A

PROJECT REPORT ON

“Plate Analysis of Shell Core Shooter Machine”

Submitted by:
Sr No. Name Enrollment No.
1 Pethani Hemang B. 150760119090
2 Satani Vivek V. 150760119098
3 Savaliya Kaushal B. 150760119101
4 Shyani Maulik R. 150760119109
5 Thummar Tushar R. 150760119113

UNDER THE GUIDANCE OF:

Prof. Vijay A. Radadiya

Assistant Professor, MED, SSASIT, Surat.

Mr. Naimesh Shethiya, Production Engineer

(Industrial Guide, Susha Funders and Engineers)

Submitted to
Gujarat Technological University
In Partial Fulfillment for the subject PROJECT-1(2170001)
The Degree of Bachelor of Engineering
in
MECHANICAL ENGINEERING

October-2018
Shree Swami Atmanand Saraswati Institute of Technology,
Surat – 395 006
 Shree Swami Atmanand Saraswati
Institute of Technology

CERTIFICATE
This is to certify that the project entitled “Plate Analysis of Shell Core
Shooter Machine”

Submitted by

PETHANI HEMANG 150760119090

SATANI VIVEK 150760119098
SAVALIYA KAUSHAL 150760119101
SHYANI MAULIK 150760119109
THUMMAR TUSHAR 150760119113

In partial fulfillment of the requirement for the award of the Bachelor

Degree in Mechanical Engineering of the Gujarat Technological
University (GTU), Ahmedabad, at Shree Swami Atmanand Saraswati
Institute of Technology, Surat is a record of their work carried out under
our supervision and guidance.

Prof. VIJAY A. RADADIYA Prof. Jignesh Vaghasia

Assistant Professor, Head of Department
Mechanical Engineering Department Mechanical Engineering Department
(Project Guide)
 Shree Swami Atmanand Saraswati
Institute of Technology, Surat

EXAMINER’S CERTIFICATE
OF
APPROVAL
This is to certify that project entitled “Plate Analysis of Shell Core Shooter
Machine”
submitted by

PETHANI HEMANG 150760119090

SATANI VIVEK 150760119098
SAVALIYA KAUSHAL 150760119101
SHYANI MAULIK 150760119109
THUMMAR TUSHAR 150760119113
In partial fulfillment of the requirement for the award of the Bachelor
Degree in “Mechanical Engineering” of the Gujarat Technological
University (GTU), Ahmedabad, at Shree Swami Atmanand Saraswati
Institute of Technology, Surat.

Examiners: 1) ………………………………

2) ………………………………
 ACKNOWLEDGMENT
Successful completion of work will never be one man’s task. It requires
hard work in right direction. There are many who helped to make my
experience as a student a rewarding one. In particular, I express my gratitude
and deep regards to my thesis guide Prof. VIJAYKUMAR RADADIYA,
Department of Mechanical Engineering, SHREE SWAMI ATMANAND
SARSWATI INSTITUTE OF TECHNOLOGY for kindly providing me to
work under his supervision and guidance. I extend my deep sense of
indebtedness and gratitude to his first for his valuable guidance, inspiring
discussions, constant encouragement and kind co-operation throughout period of
work which has been instrumental in the success of thesis.

I extend my thanks to Prof. Jignesh G. Vaghasia, Head of Mechanical

Engineering Department for extending all possible help in carrying out the
dissertation work directly or indirectly.

I express my sincere gratitude to Mr. Naimesh Shethiya, Production

Engineer, Susha Founders and Engineers, Surat, Entire staff members of
Shri Swami Atmanand Saraswati Institute of Technology, Surat and my
colleagues for their indebted help in carrying out experimental work and
valuable suggestions.

I feel pleased and privileged to fulfill my family’s ambition and I am greatly

indebted to
them for bearing the inconvenience during my B.E. course.

PETHANI HEMANG 150760119090

SATANI VIVEK 150760119098
SAVALIYA KAUSHAL 150760119101
SHYANI MAULIK 150760119109
THUMMAR TUSHAR 150760119113
 TABLE OF CONTENTS
Title Page
Certificate Page
External Examiner Certificate
GTU Certificate
Company Certificate
Plagiarism Report
Acknowledgement
Table of Contents
List of Figure
Abstract

CHAPTER 1: INTRODUCTION

1.1 Introduction of Company 1

1.2 Introduction of shell core shooter machine 2

CHAPTER 2: LITERATURE REVIEW

2.1 Literature review 3

CHAPTER 3: SETUP AND WORKING

3.1 Components of shell core shooter machine 4

3.2 Shell core shooter machine use in company 5
3.3 Working of shell core shooter machine 6

CHAPTER 4: SOLUTION TO REDUCE THICKNESS OF THE PLATE

4.1 Calculation 7

CHAPTER 5: RESULT

5.1 Result Table 8

5.2 Analysis 9

CHAPTER 6: CONCLUSION
REFERENCES 10

APPENDIX 11

1) AEIOU Summary canvas

2) Empathy Summary Canvas
3) Ideation canvas
4) Product Development Canvas
5) Business Model Canvas
6) Business Model Canvas Report
7) Pattern Drafting Exercise
8) Periodic Process Report
 Shree Swami Atmanand Saraswati
Institute of Technology

Submitted by:

PETHANI HEMANG 150760119090

SATANI VIVEK 150760119098
SAVALIYA KAUSHAL 150760119101
SHYANI MAULIK 150760119109
THUMMAR TUSHAR 150760119113

Supervised by:
Prof. Vijay Radadiya
Mechanical Engineering Department
SSASIT, SURAT

ABSTRACT

In recent years, Shell Core Shooter Machine is used for core making
process. This machine is used to make the different size of core. This core is
used for casting process. From these cores uneven shape of required
products can be made. To make the core different dies are used. These dies
are carrying on plates. There are main three plates in Shell Core Shooter
Machine. Two of three plates are fix and one plate is movable. This
movable plate carry one side of die and other side of die is carry by one of two
plates which are fixed. Thus, one plate of Shell Core Shooter Machine is used
for only support system. So, we are going to analysis of that three plates (fix &
movable) of Shell Core Shooter Machine and reduce the cost of machine,
thickness of plate and material optimization. We are going to analysis of force,
temperature and pressure which are impacts on that three plates and derive the
proper and suitable thickness of that three plates. So, we can reduce the cost of
this machine. So, Other small-scale industries can afford this machine.
 CHAPTER-1

INTRODUCTION

1.1 Introduction of company

We found our Industrial project at Susha founders and engineers. This industry
includes many works related to Shell Core Shooters, Low Pressure Die Castings,
Gravity Die Castings, Shell Moulding, Hot Box Core Shooter, etc. Amongst
them, we are working for the betterment of SHELL CORE SHOOTER. The
machine consists of three main plates. These three plates are supporting plates.
The plates are generally made up of Mild steel. The function of this plates is to
sustain the loads applied by the pneumatic cylinder. Thus it becomes necessary
to design this plate more sustainable with optimum material used. Also the plate
experiences ending moment due to the load applied by the Pneumatic Cylinder.

Company Detail:
Company Name:-Susha Founders And Engineers

Address: 158-159, indust1rial estate udhana, surat,

Gujarat, 394221

Guided name: Naimish Shethiya

Contact No.:- 9825610175

Manufacturing unit: Casting Machine

1.2 Introduction of shell core shooter machine

Shell Core Shooter Machine is used for core making process. This machine is
used to make the different size of core. This core is used for casting process.
From these cores uneven shape of required products can be made. To make the
core different different dies are used. These dies are carrying on plates. There
are main three plates in Shell Core Shooter Machine. Two of three plates
are fix and one plate is movable. This movable plate carry one side of die
and other side of die is carry by one of two plates which are fixed. Thus, one
plate of Shell Core Shooter Machine is used for only support system.
Thus, the analysis of the plates becomes necessary to optimize the use of
material simultaneously maintaining the sustainability of the plate. This is
what the topic is on which are working. Also the thermal analysis is to be
done.
To increase the benefit of the industries, through analysis we are reducing the
thickness of the plates. Which results in cost reduction and also affordable
by the small scale industries.
 CHAPTER-2

LITERATURE REVIEW

2.1 Literature Review

2.1.1 Design Based:
M. Asłanowicz et. al [1] prepare Automatic systems for small and
middle-sized
core manufacturing typically use core shooting or blowing machines for core
box filling and sand compaction. Such machines are now available
from well-known European manufacturers, such as DISA (Norica Group),
LAEMPE and EUROTEK, enabling core- making by various technologies. The
machines differ in the level of automation of core- making processes, the core
size, core box separation area and the capacity. The analysis of current demand
from the domestic foundry plants has prompted the design engineers to prepare
the technical documentation required to commence the production of a series of
universal core making machines, with the sand shooting tank volume Vkm=12,
16, 20,25, 40 dcm3, the basic machine in this series being a core shooter with
the shoot volume Vkm= 20 dm3. The model of the blowing process has
been developed, based on the analysis of functional units and components in
a shooting machine. The objectives and input data for modelling of the
blowing processes are confined to the analysis of functional units and
factors affecting the air flow in the sand-free system comprising the grid-
equalising tank- shoot tank- core box- ambience. The variables in the
calculation procedure include the air pressure in the grid, volumes of the
equalising tank, shoot tankAnd of the core box, the surface area of the shooting
valve and the exhaust opening in the shooting head, the level of venting.
 Fig (2.1.1) Fig (2.1.2)

M. Schneider et. al [2] carry out Simulation of core production process

when it comes
to determining if the sand cores required for a new casting can be
manufactured at an economical price. This uncertainty about the
manufacturability of complex cores limits designers as they attempt to design
castings that will meet the requirements of the final application. When it comes
to core production there may be even more uncertainty about the specifics of
how to efficiently produce a quality core. In most cases core boxes are laid out
based on past experience or by using a trial and error method of testing different
tooling set ups and process parameters. The process of getting a core box layout
and core making process parameters fully optimized consistently
requires numerous time consuming and expensive sampling cycles. This
trial and error approach to process development may require multiple
modifications to the tooling to get the desired results and does not provide any
quantitative information about the actual cause of problems that are observed
during the trials. A thorough scientific evaluation of all core making
processes has yet to be conducted and the application of root-cause analysis
to explain complex phenomena in the core making process are
currently non-existent. The simulation of the core making process can
significantly improve the predictability of the entire casting production process.
The technical and economic feasibility of sand cores can be predetermined
prior to production as designers evaluate the feasibility of their designs
and consider both the core production and casting processes during the
design phase of the product development process. As a result, the entire
process chain and relevant physical parameters become more transparent.
Simulation also broadens the understanding of the core making processes and
provides three dimensional visualization of the core shooting and curing
processes. This insight and understanding will help engineers understand
root causes of defects in cores and also provide the means to more efficiently set
up core box layout and process parameters that produce quality cores. As a
result foundries that use core production simulation will ultimately realize
improved casting quality and lowered overall production costs.
 Fig (2.1.3)

1.2.2 Application Based:

Aside from simulation, core box designers have very few options for evaluating
the many different variables that effect how a core box will fill with sand.
Simulation allows users to visualize the sand flow inside of the core box
and evaluate criteria functions at any point of the process. for example,
shows the sand fraction result at four separate steps in time throughout the
filling of the core box. The areas with low sand fraction values at the end of this
this simulation correlate very well with core defects that have been observed for
this water jacket core in production as seen in Core shooting simulation also
provides a differentiating analysis of the inside of cores as well.
Unintended volume deficits or voids inside of a core can be detected and
evaluated by using sand fraction and sand density predictions. After such
subsurface voids are identified they can then be eliminated with changes to the
design and/or process parameters. The identification of areas of low density
through simulation can also be useful for determining if a given area of
low density will cause problems during the life span of the core.
 CHAPTER-3

SETUP AND WORKING

3.1 Components of Shell Core Shooter Machine

1. Cylinder:-
It is the basic component of shell core shooter machine in which
we should have a maximum pressure of cylinder is 7 bar and we have to use 4-5
bar in working of shell core shooter machine. There are two types of cylinder.
1. Pneumatic cylinder
2. Hydraulic cylinder

Fig. no

2. Moving frame:-
Moving frame is motion between fix frames. Cylinder shaft is
attached with moving frame. One part of core box is also connected with the
moving frame which is work as a major part of core making process.
 Fig. no

3. Fix frames:-
There are two fix frames. Cylinder is mounted on one fix frame and on
other fix frame second part of core box is mounted. On which second part of
core box is mounted its function is only to support the moving frame.

Fix frame: - Ejection side

Fig. no
Fix frame: - Cylinder side

CHAPTER -4

SOLUTION TO REDUCE THICKNESS OF THE PLATE

CHAPTER-5

RESULT
 CHAPTER-6

CONCLUSION
REFERENCES
 APPENDIX

CANVAS

1. AEIOU Summary:
 Environment:
 Lighting
 Noisy
 Warm
 Dusty

 Interactions:
 Engineers
 Manager
 Worker
 Employer
 Customer
 Peon

 Users:
 Engineer
 Worker
 Employer
 Customer

 Activities:
 Inspection
 Assembly
 Boring
 Transportation
 Core-making
 Moulding
 Objects:

 Drilling Machine
 Cutting machine
 Lathe machine
 VMC machine
 Welding machine
 Boring machine

2. Ideation Summary:-
  People:
 People
 Customer
 Labor
 Manager

 Activities:
 Cutting
 Welding
 Milling
 Drilling
 Assembly
 Boring

 Situation/Context/Location:

 Large area
 Noisy
 dusty
 Lighting
 Workshop

 Props/Tools/Objects/Equipments:

 optimize material
Reduce
 cost Increasing speed
3. Product Development Canvas:
 Purpose:
 To make core
 Cost reduction
 Automatic
 Material optimization

 Product Experience:
 High sensitivity
 Reliability
 Accuracy

 Product Functions:
 Making core
 Making other die

 Product Features:
 An automatic
 Semi automatic
 Less time consuming
 Effective

 People:

 Patient
 Traffic police
 Doctors
 Patient’s family

 Components:
 Labour
 Employer
 Analyser
  Customer Revalidation:

 Failure analysis by Solid works can be use to prepare core making machine
plate to reduce cost and thickness of plate.
 Overall nice work

 Reject, Redesign, Retain:

 Retain ( by proper node selection during analysis )

4. EMPATHY CANVAS:
 User:
 At household
 Automobile industry

 Stakeholders:
 Customer
 Owner

 Activities:

 Cutting
 milling
 drilling
 Boring
 welding
 Assembly
5. Business model canvas:-
 BUSINESS MODEL CANVAS ON

“PLATE ANALYSIS OF SHELL CORE

SHOOTER MACHINE”

 KEY PARTNERS

1) SUSHA FOUNDERS AND ENGINEERS

 CUSTOMER SEGMENT:
1) MATERIAL OPTIMISATION:- Due to plate thickness material of the
plate will be optimize.
2) ECONOMIC BANEFITS:- Due to reduction in plate thickness ,despite
that already considerably fall down in cost.
3) INCREASE OF AVAILABILITY:- With improve design and cost
,more product available for customers.

 CUSTOMER RELATIONSHIPS:
1) SERVICE:- Industry provide good service to the customers with good
quality.

2) AVAILABILITY:- Availability means provide products when required.

with high availability customer relations improves.

3) MAINTANANCE:- with proper maintenance customer relation increase.

 CHANNELS:
1) INDIRECT SERVICE:- In this service indirect involvement like
transportation.

2) DIRECT SERVICE:- direct service is to be connect with the customers

and workers also.

3) CUSTOMERS:- produce final products as per customers requirements.

 KEY ACTIVITIES:
1) PRODUCTION BY ORDER: it can be produced be order as per the
customer requirement.
 2) STATIC ANALYSIS:- first company make design analysis based on
software so that they realize what is actually working condition.

3) TESTING OF MACHINE:- after completed the machine ,company

should be done the test.

 REVANUE STREAMS:

1) INCREASE PRODUCTION:- To make profit production must be

improving.

2) REDUCE COST OF PRODUCTION:- By reduce cost profit can be

increase.

3) MATERIAL REDUCTION:- due to material reduction ,company

generate revenue.

 COST STRUCTURE:
1) FIX COST:- It is the cost which are fix for all time it does not
depend on production.

2) MISCELLANEOUS COST:- It is the miscellaneous cost.

3) LUBRICATION COST:- It is one type of maintenance cost for

reduce stoppage of plant.

4) MAINTANANCE COST:- Maintenance cost improves quality

which is healthy cost for quality.