TUSHAR UDYOG

CHAPTER: 1
Introduction:-

1.1 Company Profile:-

Company Name:- TUSHAR UDYOG

Address:-D-80, MIDC, Ambad, Nashik, Maharashtra-422010

Company Functional Area:- Castings by sand and Gravity Die Castings

(100gms to 25kg),Heat treatment and Machining

TUSHAR UDYOG is committed to satisfaction, delivery and competitive cost. With the use of
latest state of the art technology and technically competitive workforce, we maintain quality of
products all the time.
TECHNOLOGY : VMC, CNC Machines, Gravity Dies with Hydraulic Automation, Tilting
Machines and fully equipped machine shop.

QUALITY: Incoming ingots are checked spectrometrically. Each melt is checked for structure,
pinholes and temperature.

VALUES: Honesty, Humane Approach, Knowledge Enrichment of employees and associates

TESTING: Periodically testing of tensile and elongation. Each component is checked at every
stage.

All the employees at TUSHAR UDYOG are committed to manufacture aluminium castings
by using sand casting and gravity die casting components and other components to meet customer
needs and expectations in dynamic environment. They work hard to achieve this through a process
of continuous improvements in all areas of operations, by giving emphasis on defect prevention,
reduction in variation & waste, development of employees, reducing manufacturing cost, reducing
customer complaints and maintaining Quality Systems by complying the requirements of the
Quality Management system as well as statuary and regulatory
requirements…………………………………………………………………………
This policy shall be reviewed periodically and revised to meet their commitments to customer.

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Company Clients:-

 ABB
 ATLAS COPCO
 CRYTRON:
 CTR:
 DHUMAL
 RACON ENTERPRISES
 SUKRUT
 WELDCON
 DYNOPAC,INDIA

1.2 Company focus and belief:-

Tushar Udyog is committed to satisfaction, delivery and competitive cost.

With the use of latest state of the art technology and technically competitive workforce, we
maintain quality of products all the time.

1.3 company strategy:-

 Team Work.
 Organizational and individual discipline, perform duty in aggressive manner to achieve
organizational goals.
 Constantly increase use of computers to improve functioning in order to reduce operational costs.
 Constant increase of productivity of labour & returns on capital.
 Steady improvement of quality & reduction of cost.
 Customer Orientation.
 Having long term objectives policies and confidence in attaining our goals.
 Respect for laws, ethics and Human beings.

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1.4 Company layout

Foundry:-

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Machining Area:-

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CHAPTER: 2
2.1 Material flow:-

RAW MATERIAL (ALUMINIUM )

MELTING OF ALUMINIUM IN FURNACE

POURING OF MOLTEN ALUMINIUM IN MOULD

ALLOW TO SOLIDIFY WHICH IS KNOWN AS CASTING

RISER CUTTING

FETTLING AND GRANDING

HARDNING

MACHINING AS PER REQUIRED DIMENSIONS

FILLING AND DEBOURING

CLEANING AND WASHING

FINAL QUALITY INSPECTION

THIRD PARTY INSPECTION

DISPATCH

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2.2 Operation Shops:-

2.2.1 Raw material storage shop:-

Material used for manufacture of casting component is Aluminium alloy. It is used LM5,
LM6, LM25,grade aluminium alloy. Which contain Silicon, Magnesium, Copper, Nickel alloying
elements. According to the variation of alloying elements in the Aluminium parent metal LM
Grade vary.

2.2.2 CNC Machining:-

Numerical control (NC) (also computer numerical control (CNC)) is the automated control
of machining tools (drills, boring tools, lathes) and 3D printers by means of a computer. An NC
machine alters a blank piece of material (metal, plastic, wood, ceramic, or composite) to meet
precise specifications by following programmed instructions and without a manual operator.

NC machines combine a motorized manoeuvrable tool and often a motorized manoeuvrable

platform, which are both controlled by a computer core, according to specific input instructions.
Instructions are delivered to an NC machine in the form of graphical computer-aided design (CAD)
files, which are transformed into a sequential program of machine control instructions such as G-
code, and then executed. In the case of 3D Printers, the part to be printed is "sliced", before the
instructions (or the program) is generated.

NC is a major advance in machining, and is a vast improvement over non-computer type machining
that requires manual control, by hand wheels or levers, or mechanical control by fabricated pattern
guides (cams). In modern CNC systems, the design of a mechanical part and its manufacturing
program is highly automated. The resulting directives are transformed (by "post processor"
software) into the specific commands necessary for a particular machine to produce the
component, and then are loaded into the CNC machine.

Since any particular component might require the use of a number of different tools – drills, saws,
etc. – modern machines often combine multiple tools into a single "cell". In other installations, a
number of different machines are used with an external controller and human or robotic operators
that move the component from machine to machine. In either case, the series of steps needed to
produce any part is highly automated and produces a part that closely matches the original CAD.
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Specifications:-
Table no: 2.1: CNC machine specifications

Model IGLOO
Serial No. 7331
Refrigerant R-134a
Nominal cap3 926 Kcal/hrs
Supply 230V single phase
Frequency 50 HZ
Full LOAD AMPS 10A

Fig.2.2.2 CNC Machine

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2.2.3 VMC Machine:-

It means vertical milling machine, it has a vertical Z-axis Spindle. CNC machining is a
manufacturing process in which pre-programed. Computer software dictates the movements of
factory tools and machinery. The process can be used to control a range of complex machinery
from grinders and lathes to mills and routers with CNC machining, three dimensional cutting task
can be accomplished in a single set of prompts. short for 'computer numerical control,' the CNC
process runs in contrast to-and their by supersedes-the limitation of manual control where live
operation are needed to promote and guide the commands of machining tools via levers, buttons
and wheels. To the on looker a CNC system might resemble a set of computer components but the
software program and console employed on CNC machining distinguish it from all other forms of
computation.

Vertical Machining Centre has been leaders in machine tools for the past 20 year in aerospace, die-
molds, medical and energy industries.

Specifications:-

Table No: 2.2: VMC specifications

Model number Turbo- 500-R50

Serial number 4928/02-14/53840
Phase 1
Capacity 500 watt
Volts 230
Frequency 50HZ
Amperes 2.5
Refrigerant R-134a
Temperature range 10-45 deg
Setting time 40min

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Fig.2.2.3VMC Machine

2.2.4 Milling Machine:-

Milling machine is one of the most versatile conventional machine tools with a wide range of metal
cutting capability. Many complicated operations such as indexing, gang milling, and straddle
milling etc. can be carried out on a milling machine.

This training module is intended to give you a good appreciation on the type of milling machines
and the various types of milling processes. Emphasis is placed on its industrial applications,
operations, and the selection of appropriate cutting tools.

On completion of this module, you will acquire some of these techniques from the training
exercises as illustrated in figure 1. However, to gain maximum benefit, you are strongly advised

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to make yourself familiar with the following notes before undertaking the training activities, and
to have a good interaction between yourself and the staff in charge of your training.

Assessment of your training will be based on a combination of your skill and attitude in getting
the work done.

Specification:-
Table no: 2.3: Milling machine specifications

Machine type Turbo universal milling

Model MAC-2
Sr. no. 3
Size 1120.M.M*280 M.M

Fig.2.2.4 Milling Machine

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2.2.5 Lathe Machine:-

Lathe is a machine, which removes the metal from a piece of work to the required shape and size.
Lathe is one of the most important machine tools in the metal working industry. A lathe operates
on the principle of a rotating workpiece and a fixed cutting tool. The cutting tool is feed into the
workpiece, which rotates about its own axis causing the workpiece to be formed to the desired
shape. Lathe machine is also known as “the mother/father of the entire tool family”.

Function of lathe is to remove excess material in the form of chips by rotating the work piece
against a stationary cutting tool

1 .Industrial revolution demanded

2. More production

3. More Precision

4. Changes in manufacturing process

5. Lead to the development of high speed

6. Special purpose lathes

Main Parts

Lathe Machine is also known as “Centre Lathe”, because it has two centres between which the job
can be held and rotated. The main parts of centre lathe are: Bed, Head stock, Tail stock, Carriage,
etc.

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Fig.2.2.5 (i) Thread Chart

Fig.2.2.5 (ii) Lathe Machine

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2.2.6 Drilling Machine:-

Drilling machines: Classification, constructional features, drilling & related operations, types of
drill & drill bit nomenclature, drill materials. Basic purposes of use of drilling machines

• Drilling machines are generally or mainly used to originate through or blind straight cylindrical
holes in solid rigid bodies and/or enlarge (coaxially) existing (pre-machined) holes:

9 of different diameter ranging from about 1 mm to 40 mm

9 of varying length depending upon the requirement and the diameter of the drill

9 in different materials excepting very hard or very soft materials like rubber, polythene etc.

Table sensitive drilling machine:

These small capacity (≤ 0.5 kW) upright (vertical) single spindle drilling machines are mounted
(bolted) on rigid table and manually operated using usually small size (φ≤ 10 mm) drills. Fig. 4.1
typically shows one such machine.

Specification:-

Fig 2.2.6(i) Speed Chart

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Fig 2.2.6(ii) Drilling Machine

2.2.7 Angle Grinder:-

An angle grinder, also known as a side grinder or disc grinder, is a handheld power tool used for
grinding (abrasive cutting) and polishing.

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Fig.2.2.7 Angle Grinder

Angle grinders can be powered by an electric motor. The motor drives a geared head at a right-
angle on which is mounted an abrasive disc or a thinner cut-off disc. Angle grinders typically have
an adjustable guard and a side-handle for two-handed operation. Certain angle grinders, depending
on their speed range, can be used as sanders, employing a sanding disc with a backing pad or disc.
Angle grinders are standard equipment in industry. They are also common in machine shops, along
with die grinders and bench grinders.
Angle grinders may be used for removing excess material from a piece. There are many different
kinds of discs that are used for various materials and tasks, such as cut-off discs (diamond blade),
abrasive grinding discs, grinding stones, sanding discs, wire brush wheels and polishing pads.

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2.2.8 Riser Cutter:-

It is used after casting to cut the runner, riser and extra material of casting. This operation is
carried out for reduced the load of parts for future machining operations, and easy handling.

Fig.2.2.8 Riser Cutter

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2.2.9 Brinell Hardness Testing Machine:-

Principles :-

An indenter (hard metal ball with diameter D) is forced into the surface of a test piece and the
diameter of the indentation d left in the surface after removal of the force F is measured.

The Brinell hardness is proportional to the quotient obtained by dividing the test force by the
curved surface area of the indentation. The indentation is assumed to be spherical with a radius
corresponding to half of the diameter of the ball.

Fig.2.2.9 Brinell Hardness Testing Machine.

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Hardening Processes:-

1. Solutionising:-

Fig No.2.11 Solutionising

Process:-

Solution heat treatment is done by raising the alloy temperature to about 525 degrees C and
holding it there for about an hour. The purpose of this is to dissolve all the alloying elements in a
solid solution in the aluminum. The heated components are put in water tank. Then quenching
is done in water.

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2. Aging:-

Fig No.2 Aging Process

Process:-

The process of aging is commonly described as a time-temperature-dependent change in the

properties of certain alloys. Except for strain aging and age softening, it is the result of precipitation
from a solid solution of one or more compounds.

It is called precipitation hardening as it makes use of solid impurities or precipitates for the
strengthening process. Through the age hardening process the tensile and yield strength are
increased. The precipitates that are formed inhibit movement of dislocations or defects in the
metals crystal lattice.

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CHAPTER: 3
Casting Process:-

3.1 Introduction:-
Casting is a manufacturing process in which a liquid material is usually poured into a mold,
which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified
part is also known as a casting, which is ejected or broken out of the mold to complete the process.
Casting materials are usually metals or various time setting materials that cure after mixing two or
more components together; examples are epoxy, concrete, plaster and clay. Casting is most often
used for making complex shapes that would be otherwise difficult or uneconomical to make by
other methods. Casting is a 7000-year-old process. The oldest surviving casting is a copper frog
from 3200 BC.

3.2 Sand Casting:-

Sand casting also known as sand molded casting, is a metal casting process characterized
by using sand as the mold 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 60% of all metal castings are produced via sand casting process. Molds made of sand are
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.

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Fig.No.3.2.1 Process Flow Chart

3.2.1 Basic Process:-

There are six steps in this process:

1. Place a pattern in sand to create a mold.

2. Incorporate the pattern and sand in a gating system.

3. Remove the pattern.

4. Fill the mold cavity with molten metal.

5. Allow the metal to cool.

6. Break away the sand mold and remove the casting.

3.2.2 Components:-

Furnace:-

It is the pot or vessel in which the metal is melted. Furnaces are refractory-lined vessels that
contain the material to be melted and provide the energy to melt it. Modern furnace type include
electric arc furnace, induction furnace, cupolas, reverberatory, and crucible furnaces.

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Electric heating furnace:-

Fig.No.3.2.2 Electric Furnace and melted aluminum

Patterns:-
From the design, provided by a designer, a skilled pattern maker builds a pattern of the
object to be produced, using wood, metal, or a plastic such as expanded polystyrene. Sand can be
ground, swept or stickled into shape. The metal to be cast will contract during solidification, and
this may be non-uniform due to uneven cooling. Therefore, the pattern must be slightly larger than
the finished product, a difference known as contraction allowance. Different scaled rules are used
for different metals, because each metal and alloy contracts by an amount distinct from all others.
Patterns also have core prints that create registers within the molds into which are placed sand
cores.

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Fig. No. 3.2.3 Wooden Pattern

Cores:-

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 molded, 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 mold at
the appropriate moisture content, the box containing the sand mold 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 being filled 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. Floating the mold occurs
when the pressure of the metal pushes the sand above the mold 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.

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Fig.No.3.2.4 Sand Core

Cope and Drag:-

In foundry work the term cope and drag refers respectively to top and bottom parts of two
part casting flask, used in sand casting. The flask is a wood or metal frame, which contains the
molding sand, provide in support to the sand as the metal is poured into mold. In flask-less
molding, the same term are used, cope for the top or upper piece and drag for the bottom or lower
piece.

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Fig.No.3.2.5 Cope and Drag

3.2.3 Design Requirement:-

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 molding 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 mold. 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 mold in order to avoid an incomplete casting. Should a piece of core or mold
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, nondestructive testing methods may be applied before
further work is performed.

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Mold Material:-

There are four main components for making a sand casting mold: base sand, a binder,
additives, and a parting compound.

Fig. No.3.2.6 Mold Material

Molding sands:-

Molding sand also known as foundry sands, are defined by eight characteristics:
refractoriness, chemical inertness, permeability, surface finish, cohesiveness, flowability,
collapsibility, and availability/cost.

Binders:-

Binders are added to a base sand to bond the sand particles together (i.e. it is the glue that
holds the mold together).

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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 mold).

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 diphenyl
disocyanate) is also a commonly used binder resin in the foundry core process.

Parting compounds:-

To get the pattern out of the mold, prior to casting, a parting compound is applied to the
pattern to ease removal. They can be a liquid or a fine powder (particle diameters between 75 and
150 micrometers (0.0030 and 0.0059 in)). Common powders include talc, graphite, and dry silica;
common liquids include mineral oil and water-based silicon solutions. The latter are more
commonly used with metal and large wooden patterns.

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3.3 Die Casting:-

Die casting is a metal casting process that is characterized by forcing molten metal under
high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies
which have been machined into shape and work similarly to an injection mold during the process.
Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminum,
magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot-
or cold-chamber machine is used.

The casting equipment and the metal dies represent large capital costs and this tends to limit the
process to high-volume production. Manufacture of parts using die casting is relatively simple,
involving only four main steps, which keeps the incremental cost per item low. It is especially
suited for a large quantity of small- to medium-sized castings, which is why die casting produces
more castings than any other casting process. Die castings are characterized by a very good surface
finish (by casting standards) and dimensional consistency.

Fig.No.3.3.1 Die Casting Process Flow Chart

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Cast metals:-

The main die casting alloys are: zinc, aluminum, magnesium, copper, lead, and tin

Aluminium:- lightweight; high dimensional stability for complex shapes and thin walls; good
corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains
strength at high temperatures.

3.3.1 Design Geometry:-

There are a number of geometric features to be considered when creating a parametric

model of a die casting.

Fig. No.3.3.2 Die Geometry

Draft:-

Draft is the amount of slope or taper given to cores or other parts of the die cavity to
allow for easy ejection of the casting from the die. All die cast surfaces that are parallel to the

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opening direction of the die require draft for the proper ejection of the casting from the die. Die
castings that feature proper draft are easier to remove from the die and result in high-quality
surfaces and more precise finished product.

Fillet:-

Fillet is the curved juncture of two surfaces that would have otherwise met at a sharp
corner or edge. Simply, fillets can be added to a die casting to remove undesirable edges and
corners.

Parting line:-

Parting line represents the point at which two different sides of a mold come together. The
location of the parting line defines which side of the die is the cover and which is the ejector.

Bosses:-

Bosses are added to die castings to serve as stand-offs and mounting points for parts that
will need to be mounted. For maximum integrity and strength of the die casting, bosses must have
universal wall thickness.

Ribs:-

Ribs are added to a die casting to provide added support for designs that require maximum
strength without increased wall thickness.

Holes and windows:-

Hole and windows require special consideration when die casting because the perimeters
of these features will grip to the die steel during solidification. To counteract this effect, generous
draft should be added to hole and window features.

3.3.2 Types of Die Casting:-

There are two basic types of die casting machines: hot-chamber machines and cold-
chamber machines. These are rated by how much clamping force they can apply.

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Typical ratings are between 400 and 4,000 st (2,500 and 25,400 kg). Equipment

Hot-chamber die casting:-

Hot-chamber die casting, also known gooseneck machines, rely upon a pool of molten
metal to feed the die. At the beginning of the cycle the piston of the machine is retracted, which
allows the molten metal to fill the "gooseneck". The pneumatic- or hydraulic-powered piston then
forces this metal out of the gooseneck into the die. The advantages of this system include fast cycle
time and the convenience of melting the metal in the casting machine. The disadvantages of this
system are that it is limited to use with low-melting point metals and that aluminium cannot be
used because it picks up some of the iron while in the molten pool. Therefore, hot-chamber
machines are primarily used with zinc-, tin-, and lead-based alloys.

Cold-chamber die casting:-

These are used when the casting alloy cannot be used in hot-chamber machines; these
include aluminium, zinc alloys with a large composition of aluminium, magnesium and copper.
The process for these machines start with melting the metal in a separate furnace. Then a precise
amount of molten metal is transported to the cold-chamber machine where it is fed into an unheated
shot chamber (or injection cylinder). This shot is then driven into the die by a hydraulic or
mechanical piston. The biggest disadvantage of this system is the slower cycle time due to the need
to transfer the molten metal from the furnace to the cold chamber machine.

3.3.3 Process:-

The following are the four steps in traditional die casting, also known as high pressure die
casting, these are also the basis for any of the die casting variations: die preparation, filling,
ejection, and shakeout. The dies are prepared by spraying the mold cavity with lubricant. The
lubricant both helps control the temperature of the die and it also assists in the removal of the
casting. The dies are then closed and molten metal is injected into the dies under high pressure;
between 10 and 175 mega-pascals (1,500 and 25,400 psi). Once the mold cavity is filled, the
pressure is maintained until the casting solidifies. The dies are then opened and the shot (shots are

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different from castings because there can be multiple cavities in a die, yielding multiple castings
per shot) is ejected by the ejector pins. Finally, the shakeout involves separating the scrap, which
includes the gate, runners, sprues and flash, from the shot. This is often done using a special trim
die in a power press or hydraulic press. Other methods of shaking out include sawing and grinding.
A less labor intensive method is to tumble shots if gates are thin and easily broken; separation of
gates from finished parts must follow. This scrap is recycled by re-melting it.

Fig.No.3.3.3 Casting Parts

3.4 Inspection:-
After the shakeout of the casting it is inspected for defects. The most common defects are
misruns and cold shuts. These defects can be caused by cold dies, low metal temperature, dirty
metal, lack of venting, or too much lubricant. Other possible defects are gas porosity, shrinkage
porosity, hot tears, and flow marks. Flow marks are marks left on the surface of the casting due to
poor gating, sharp corners, or excessive lubricant.

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3.5Advantages of Die Casting:-

1.Excellent dimensional accuracy (dependent on casting material, but typically 0.1 mm for the first
2.5 cm (0.004 inch for the first inch) and 0.02 mm for each additional centimeter (0.002 inch for
each additional inch).

2.Smooth cast surfaces (Ra 1–2.5 micrometeres or 0.04–0.10 thou rms).

3.Thinner walls can be cast as compared to sand and permanent mold casting (approximately
0.75 mm or 0.030 in).

4. Inserts can be cast-in (such as threaded inserts, heating elements, and high strength bearing
surfaces).

5.Reduces or eliminates secondary machining operations.

6. Rapid production rates.

7. Casting tensile strength as high as 415 megapascals (60 ksi).

8.Casting of low fluidity metals.

3.6 Disadvantages:-
1.The main disadvantage to die casting is the very high capital cost. Both the casting equipment
required and the dies and related components are very costly, as compared to most other casting
processes.

2. To make die casting an economic process, a large production volume is needed.

3. The process is limited to high fluidity metals, and casting weights must be between 30 grams
(1oz) and 10 kg. In the standard die casting process the final casting will have a small amount of
porosity.

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3.7 Degassing:-

Degasification is the removal of dissolved gases from liquids, especially water or aqueous
solutions. There are numerous possible methods for such removal of gases from liquids. The
formation of gas bubbles when a liquid is frozen can also be undesirable, necessitating degassing.
This process is called degasification.

Rotary degasser:-

Rotary degasser In the rotary degassing method an inert or chemically inactive gas (Argon,
Nitrogen) is purged through a rotating shaft and rotor. Energy of the rotating shaft causes formation
of a large number of fine bubbles providing very high surface area-to volume ratio. Large surface
area promotes fast and effective diffusion of hydrogen into the gas bubbles resulting in equalizing
activity of hydrogen in liquid and gaseous phases. Rotary degasser allows achieve more complete
hydrogen removal as compared to the flux degassing. Additionally rotary degasser does not use
harmful chlorine and fluorine containing salts. degasser may also combine the functions of
degassing and flux introduction. In this case the inert gas serves as carrier for granulated flux. The
method is called flux injection.

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Fig.No.3.7.1 Rotary Degasser

Pore Free Casting:-

When no porosity is allowed in a cast part then the pore-free casting process is used. It is
identical to the standard process except oxygen is injected into the die before each shot to purge
any air from the mold cavity. This causes small dispersed oxides to form when the molten metal
fills the die, which virtually eliminates gas porosity. An added advantage to this is greater strength.
Unlike standard die castings, these castings can be heat treated and welded. This process can be
performed on aluminium, zinc, and lead alloys

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CHAPTER:4

Quality Control:-

Quality control (QC) is a process by which entities review the quality of all factors involved in
production. ISO 9000 defines quality control as "A part of quality management focused on
fulfilling quality requirements"

It depends on various factors that affects the quality of product i.e. material, tools, machines, type
of labour, working condition, measuring instruments etc.

Objectives of Quality Control

 To improve the company’s income by making the product more acceptable to the customer,
by providing long life, aesthetic aspect etc.
 To reduce company’s cost through reduction of total losses due to defects.
 To produce optimum quality at minimum price
 To ensure satisfaction of customer with products of high quality level, to build customers
good will, confidence and reputation of manufacturer.

Quality Improvement Technique:-

 Kaizen :-
A Japanese business philosophy of continuous improvement of working practices.

 Kanban :-
A Japanese manufacturing system in which the supply of components is regulated through
the use of an instruction card sent along production line.

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 5S :-
1. Seiri (Sort): Sort through materials, keeping only the essentials items need to
complete task.
2. Seiton (Set in Order): Ensures that all items are organized and each item has
designated place.
3. Seiso (Shine): Proactive efforts to keep workplace areas clean an orderly to ensure
purpose driven work.
4. Seiketsu (Standardize): Create set of standards for both organisation and processes.
5. Shitsuke (Sustain): Sustain new practices and conduct audits to maintain.
.
4.1 Inspection:-
Inspection is a part of quality control. Inspection is an act of checking materials, parts, components
or products at various stages of manufacturing and sorting out the faulty or defective items from
the good items.

Method of inspection:-

4.1.1. Visual Inspection:-

It consists of inspecting the surface of the casting with naked eye or sometimes with a
magnifying glass or microscope. It can only indicate surface defects such as blow holes,
fusion, swells, external cracks, and mismatch. Almost all castings are subjected to certain
degree of visual inspection.

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Fig No.4.1. Visual Inspection

4.1.2. Dimensional Inspection:-

Dimensional inspection is carried out to make sure that the castings produced have the
required overall dimensions including allowances for machining. It may sometimes be
necessary to break a part of the casting to take measurements of inside dimensions.

Fig.No.4.2. Dimensional Inspection

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4.1 Instruments used for Inspection:-

Sr. no. Instrument Purpose

1 Vernier Calliper For measuring length, internal and external
diameter
2 Micrometer For measuring accurate diameter
3 Measuring Tape To measure linear dimensions

5 Filler Gauge To measure the clearance

6 ID clipper To measure linear dimension
7 Brinell Hardness tester To measure hardness
8 Vernier height gauge To measure height
9 Go no-go gauge To check the dimension of thread
10 Snap Gauge To check the external diameters
11 Dial Indicator To check close tolerances

Table No.4.1.3 Inspection Instruments

4.2 Testing:-

Methods of testing:-

4.2.1 Destructive Testing:- Destructive testing are the tests which are carried out to the
specimens failure. In destructive testing they cut the specimen in half section around which
specimen is symmetrical.

So that they can measure internal thickness of cavities as well as can check blow holes or any
other casting defects very efficiently.

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Fig No.4.2.1 Half Cut off Section of Work piece

4.2.2Dye Penetrant Testing:-

This method also is used for detecting very small surface cracks and has the advantage over
the magnetic particle method that it can be used for any material. The parts to be tested are
either dipped into or covered with a penetrant testing liquid which has very good wetting
and penetrating ability. The liquid is drawn into the cracks or voids by capillary action.

After the penetrant has been applied to the surface to be tested extra penetrant is wiped off
the surface is dried and a developer applied to it. This developer helps in drawing out the
penetrant so that it becomes visible on the surface. The penetrant liquids often contain
materials which fluoresce under ultraviolet light or a die to indicate their presence.

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Fig No.4.2.2 Dye Penetrant Test

4.2.3 Air Leak Detection of Castings:-

In this testing the component is filled with air at a 0.3 bar and dipped in water tank. If the
bubbles are appears near the joints and at surface then it shows that the tank is leak. If not then
the tank is proceeds to next process.

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Fig No.4.2.3. Air Leak Detection Test

4.2.4 Hardness Testing:-

The Brinell method applies a predetermined test load (F) to a carbide ball of fixed diameter
(D) which is held for a predetermined time period and then removed. The resulting
impression is measured with a specially designed Brinell microscope or optical system
across at least two diameters – usually at right angles to each other and these results are
averaged (d). Although the calculation below can be used to generate the Brinell Hardness
number.

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Fig No.4.2.4Hardness Report

4.2.5 Chemical Testing

Chemical testing is carried out to get ensure that aluminium castings having desired
chemical composition as per standards. So, to carry out the chemical testing a small piece
of specimen is sent to laboratory which is accredited by NABL(National Accreditation
Board for Testing and Calibration Laboratories).

After inspection laboratory issues the certificate which claims the chemical composition of
material is as per standard or not.

Fig No.4.2.5 (i) Sample For Testing

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Fig No.4.2.5 (ii) Chemical Certification

4.2.6. Mechanical Testing

Mechanical testing involves applying forces and pressure to a component or system and
measuring its response. This is designed to check that the physical and mechanical
properties meet the expected requirements and it performs as needed. This form of testing
is used to measure properties such as tensile strength, hardness, impact resistance and
elongation.

A test bar is sent to the laboratory which is accredited by NABL (National Accreditation
Board for Testing and Calibration Laboratories).They issues the certificate which defines
all the mechanical properties of material.

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Fig No.4.2.6 (i) Test Bar For Testing

Fig No.4.2.6 (ii) Physical Properties Certification

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4.3 Calibration:-

Fig.No.4.3 (i) Calibration

Calibration in measurement technology and metrology is the comparison of measurement values

delivered by a device under test with those of a calibration standard of known accuracy. Such a
standard could be another measurement device of known accuracy, a device generating the
quantity to be measured such as a voltage, sound tone, or a physical artefact, such as a metre ruler.

The outcome of the comparison can result in no significant error being noted on the device under
test, a significant error being noted but no adjustment made, or an adjustment made to correct the
error to an acceptable level. Strictly speaking, the term calibration means just the act of
comparison, and does not include any subsequent adjustment.

The calibration standard is normally traceable to a national standard held by a National

Metrological Institute.

Industry undergo through calibration after every 6 months or a year. Instruments are send to some
calibration consultancy and they calibrate it .After approval or certification is done then only instrument
is again comes in use.

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Fig.No.4.4 (ii) Calibration Certificate

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CHAPTER: 5
1. Case Study
Degasing Case Study:-
Degassing of molten Aluminium alloys is a foundry operation aimed to
remove Hydrogen dissolved in the melt. In the rotary degassing method an inert or
chemically inactive gas (Argon, Nitrogen) is purged through a rotating shaft and rotor.
Energy of the rotating shaft causes formation of a large number of fine bubbles providing
very high surface area-to volume ratio. Large surface area promotes fast and effective
diffusion of hydrogen into the gas bubbles resulting in equalizing activity of hydrogen in
liquid and gaseous phases.

Disadvantages:-
 Dependence on outside suppliers: Delivered gas is subject to price increases, rental
agreements, long-term contracts, hazmat fees, inflexible delivery schedules, surcharges
and taxes as well as extra administrative work.
 Environmental considerations: Nitrogen is generated through fractional distillation of air.
While N2 is not considered a greenhouse gas, it is important to recognize that isolation of
the gas from air by fractional distillation is an energy-intensive process.
 The energy employed to generate N2 produces a significant quantity of carbon dioxide
(CO2). Also, nitrogen deliveries are made by heavy trucks that further contribute to
CO2 emissions.
 Safety risks: High-pressure cylinders are typically filled to 2000 psi. They must be
carefully handled and stored because leaks or explosions could occur.

Analysis:-
In order to overcome this disadvantages the new method of degassing can be use that is
‘VACUUM DEGASSING’. In order to keep a low hydrogen content all the time during
the continual pouring (such as the case in low pressure die casting, high pressure casting

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and permanent gravity casting), a patented degassing method is investigated. A porous

refractory absorber that is connected with a vacuum system is immersed in the molten
aluminum. The vacuum is started inside the porous absorber and the dissolved hydrogen
atom will diffuse towards the absorber. In this way, the hydrogen in the melt is removed
through the vacuum system. The absorber is made of mullite and of porous structure. It is
permeable with gas but can’t be penetrated by the molten aluminum. RPT experiment
(Reduced Pressure Test) and density test were conducted to evaluate effectiveness of the
new method. The experiments indicate that use of the absorber can improve the
metallurgical quality of the melt.

2. Case study

Sand Casting:-

Sand casting, also known as sand molded casting, is a metal casting process characterized by using
sand as the mold 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
60% of all metal castings are produced via sand casting process.

Molds made of sand are 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 the
strength and plasticity of the clay and to make the aggregate suitable for molding. The sand is
typically contained in a system of frames or mold boxes known as a flask.

Sand Casting Disadvantages:-

1. Low strength: - low material strength due to high porosity compared to machined part.

2. Low dimensional accuracy: - because of shrinking and the surface finished dimensional
accuracy very poor.

3. Poor surface finish: - due to internal sand mold wall surface texture.

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Sand Casting Defects:-

1. Gas porosity- blowholes, open holes, pin holes.

2. Shrinkage defect- shrinkage cavity

3. Mold material defect- cold shut, misran, slag inclusion.

4. Metallurgical defect- hot tears, hot spot

How To Overcome Porosity:-

1. Porosity can be eliminated through good mold design or by introducing nitrogen into the
aluminum before pouring.

2. HIPPING can also be done to eliminate small amount of porosity.

3. Sufficient ramming should be done.

4. High permeability sand should be used.

5. By reducing the moisture content of the molding sand.

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CONCLUSION

 We studied and gained detailed knowledge about various processes such as heat treatment (
Quenching), Die penetrant testing, Leakage testing,
 Some quality control methods like dimension checking, blow holes checking, chemical and
mechanical testing of various aluminium grades and calibration analysis were studied.
 We have implemented 5S.
 The purpose of various sections in an industry such as CNC & VMC room, foundry section,
machining section and inspection lab is studied.
 We have gained detailed knowledge about packing and Dispatching.
 The knowledge about frequent maintenance of machineries are studied.
 The company discipline, manners and etiquettes were understood.

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