc cutting methods may be employed.
g. 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. Abrasive cut of machine shown in
Figure 3.9 below.
Fig. 3.9 Abrasive cut of Machine
h. REMOVAL OF FINS, ROUGH SPOTS AND UNWANTED PROJECTION: The
casting surface after removal of the gates may still contain some rough surfaces left at
the time of removal of gates. Like Sand that is fused with surface. Some fins and
other projections on the surface near the parting line. They are needed to be cleaned
thoroughly before the casting is put to use.
i. CNTD : The fins and other small projections may easily be chipped off with the help
of either hand tools or pneumatic tools. But for smoothing the rough cut gate edges
either the pedestal or swing frame grinder is used depends upon the size of castings.
j. CLEANING TUMBLING: Traditional and old process. Casting is put in a chamber
and rotated with 60-70 rpm speed in presence of small pieces of white cast iron.
Shot blasting is a method used to clean, polish and strengthen metals. It is used in almost
every industry that uses metals, including construction, automotive, ship building and rail
industries. There are two technologies used in shot blasting, including air blasting and wheel
blasting. Shot Blasting Machine shown in Figure 3.10 in below.
Fig.3.10 Shot Blasting Machine

4. Test performance
4.1. Foundry sand testing is a process used to determine if the foundry sand has the
correct properties for a certain casting process. The sand is used to make moulds and cores
via a pattern. In a sand casting foundry there are broadly two reasons for rejection of the
casting metal and sand each of which has a large number of internal variables. The defects
arising from the sand can be prevented by using sand testing equipment to measure the
various properties of the sand.
Process
The testing process is divided into three stages: sampling of the bulk material, sample
preparation, and testing.
It done at three different points of the process: upon first arrival from the supplier, en
transport for processing (usually on a conveyor), and after processing. In each situation it is
important to take a representative sample by mixing the sand or by taking multiple samples in
different locations. Also, the sample must be stored in an airtight container to keep from
spoiling it.
There are more than 25 basic tests, however only the important ones for the given
casting process are used. The basic tests measure the following parameters: wet tensile
strength, cone jolt, friability, moisture content, permeability, green compression strength,
compact ability, loss on ignition, volatiles content, grain size & distribution, dust (dead clay)
content, and active clay content. Each of these tests can lead you to obtain specific
characteristics of sand which can be crucial quality of casting. Advanced testing tests for
other parameters, such as splitting strength, shear strength, and high-temperature compression
strength.
4.1.1 UNIVERSAL SAND STRENGTH MACHINE
This highly accurate machine consists of three major parts; frame, pendulum weight, and
pusher arm. The pendulum weight swings on ball bearings which are mounted on a steel
shaft. Various accessories may be easily attached to perform different tests such as

COMPRESSION, SHEAR, TENSILE, TRANSVERSE and SPLITTING strength. The
Universal Sand Strength Machine Shown in Figure 4.1 is below.
Fig. 4.1 Universal Sand Strength Machine
TEST PROCEDURE
When testing green-sands the test heads are placed in the lower holes of the pusher arm and
weight. For dry sands they are inserted in the upper holes where the breaking force is
increased by a factor of five. (The breaking force can be increased by a further factor of three
by using the High Dry Strength Accessory). A magnetic rider on the scale records the
position at which the specimen collapses, and the strength of the sand is read direct from the
scale.
4.1.2 CORE HARDNESS TESTER
This instrument is used to determine accurately the surface hardness of cores. The surface of
the core is subjected to controlled abrasion by a four-point penetrator and the depth of
penetration measured on a horizontally mounted dial gauge. Core Hardness Tester Shown in
Figure 4.2 is below.
Fig. 4.2 Core Hardness Tester

TEST PROCEDURE
a. Hold the curved section of the tester body with the thumb and forefinger. Turn the
knurled index ring assembly until the line on the index ring is opposite the reference
line on the housing projection. Do not move the dial indicator bezel.
b. Press the base of the instrument firmly against the core and rotate the ring assembly
clockwise through two revolutions, until the lines are again matched. Read the
hardness directly from the indicator. As long as the reference lines are together no
further resetting of the unit is required for the next test.
c. For routine testing two revolutions may be considered as the standard procedure. To
increase the sensitivity of the instrument when testing harder cores, three or more
revolutions should be employed, and for very weak cores it may be desirable to use
only one revolution. The number of revolutions should be recorded along with the
hardness value.
4.1.3 MOULD STRENGTH TESTER
The Mould Strength Tester is used to measure the green compression strength of moulds on
the foundry floor. Any reasonable flat or gently curved mould surface may be used. The
tester can be operated at any angle, thus making it possible to take strength measurements on
vertical surfaces of a mould.
A reading is obtained, which is comparable to the green compression strength test,
obtained on a standard test specimen, rammed to the same degree as the mould. Mould
Strength Tester Shown in Figure 4.3 is below.
Fig. 4.3 Mould Strength Tester

TEST PROCEDURE
a. Release the bezel clamping screw and rotate the milled bezel until the indicating
pointer is at zero. Re-clamp the bezel. Turn the centre button to bring the slave
pointer to rest against the indicating pointer.
b. Holding the tester at right angles to the mould surface, press the probe slowly into the
sand. The force applied should be only enough to keep the probe just moving into the
surface.
c. Stop applying pressure when the graduation on the probe is level with the mould
surface. The green compression strength of the mould is indicated by the maximum
reading slave pointer.
4.1.4 Grain Fineness Test:
Grain size of a sand is designated by a number called “grain fineness number” that indicates
the average size as well as the proportions of smaller and larger grains in the mixture. A give
grain fineness number corresponds to a standard sieve of 280 mm diameter, which has the
identical number of meshes in it. The test of fineness is conducted by screening sand grains
by means of a set of standard sieves that are graded and numbered according to the fineness
of their mesh.
4.1.5 Test for moisture content:
This test is performed by drying 50 gms of the moist sand to constant weight between 105
degrees and 110 degrees in a uniformly heated oven, cooling to room temperature in a
desiccator and then weighing the dry sample. The difference between the moist and dry
weights of the sample in grams divided by 50 gm gives the percentage of moisture content in
the given sand. For this an instrument called moisture teller is widely used in here. The
instrument blows hot air through the moist sand in a pan, the bottom of which is made of
500-mesh metal screen. The sand sample is spread over the pan in a thin layer, and hot air is
blown for a period of approximately three minutes through a 50 gm sample. The moisture is
effectively removed and precision balance determines the loss in weight of sample.

4.2 NON-DESTRUCTIVE TESTING METHODS
Non-destructive testing gives the metal casting facility the capability of assuring the quality
of a casting without destroying it. A metal casting facility may have internal standards
regarding non-destructive testing, but it is up to the customer to specify specific tests or
frequency of testing. While various methods of non-destructive testing exist to measure
mechanical properties, chemical composition, casting soundness or maximum service loads, a
single test that encompasses all these factors does not exist. A combination of non-destructive
methods may be required to document the soundness and quality of a casting. The most
common methods available are described below.
a. Visual Inspection
Visual inspection is based on the use of the human eye to identify surface defects, improper
filling and moulding errors. Casting defects that can be detected via visual inspection include
sand holes, excessively rough surface, surface shrinkage, blowholes, misruns, cold shuts, and
surface dross or slag.
b. Dimensional Inspection
To ensure a part meets dimensional requirements, such as tolerances, a metal casting facility
can check the dimensional accuracy of a part manually or with a coordinate measuring
machine (CMM). Checking the dimensional accuracy of a part helps guarantee the customer
won’t have to perform further costly machining on a part to meet the specified dimensions.
CMM has improved the speed and accuracy of measuring casting dimensions, and
computerization has made it repetitive and able to be used as a statistical tool.
c. Magnetic Particle Inspection
Magnetic particle inspection is quick, inexpensive and sensitive to defects, particularly
shallow (0.003 in.) surface cracks and other lineal indications.

It detects small cracks on or near the surface of ferrous alloys that can be magnetized
(basically any ferrous alloy except austenitic material). A high-amperage, low-voltage current
is passed through the casting, which establishes a magnetic field.
Cracks and defects have magnetic properties different than those of the surrounding
material, so their presence will interrupt the magnetic field, causing distortion. Small
magnetic particles show the path of the flux line that spreads out in order to detour around the
distortion, thereby indicating the shape and position of the crack or void.
d. Ultrasonic Testing
Internal defects that are detected by radiography may also be detected by sound. Sound
waves have been used by fisherman to locate hot fishing spots and depth of water and by the
U.S. Navy to identify approaching objects. In casting inspection, ultrasonic testing uses high
frequency acoustic energy that is transmitted into a casting. Because ultrasonic testing allows
investigation of the cross-sectional area of a casting, it is considered to be a volumetric
inspection method.
The high frequency acoustic energy travels through the casting until it hits the
opposite surface or an interface or defect. The interface or defect reflects portions of the
energy, which are collected in a receiving unit and displayed for the analyst to view. The
pattern of the energy deflection can indicate the location and size of an internal defect, as
well as wall thickness and the nodule count of ductile iron.
Ultrasonic testing requires a high doses of knowledge and experience for an accurate
interpretation of the results, which will affect the cost added to the part for the inspection.
e. Radiographic Inspection
Another method used to detect internal defects is radiographic inspection. When done
correctly, radiographic inspection is the best non-destructive method for detecting internal
defects, such as shrinkage and inclusions.
In this method, a casting is exposed to radiation from an x-ray tube. The casting
absorbs part of the radiation, and the remaining portion of the radiation exposes the

radiographic film. Dense material withstands the radiation penetration, so the film is exposed
to a lesser degree in those areas, giving the film a lighter appearance. Less dense materials
allow more penetration and correlates to darker areas on the film. Any hole, crack or
inclusion that is less dense than the casting alloy is revealed as a dark area.
When done correctly, radiographic inspection is the best non-destructive method for
detecting internal defects, such as shrinkage and inclusions, and the radiograph serves as a
permanent record of the casting quality that can be reviewed by multiple personnel. Casting
thickness and density will limit the rang of inspection possible, depending on the energy level
of the radiation.
Radiographic inspection also can be performed without film. Instead, the x-ray image
is viewed on a video screen. Computerized axial tomography (CAT scanning) also is being
used to develop 3-D computer imagery to inspect a casting’s soundness.
f. Pressure Leak Testing
When a casting is specified to be pressure tight or leak-proof, it is often tested by sealing
openings in the casting and pressurizing it with air, inert gas or water.
When water, or hydrostatic, pressure is used, water seeping through the casting wall
indicates leaks. If air or gas pressure is used, the pressurized casting is put into a tank of clear
water. The appearance of bubbles indicates the air has penetrated through the casting wall
and a leak is present.

5. CONCLUSION
Indo Farm foundry sections it is necessary to increase the production rate of the product,
which is being manufactured in that foundry. So in past the core making was done manually,
which takes very much time and due to that production rate decreases. So due to development
of core shooter, the production rate of the core increases and ultimately demand for the
product also increases. Therefore it results in following,
1) Increased production rate.
2) Cost effectiveness.
3) Quality assurance.
4) Energy conservation.
5) Reduces human skill required and human fatigue.
Now, finally we conclude that at present it is essential to increase the production rate of the
product due to its increased demand. So to fulfill such kinds of requirements it is the best way
of developing and modifying such types of core shooters according to the product demand at
present as well as in future.

6. ACHIEVMENTS
The extensive in-house infrastructure, commitment to quality, conformance to specifications
and deliver under tight schedules are the key strengths of Indo-farm. Consequently Indofarm
has earned a formidable reputation internationally, for the quality and conformance of
specifications of its products, over the years. Not resting on its achievements Indo-farm
remains in an unending quest to increase its productivity and enhance customer value through
implementation of quality systems.Team Indofarm is hectically involved in a series of best
practices like statistical process control(SPC),failure mode and effect analysis(
FMEA),production part approval process(PPAP), Advaced product quality
planning(APQP),measurement system analysis( MSA),seiri ,seiton ,seiso, seiketsu, shitsuke
(5S), Histograms, cause and effect diagram,check sheets, pareto diagram ,graphs, control
charst, scatter diagrams(7 QC Tools), (Poka Yoke) mistake proofing, (DWM) , TEI, etc.
Indofarm was accredited with ISO 9001 certification by Underwriter Laboratories (UL) in
year 2000 but it never rested on its oars in further improvement of its quality management
system. Today, Indofarm is earnestly working towards getting TS: 16949 certification by
March 2008.

7. LIMITATION
1.First limitation is that time interval for this training that is four weeks was really short.
2 Irregular power cut off .
3. Daily working period in the industry was also limited.
4. Lack of transportation.

8. SOLUTION TO THE PROBLEMS
As a blast cleaning equipment, is frequently applied for surface cleaning of large work pieces
and forging parts. In the daily use of shot blasting device, there might be different kinds of
troubles with the shot blasting machine. Here professional solutions are offered. Try the
solutions one by one and the difficulties will be solved smoothly.
Unsatisfactory Cleaning Effect
1. Maybe the supply of shots is not enough, so we shall add new shots.
2. There might be slight error with the throwing direction of the impeller head. The impeller
head should be adjusted to the window of the control cage.
3. The grain size of the shots is not appropriate. Re-elect the grain size of the shots.
4. The shot material has formed into mass after long term use. Replace the shot material.
Low Efficiency of Dust Remover
1. There might be wrong connection with the air blower of the dust remover, which makes
the air blower blows reversely. Connect the wires again.
2. The filter cartridge in the dust remover is installed loosely or is damaged. Or there is no
filter cartridge.
3. The sealing at the pipe joints of dust remover is bad. Make sure the perfect sealing of each
part.
4. The back flowing system of the dust remover is not used, or used less, which will make the
dust block the filter cartridge. Clean the dust attached on the filter cartridge in time.

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