Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                
Scribd Logo
Upload

Welcome to Scribd!

  • 57 views

    Yield Improvement S.G Iron in Shell Moulding

    Uploaded by

    IJRASETPublications
    In manufacturing sector metal casting is one of the basic principal and most important processes. The casting process is optimized there will be very lesser wastage thus it results in yield improvement. For improving casting yield, optimize the gating system design, optimize mold filling, avoid shrinkage scrap, hot tears etc. The casting produced by foundry improper design of gating frame work and riser system result in internal shrinkage which is a major defecting cast product.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Yield Improvement S.G Iron in Shell Moulding

    Uploaded by

    IJRASETPublications
    57 views4 pages
    In manufacturing sector metal casting is one of the basic principal and most important processes. The casting process is optimized there will be very lesser wastage thus it results in yield improvement. For improving casting yield, optimize the gating system design, optimize mold filling, avoid shrinkage scrap, hot tears etc. The casting produced by foundry improper design of gating frame work and riser system result in internal shrinkage which is a major defecting cast product.

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    In manufacturing sector metal casting is one of the basic principal and most important processes. The casting process is optimized there will be very lesser wastage thus it results in yield improvement. For improving casting yield, optimize the gating system design, optimize mold filling, avoid shrinkage scrap, hot tears etc. The casting produced by foundry improper design of gating frame work and riser system result in internal shrinkage which is a major defecting cast product.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    57 views4 pages

    Yield Improvement S.G Iron in Shell Moulding

    Uploaded by

    IJRASETPublications
    In manufacturing sector metal casting is one of the basic principal and most important processes. The casting process is optimized there will be very lesser wastage thus it results in yield improvement. For improving casting yield, optimize the gating system design, optimize mold filling, avoid shrinkage scrap, hot tears etc. The casting produced by foundry improper design of gating frame work and riser system result in internal shrinkage which is a major defecting cast product.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 4

    8 X October 2020

    https://doi.org/10.22214/ijraset.2020.32010
    International Journal for Research in Applied Science & Engineering Technology (IJRASET)
    ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.429
    Volume 8 Issue X Oct 2020- Available at www.ijraset.com

    Yield Improvement S.G Iron in Shell Moulding


    G. Kannan1, R. Madhan2, S. Nisanth3, P. Prakash4, K. Karthick5
    1
    Assistant Professor, 2, 3, 4, 5UG Scholar, Department of Mechanical Engineering,Erode,Tamilnadu, INDIA

    Abstract: In manufacturing sector metal casting is one of the basic principal and most important processes. The casting process
    is optimized there will be very lesser wastage thus it results in yield improvement. For improving casting yield, optimize the
    gating system design, optimize mold filling, avoid shrinkage scrap, hot tears etc. The casting produced by foundry improper
    design of gating frame work and riser system result in internal shrinkage which is a major defecting cast product. So good
    design of gating system reduces defect. Thus by this analysis increase yield without affecting the quality it would help the
    company to improve the quality of the product and thereby decreases the rejection level of the product.
    Keywords: Yield improvement, shell molding, reduce defect.

    I. INTRODUCTION
    Manufacturing Ductile Iron, Grey Iron, SG Iron (Vermicular graphite Iron), ADI, Ni Resist & Steel Castings using shell moulding,
    has a history of continuous improvement. A concept that has given it a past that it can be proud of and a future it can look forward
    to with confidence. The vision of Promoter and Managing Director that an illustrious organization should emerge is realized
    through his hard work and commitment. Today, Shell Moulded SG Iron Castings, Shell Moulded Grey Iron Castings, High, Low
    Pressure and Gravity Die Castings and exports to leading International Industrial giants. As part of the diversifying plans in related
    areas, Unique Shell Mould India Private Limited – Sister Concern, was founded in 1983 in response to the growing demand for
    quality aluminum castings with a focus on emerging technologies that meet client requirements. A diverse and well-structured
    group that strives to produce quality products that conform to the standards, that would satisfy both domestic and international
    markets while emphasizing on efficiency in every facet of the operation from manufacturing to marketing. The Surface finish and
    dimensional accuracy of the shell-moulded casting is superior to the conventional green sand mould castings .It has a strong
    metallurgical base and experience. Its metallurgical quality of their SG Iron is very much acclaimed by their domestic & overseas
    customers.
    Shell Moulding: Semi-Automatic 4 station shell moulding (PLC controlled) machines are capable of producing 15000 moulds
    everyday which finds its application in casting intricate shaped hydraulic and automobile components ranging from 0.05 Kg's to
    15.0Kg's.

    II. EXPERIMENTAL SETUP


    Riser sleeves act as a reservoir of liquid metal in the sand mould for steel/iron castings in foundry .It keeps the molten form and feed
    the metal to the casting till solidification of casting gets completed by providing an exothermic reacting along with insulating
    properties and it solidifies at last.
    Types of sleeve:1. Insulative sleeve,2.Exothermic sleeve. Insulative sleeve helps in liberating heat thus increasing the temperature
    enough to keep the steel in molten state for extended period of time. Exothermic sleeve is High performance to feed castings in
    iron,steel and all the alloys of these metals ,molded in sand and other systems. These sleeves provide healthly pieces, without
    porosity and without reaction of the metal with the sleeve.
    Filters: Depending on the purpose, Zirconium oxide, silicon carbide and mullite are used as filter materials. The most common filter
    positions are vertical or horizontal in the gate system runner the upper sprue part or at them bottom of the sprue (see bottom of the
    sprue).Types of Filters: Ceramic filter ,Foam filter. Ceramic filters are used to remove impurities from molten metal in the casting
    process at foundries worldwide. filters can be used with all types of cast irons, aluminium and copper based alloys are available in a
    broad range of sizes shapes and performances levels.
    Foam filters are air cleaner filters that use polyurethane foam elements as the filtering material to trap unwanted air contaminants
    and particulates. foam filters are made up of tiny interlocking cells that prevent the passage of dirt particles and distribute these
    throughout the entire volume of the foam. this materials are used in many performance air filters for engines on appliances such off-
    roading , rallying and other motor sports in rugged and high dust environments, foam filters are a popular choice due to their dirt
    retention capacity.

    ©IJRASET: All Rights are Reserved 753


    International Journal for Research in Applied Science & Engineering Technology (IJRASET)
    ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.429
    Volume 8 Issue X Oct 2020- Available at www.ijraset.com

    TRIAL-1 The sleeve to feed through without affecting the quality of the product
    Sleeve size 90*200
    Casting weight(Kg) 12.690
    Pouring weight (Kg) 20.10
    Yield 63.1%
    RT report Found OK
    Micro analysis report Found OK
    X-Ray OK
    Number of shells(per 1Ton) 54

    TRIAL-2 The sleeve to feed through without affecting the quality of the product
    Sleeve size 80*150
    Casting weight(Kg) 12.690
    Pouring weight (Kg) 16.6
    Yield 76%
    RT report Found OK
    Micro analysis report Found OK
    X-Ray OK
    Number of shells(per 1Ton) 68

    In the calculation of the sleeve size 65*150 pouring weight(kgs) is 13.10 and the wasteage of per piece 0.31 kgs but in this sleeve
    size can be occur the blow holes. So doesn’t move to the huge production and the next sleeve size 70*100 pouring weight is 14.60
    and the wasteage of per piece 1.91 kgs but in this sleeve size can be occur the surface shirnkage.so move to the next sleeve size
    80*150 pouring weight is 16.60 kgs and the wasteage of per piece 3.91 kgs this sleeve size can be doesn’t occur any defects.

    III. RESULT & CONCOLUTION


    It is cleared that from experimental results and casting simulation that modified gating (sleeve size) system . Initially defects such as
    micro porosity, blow holes and shrinkage are absent in the casting. Yet initially molten metal required is 20.100 kg and when
    modified sleeve size is used molten metal required is 16.60 kg and weight of actual casting is 12.690 kg. hence with the modified
    sleeve size the yield improved is 12.9% that can be increased. Due to yield improvement saving of energy and resources required for
    melting and recycling is also done. As saving of energy is there productivity increases and as increase the profit

    REFERRENCE
    [1] Dhruva Sadekar1, G.R. Bharath Sai Kumar, ‘‘Yield Improvement of Castings using Computer Aided Simulation – A Case Study’’, Theoretical and Applied
    Research in Mechanical Engineering Volume 3, Issue-3, 2014.
    [2] C. M. Choudhari, B. E. Narkhede, S. K. Mahajan, ‘‘Casting Design and Simulation of Cover Plate using Auto CAST-X Software for Defect Minimization with
    Experimental Validation’’, Procedia Materials Science 6 ( 2014 ) 786 – 797
    [3] Uday A. Dabade and Rahul C. Bhedasgaonkar,‘‘Casting Defect Analysis using Design of Experiments (DoE) and Computer Aided Casting Simulation
    Technique’’, Procedia CIRP 7 (2013) 616 – 621
    [4] Vipul Vasava, Dhaval Joshi,‘‘Simulation of shrinkage defect-A review’’," International Journal of Engineering Trends and Technology (IJETT) – Volume 4
    Issue 6- June 2013.
    [5] Vishal S. Jadhao , Prof. J.J.Salunke, ‘‘Review Paper on Simulation Based Casting’’, International Journal of Innovative Research in Science Engineering And
    Technology Vol. 3, Issue 11, November 2014.
    [6] Bob Bryant1, Kent D. Carlson2, Shouzhu Ou2, Christoph Beckermann2, ‘‘Tilt Pour Trials And Analysis’’, SFSA technical operating conference, paper no 2.6,
    2003.
    [7] Yazad N. Doctor, Dr. Bhushan T. Patil, Aditya M. Darekar, ‘‘Review of Optimization Aspects for Casting Processes’’, Index Copernicus Value (2013): 6.14.
    50
    [8] Yogini S. Jadhav, Roshni H. Bajgude, Prerana R. Gore,4Priyanka P. Lonkar, ‘‘A review on yield improvement in gating system’’, 2017 IJEDR | Volume 5,
    Issue 2 | ISSN: 2321-9939.
    [9] Arunkumar P, Anand.S.Deshpande2, Sangam Gunjati, ‘‘Analysis and Optimization of Investment Castings to Reduce Defects and Increase Yield’’, May 2015,
    Volume 3 Special Issue, ISSN 2349-4476.
    [10] C. M. Choudhari, B. E. Narkhede, S. K. Mahajan, ‘‘ Casting Design and Simulation of Cover Plate using Auto CAST-X Software for Defect Minimization with
    Experimental Validation’’, Procedia Materials Science 6 ( 2014 ) 786 – 797.

    ©IJRASET: All Rights are Reserved 754

    You might also like