International Journal of Innovative Technology and Exploring Engineering (IJITEE)

ISSN: 2278-3075, Volume-9 Issue-2S2, December 2019

Manufacturing Process of Ductile Pipe using

Casting Technique
R.Manikandan, S.Rajesh, T.Nikhil Babu, P.Vaibhav, P.Pradeep kannan

 slag cement. Produced LAM Coke is used to produce Pig Iron

Abstract:In this paper, study the behavior of bendable iron and Molten Iron is used to produce the study of work done by
which is used to the manufacturing of ductile steel pipe. Bendable M. Jagdishwar, Casing Feeder Design [1] D.I Spun pipes.
Iron offers higher elasticity than mellow steel and holds the The die has been manufactured by using ductile iron
intrinsic consumption opposition of cast iron because of its because of the durability, strength and its hardness. The
spheroidal graphite small scale structure. Thus this bendable iron property of ductile iron is described [2]. The behavior of
is utilized in the production of channels by Srikalahasthi Pipes
ductile iron pipe is described [3]. Many researched are done
Limited. The state of graphite in the microstructure of the metal
ranges from 100mm to 1100mm measurement for ductile and cast their research work in ductile iron materials by changing the
iron. Channels produced using Ductile Iron give considerable ingredients along with ductile iron material and tests are
advantages as far as weight bearing capacity, sway opposition and carried out. The structural failure of the cast iron and ductile
ability to continue outer static/unique stacking. These channels iron pipeline was done using fuzzy logic variables [4].
have adaptable push-on joints which don't spill at a high or low Engineering material is classified as a ductile and brittle
weight, notwithstanding when avoided and are prominently material. In generally ductile material have five percent and
known as 'Prepared to utilize' funnels, because of the simplicity of above tensile strain before getting the fracture. The ductile
jointing these channels. In the assembling procedure of Ductile iron pipe has high axial compressive load property and it is
Iron funnels water is utilized for cooling frameworks in different
used as a coupling in two different pipelines [5]. The
areas. Keeping in perspective on generally water necessity and to
lessen groundwater tapping, a 5 MLD sewerage treatment plant self-restrained ductile iron fitting was manufactured for the
has been set up in 2011 at a capex of Rs 20crores which is sealing and restraint system in the pipeline with the different
adequate for procedure water prerequisite of the plant, which application [6]. The ductile iron pipe is manufactured using a
helped in sparing water amid the assembling procedure. The casting technique by changing the parameters like
investigation of utilization of Ductile iron in the assembling of temperature, flow rate during pouring the molten metal into
channels by Srikalahasthi Pipes Limited is giving beneficiaries in the mold and behavior is analyzed [7]. The ductile pipe
different segments as these are provided to different water sheets, performance is affected by changing the parameter like
civic enterprises, military specialist administrations, railroads, temperature, pressure and flow rate of the molten metal
and contractual workers the nation over for their water
during the casting process. In this work, the ductile pipe
foundation ventures.
manufacturing process using a casting technique is studied
Keywords:Ductile iron, Cast iron, Graphite, Pipes. and compared with cast iron pipe.

I. INTRODUCTION
II. METHODOLOGY
Now as part of the expansion, SPL proposed to In industry, the steel pipe has been manufactured using
enhance the production capacity of Ductile Iron pipes, pig different stages. The following steps are used to manufacture
iron & LAM Coke and power generation. In addition to the a steel pipe.
expansion, the company proposed to produce Ductile Iron
fittings also.  Pig Iron (Material selection)
Lanco Industries Ltd. is manufacturing a total of 4  Raw materials handling systems
products namely Pig iron, Slag cement, D.I. Spun pipes and  Batching and charging system
LAM Coke. Major saleable products are D.I Spun pipes and  Preparing of hot blast
 Blowing system.
Revised Manuscript Received on July 22, 2019.
*corresponding author In this industry, the ductile pipe is manufactured by using the
Mr. R.Manikandan, Department of Mechanical Engineering,
Kalasalingam Academy of Research and Education, Virudhunagar, following materials
Tamilnadu. Email: rmanikandan198@gmail.com  Recycled iron particle.
Dr.S.Rajesh*, Department of Mechanical Engineering, Kalasalingam  Magnesium metal.
Academy of Research and Education, Virudhunagar, Tamilnadu. Email:
s.rajesh@klu.ac.in  Coke content.
Nikhil Babu, Department of Mechanical Engineering, Kalasalingam  Mortar (Binding agent: Cement)
Academy of Research and Education, Virudhunagar,. Email:  Paint (Water based).
chathushvp7@gmail.com
P.Vaibhav, Department of Mechanical Engineering, Kalasalingam  A pure alloy of aluminum and zinc.
Academy of Research and Education, Virudhunagar,. Email:  Blue epoxy coatings
sibins29@gmail.com
P.Pradeep kannan M.Tech (ISE), Department of Mechanical
Engineering, Kalasalingam Academy of Research and Education,
Virudhunagar,Email: pradeepkannan45@gmail.com

Retrieval Number: B10401292S219/2019©BEIESP Published By:

DOI: 10.35940/ijitee.B1040.1292S219 Blue Eyes Intelligence Engineering
171 & Sciences Publication
 Hazard Identification and Risk assessment in the Olive products manufacturing industry

The manufacturing process of the ductile pipe is given in the pre-worked proportions of main raw material like
Fig.1 limestone with the additives (Iron ore, coke fines, clay, etc.).
Then the raw meal is burnt at a high temperature attained
in the initial ignition system in a vertical shaft result in
penultimate end product called clinker. A clinker is after
cooling, along with slag and gypsum are fed into the cement
mill and is ground to fineness to produce the finished product
Portland Slag Cement.
Ductile Iron was used in the manufacture of pipes as
it is resistant to corrosion as compared to that of cast iron. It
has good strength and shape of the graphite in the
microstructure of the metal is only varied from cast iron
metal i.e., the size ranges from 100mm to1100mm in
diameter.
It provides superior tensile strength compared to
mild steel and preserves the cast iron metal from intrinsic
corrosion resistance, because of its spheroidal graphite
(a). Manufacturing steps microstructure. Ductile iron pipe offers significant merits in
terms of bearing capacity, impact resistivity and has a good
quality maintain to exterior loads i.e., for both static and
dynamic loadings.
Pipes manufactured using Ductile Iron is known as
“Ready to use pipes” due to their ease of joining.
These pipes are manufactured in such a way that
they have zinc or epoxy coating with finishing layer of
bituminous coating externally and internally cement mortar
lining using large centrifugal force which provides excellent
anti-corrosive properties.
PROCESS OF LOW ASH METALLURGICAL COKE:
The process of low ash metallurgical that can burn a high
temperature of 1100° C.The low ash system are two different
types
1. Recovery type
2. Non-recovery type

We are only using Non-recovery type method

various advantages by the product by a heating process
that coke types will be listed below:
1. Less investment cost as no byproduct related
equipment is required.
2. Low operation and maintenance cost.
(b). Ductile pipe ingredients 3. Low conversion cost.
4. High coke.
Fig.1. Manufacturing process and ingredients Of ductile 5. The battery can be isolated and cooled down to
pipe repair at any time
6. without affecting the life of the risk
After manufacturing of ductile pipe, the performance is 7. Environmental impact cleans fuel gas resulting and
analyzed by comparing the various properties like, only emissions of burnt.
 Tensile strength 8. The non-recovery type will be operated by negative
 Percentage of elongation pressure.
 Coefficient of thermal expansion 9. By doing this type of manufacturing no pollution
 Young’s Modulus will be causes
10. resulting in clean stack discharges into the
 Hardness
atmosphere
 Density
 Bending strength The photography of the company and casting production
 The factor of safety. process is given Fig.2
The cement manufacturing process is a semi-dry
Process. The raw meal is prepared by grinding and Mixing in

Published By:
Retrieval Number: B10401292S219/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI: 10.35940/ijitee.B1040.1292S219
172 & Sciences Publication
 International Journal of Innovative Technology and Exploring Engineering (IJITEE)
ISSN: 2278-3075, Volume-9 Issue-2S2, December 2019

Table-I: A general property of ductile iron and cast

iron pipe
Property Ductile iron pipe Cast iron pipe

Tensile strength 420Mpa 414MPa

Yield strength 275Mpa 276MPa

Percentage of elongation 10% 18%

Impact strength 1.7 to 5% 1.7 to 5%

We got practiced in Srikalahasthi Pipes Limited about the

machines that can be operated by an automated machine
system. The manpower is needed to operate that machines
(a). Ductile pipe manufacturing company that can be analyzed by an engineer, we are operating the
pressure wall ON and OFF operating system through which
the ductile pipes are molded in required shape and diameter.
These pipes are molded in required shape through automated
machines but the required diameter cannot be coded
automatically. So that to maintain a proper diameter of pipes
manpower is needed. Required diameter is arranged by using
the switches which are allotted in machines through which
the diameter of pipes is set.
Many waste steel materials and waste cars are
burned to melt the material to use it. This melted material is
molded into required shapes; the especially cylindrical shape
is more frequently molded as this shape is mostly used for
various purposes.
By working with these machines we got some
knowledge how the materials are collected, stored, melted
(b). During casting work in the company and molded into different shapes of required diameter for
Fig.2. Company outlook and casting work various mankind purposes especially in water supply boards
in municipal corporations, military engineer services,
III. RESULT AND DISCUSSION railways and contractors across the country for their water
infrastructure projects.
It is observed from the studies of the property of
materials used in pipeline, a ductile pipe is stronger and IV. CONCLUSION
tougher than a cast iron pipe. Cast iron improves the
attractive like machinability, corrosion resistivity. But the From the above observation, the ductile steel pipe is
strength is less than the ductile pipe. The chemical properties improving the ductility, durability of the pipe; avoid the
of both ductile and cast iron pipe are the same. The spheroidal damage during handling and storage condition. It is also
graphite form is used to increase the strength of the ductile recyclable material through that the generation of waste also
pipe. reduced. So, Many Industries preferring manufacturing of
ductile steel pipe here we have done in manufacturing
The property of the ductile pipe is compared with cast process of steel pipes in that can be operated by automatic
iron pipe. It is observed that the following property of the machines and by the casting of need a ductile shape can be
ductile pipe is more than a cast iron pipe. The Tensile changed by their given shapes it can be molded by the top of
strength of the ductile pipe is 420 Mpa and it is more than the the different shape of head to the pipe it can be a curved shape
cast iron pipe. The percentage of elongation is higher for the it doesn't changes the to hold the grip to ground and it may
ductile pipe. The elongation of the ductile pipe is 10%. change to rectangle shape it behold very nicely to stick the
Coefficient of thermal expansion of the ductile pipe is more ground are any other area.
than cast iron pipe. Young’s Modulus is also higher for
ductile pipe compared to a cast iron pipe.
The hardness of the ductile pipe is 10 BHN and it is
lesser to cast iron pipe. Similarly, density, bending strength
and factor of safety of the ductile pipe is more than cast iron
pipe. The property of ductile and cast iron is given in Table.1

Retrieval Number: B10401292S219/2019©BEIESP Published By:

DOI: 10.35940/ijitee.B1040.1292S219 Blue Eyes Intelligence Engineering
173 & Sciences Publication
 Hazard Identification and Risk assessment in the Olive products manufacturing industry

REFERENCES
1. M.Jagdishwar,”Casing Feeder Design
Optimization based on feed path and temperature analysis,” 2012.
2. Charles W. Mooney, Jr. Dies, “The best of Ductile
iron news‖,” IL, 2001, pp. 60016-8399
3. Guss Rohrsysteme, Griesheim, “Ductile iron pipe
System,”the European association for Ductile iron pipe systems, 2004
4. H.Najjaran, R.Sadiq &B.Rajani,”Fuzzy
expert system to assess corrosion of cast/ductile iron pipes from
backfill properties,” Computer-Aided Civil and Infrastructure
Engineering, 21(1), 2006, pp. 67-77.
5. W. T.Adams Jr, U.S. Patent No. 5,480,196, “Washington, DC:
"U.S. Patent and Trademark Office,” 2010
6. J.Jones, G.Darce, R.Chinchilla, &B.G.Corbett Jr
U.S. Patent No. 7,815,225. Washington, DC: U.S. Patent and
Trademark Office, 2010.
7. E.F.Wagner, “Autogenous Healing of Cracks in
Cement Mortar Linings for Gray Iron and Ductile Iron Water Pipe,
“Journal American Water Works Association, 66(6), 2012,
pp.358-360.

AUTHORS PROFILE

R.Manikandan obtained his B.E (MECH) in 2009 from

the P.S.R Engineering College, Sivakasi, Tamilnadu,
India. He completed his M.Tech (Industrial Safety
Engineering) in 2014 at Mepco Schlenk Engineering
College,Tamilnadu, India. Currently, he is working as a
Assistant Professor in the Department of Mechanical
Engineering, Kalasalingam Academy of Research and Education,
Krishnankoil, Tamilnadu, India. His research interests include investigation
of fireworks accidents and exposure of various experimental setup like
frition, impact sensivity test, Noise level test and thermal analysis test.

I have completed in B. E in Mechanical Engineering and

M.E. (CAD) from Alagappa Chettiar Government
College of Engineering and Technology, Karaikudi,
Ph.D(Machining of Metal of Matrix Composites) from
Kalasalingam Academy of Research and Education,
Krishnankoil in the year 2014, and thesis highly
recommended by both the examiners. In the year 2018, I have received
DST – AMT project for the worth of Rs 25, 72, 400 and completed one IEDC
project for the worth of Rs 1, 00,000. I have published more than 25 journal
papers (impact factor and Scopus cited) and more than 40 international
conference papers.

T.Nikhil Babuis a final year student, Department of

Mechanical Engineering, Kalasalingam Academy of
Research and Education, Krishnankoil, Tamilnadu, India.

P.Vaibhav is a final year student, Department of

Mechanical Engineering, Kalasalingam Academy of
Research and Education, Krishnankoil, Tamilnadu, India.

P.Pradeep kannanis a second year M.Tech Industrial

Safety Engineering student, Department of Mechanical
Engineering, Kalasalingam Academy of Research and
Education, Krishnankoil, Tamilnadu, India

Published By:
Retrieval Number: B10401292S219/2019©BEIESP
Blue Eyes Intelligence Engineering
DOI: 10.35940/ijitee.B1040.1292S219
174 & Sciences Publication