A Project Report on Cost Reduction in Melting- A SQC and Six Sigma Approach

8/16/2019 A Project Report on Cost Reduction in Melting- A SQC and Six Sigma Approach

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COST REDUCTION IN MELTING- A SQC and SIX SIGMA

APPROACH

Done at ARUNA ALLOY STEELS PVT.LTD

A PROJECT REPORT

Submitted by

` ARUN KUMAR.S (105914144005)

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

RAJA COLLEGE OF ENGINEERING AND TECHNOLOGY MADURAI

ANNA UNI!ERSITY" CHENNAI #00 0$5

APRIL 20!

1


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ANNA UNI!ERSITY" CHENNAI #00 0$5

BONAFIDE CERTIFICATE

Ce"t#$#ed t%at t%#& '"o(e)t "e'o"t %COST REDUCTION IN MELTING&

A S'C * SI+ SIGMA APPROACH, #& t%e *ona$#de +o", o$

%ARUN KUMAR.S (105914144005), +%o )a""#ed ot t%e '"o(e)t +o", nde"

/ &'e"#on.

SIGNATURE SIGNATURE

P-/. S. S- K2- B.E. M.E. J.!3 B.E. M.E.

MBA. (P6.D)1

HEAD OF THE DEPARTMENT SUPER!ISOR

A&&tant '"o$e&&o"

Me)%an#)a En3#nee"#n3 Me)%an#)a En3#nee"#n3

Ra(a Coe3e o$ En334Te)%1 Ra(a Coe3e o$ En33 4Te)%1

Mad"a#- 526020. Mad"a#- 526020.

S*#tted $o" t%e '"o(e)t #)e-o)e %ed on 77777

INTERNAL E+AMINER E+TERNAL E+AMINER

2


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ACKNO7LEDGEMENT

T%#& '"o(e)t %a& *een &))e&&$/ )o'eted o+#n3 )o'"e%ene

end"an)e o$ an/ d#&t#n3#&%ed 'e"&on&.

8#"&t and $o"eo&t I +od #,e to t%an, t%e a#3%t/1 / $a#/ e*e"&

and $"#end& $o" en)o"a3#n3 e to do t%#& '"o(e)t.

I e9tend / t%an,& to C%a#"an PDG.L3. G. N8- M.A and

P"#n)#'a D-. S.M. S3:- M.E. P6.D. $o" t%e#" ad#)e and et%#)& #n))ated

d"#n3 t%e ent#"e 'e"#od o$ / &td/.

I a e9t"ee/ #nde*ted to P-/. S. S- K2- B.E. M.E.

MBA. (P6.D). T%e Head o$ De'a"tent o$ Me)%an#)a En3#nee"#n3 $o" t%e

deoted attent#on1 oe and a$$e)t#on &%o+n on e #n a,#n3 t%#& '"o(e)t 3"and

&))e&&.

I a&o t%an, t%e HR M-.M.J.R2;6*- MS7 $o" %#& a&&tan)e

and a t%o&e +%o %ae &''o"ted e to do t%e '"o(e)t #n ARUNA ALLOY

STEELS P!T.LTD. M*-3.

I +od #,e to t%an, / Co'an/ 3#de M-.M.R K2- M.T;6

M


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TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO.

ABSTRACT

iv

LIST OF TABLES

LIST OF FIGURES

xi

1 INTRODUCTION 1

1.1 G-: 3


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1.4. A8: : $$

1.5 G-*? / S

1.# C-3$

1.#.11 T-3 >>

1.#.1$ S>

1.#.1> B*= >

1.#.14 P2 ;?>

1.#.15 A83


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>.> T-2? ?* 3 2:.4 M


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# A!OIDING THE DEFECTS IN CASTING 4

ANNE+URE

REFERENCES 95

9


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LIST OF TABLES PAGE NO

T: 1.$.1 A-< C?2


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LIST OF FIGURES PAGE NO

F38- 1.$.1& A-< ;?2


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S;-? RMCN ;?


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1.1 GENERAL INTRODUCTION

;A P"o(e)t on t%e Qa#t/ Mana3eent and Co&t #t#on&+%#)% oe"a *o/ed t%e #nd&t"/ and &%o+ed &oe 3ood "e&t&.

T%o3% t%e &*'"#e )"#& %a& ead an/ e)ono#e& to "e)e&ona"/

t"end1 t%e ne3at#e e$$e)t %a& not to)%ed t%e &tee #nd&t"/ a& a +%oe.

Ho+ee" &tee '"od)t#on and )on&'t#on +# *e &''o"ted */ )ont#no&

e)ono#) 3"o+t%.

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STRUCTURE OF INDIAN STEEL INDUSTRY

Stee #& one o$ t%e )o"e 'o+e"1 'et"oe )"de1 'et"oe "e$#n#n31

&tee1 )oa and )eentB #nd&t"#e& o$ Ind#a. T%e&e )o"e #nd&t"#e& t%at %ae

a )o*#ned +e#3%ta3e o$ 25.: #n t%e #nde9 o$ #nd&t"#a '"od)t#on +%#)%

3"e+ :.2 #n Ma")% )o'a"ed to . #n t%e &ae 'e"#od 200. 8#n#&%ed

)a"*onB Stee '"od)t#on "e3#&te"ed a "o*&t 3"o+t% o$ .2 #n Ma")% 200

)o'a"ed to a ne3at#e 3"o+t% o$ .F #n Ma")% 200.

T%e &tee #nd&t"/ #n Ind#a %a& *een o#n3 $"o &t"en3t% to &t"en3t%

and a))o"d#n3 to t%e Anna Re'o"t 200-0 */ t%e M#n#&t"/ o$ Stee. Ind#a

%a& ee"3ed a& t%e $#$t% a"3e&t '"od)e" o$ &tee #n t%e +o"d and #& #,e/ to

*e)oe t%e &e)ond a"3e&t '"od)e" o$ )"de &tee */ 206-5.

CONSUMPTION OF STEEL IN INDIA

Ind#a& &tee )on&'t#on "o&e F 'e" )ent #n t%e /ea" ended Ma")% 2001

oe" t%e &ae 'e"#od o$ 200 on a))ont o$ #'"oed deand $"o &e)to"&

#,e atoo*#e1 #n$"a&t")t"e and %on3. T%e )ont"/& &tee )on&'t#on

#n)"ea&ed to 65. MT #n t%e 2 ont%& to Ma")% 200 $"o 62. MT #n t%e

/ea" 2001 a& 'e" t%e M#n#&t"/ o$ Stee.

e e9'e)t &t"on3 deand 3"o+t% #n Ind#a oe" t%e ne9t $#e /ea"&1

d"#en */ a *oo #n )on&t")t#on ! '& o$ &tee deand #n Ind#aB. Soa"#n3

deand */ &e)to"& #,e #n$"a&t")t"e1 "ea e&tate and atoo*#e&1 at %oe and

a*"oad1 %a& 't Ind#a& &tee #nd&t"/ on t%e +o"d &tee a'.

T: 1.$.1 A-< C?2


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!-6 F.55 2.F0

6-5 2.! !.F!

5-: 22.2 .2

:-F 22.5 2.0

F- 2.6 2.2

-2000 26.0 F.0

2000-200 25.F: :.!

200-2002 2:.6 .:F

2002-200 2F.F: 6.56

200-200! .5 :.F5

200!-2006 !.F 0.

2006-2005 F.6 0.

2005-200: !.::: 0.!:

200:-200F 66.:! 0.F!

200F-200 6!.F -0.5

FIGURE 1.$.1& APPARENT CONSUMPTION OF FINISHED

CARBON STEEL(IN METRIC TONNES)

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MAJOR CONSUMERS OF INDIAN STEEL INDUSTRY"

S-< /-2 *=23; ;2="

Ind#a #& t%e e)ono#) "e3#on t%at %a& en(o/ed t%e +o"d& o&t &&ta#ned

*oo. Inte"nat#ona "at#n3 a3en)/ 8#t)% Rat#n3& %a& $o"e)a&t an F 3"o+t% #n

Ind#a& GDP #n 200- +#t% t%e #nd&t"#e& and &e"#)e& *e#n3 t%e '"#a"/

d"#e"& DNA Ma/ 01 200B .T%e 3"o+t% d"#e"& a"e 'o'at#on 3"o+t%1

%an )a'#ta1 o'en#n3 o$ t%e e)ono/ and "#n3 #ne&tent. De&'#te t%e

&%a"' #n)"ea&e #n Ind#a& 'o'at#on1 'e"-)a'#ta GDP J #n '")%an3 'o+e"

'a"#t/ te"& J &%od "#&e */ nea"/ ! 'e" /ea" nt# 2020. In $a)t1 */ t%e end

o$ t%e de)ade Ind#a )od "e'a)e Ka'an a& t%e +o"d& t%#"d *#33e&t e)ono/

a$te" t%e US and C%#na.

P?3


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&t# oo, &et $o" 3"o+t%. 8"t%e"o"e1 t%e )on&t")t#on &e)to" #& *ene$#t#n3

$"o a(o" #n$"a&t")t"e '"o(e)t&. Ca'#ta e9'end#t"e #& to *e $o)&ed on

"oad *#d#n3 and t%e "a# net+o",1 a& +e a& on t%e )on&t")t#on and

e9'anon o$ 'o"t& and a#"'o"t&.

S


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Ve%#)e o+ne"&%#' )a"& and t"),&B #n Ind#a at 'e" 1000 #n%a*#tant&

a"e een e&& +#de&'"ead t%an #n C%#na +#t% #t& e"/ o+ $#3"e o$ 2. T%e

3"o+t% o$ t%e Ind#an atoo*#e #nd&t"/ #& *e#n3 d"#en */ %eat%/ doe&t#)

deand.

T%e )on&'t#on #nded1 $a&t 3"o+#n3 #dde )a&& #& a a(o" $a)to".

T%e )ont#n#n3 #n)"ea&e #n #n)oe& and o+-)o&t $#nan)#n3 $a)##t#e& a"e

*oo&t#n3 &ae&. Ho+ee"1 #t #& not n)oon $o" )a"& to *e &ed $o" 20 /ea"&

e&te"n E"o'e 2 /ea"&B1 +#t% e%#)e& t%at %ae *een ta,en o$$ "*an "oad&

o$ten *e#n3 d"#en $o" on3e" #n ""a a"ea&. T%e 'o'at#on& &tead#/ 3"o+#n3

deand $o" o*##t/ and &%a"'/ "#n3 t"a$$#) oe& +# )ont#ne to

3ene"ate &t"on3 deand $o" )a"& #n t%e $t"e. At t%e &ae t#e Ind#a&

atoo*#e &e)to" #& e&ta*#&%#n3 #t&e$ a& an e9'o"te" to #nte"nat#ona a",et&.

H/nda#1 $o" e9a'e1 &e& t%e )ont"/ a& an e9'o"t *a&e $o" &a )a"&1 and

8o"d an$a)t"e& e%#)e& t%e"e $o" Sot% A$"#)a and ot%e" a",et&.

Ho+ee"1 )o'et#t#on *et+een atoa,e"& %a& #nten$#ed a",ed/. %e"ea&

#n 6 t%e"e +e"e (&t $#e )a"a,e"& #n Ind#a t%e $#3"e %a& no+ "ea)%ed 0.

T%e *#33e&t a"e H/nda# Moto" Ind#a and Tata En3#nee"#n3 Te)oB. T%e Tata

3"o' #& een t"/#n3 to 3a#n a $oot%od #n t%e E"o'ean a",et +#t% ne+

ode&. Ind#a )""ent/ '"od)e& a tota o$ :1000 )a"& ea)% /ea" Ge"an/

6.! ##onB.

FIGURE 1.$.$ MAJOR CONSUMER INDUSTRIES OF STEEL IN

INDIA

18


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SUPPLY OF STEEL IN THE INDIAN MARKET

Oe" t%e 'a&t ten /ea"& Ind#a& )"de &tee ot't "o&e nea"/ :'e" /ea"

to 66. ##on ton& 1 +%#e 3o*a )"de &tee ot't #n)"ea&ed */ !

Ge"an/ ana3ed an #n)"ea&e o$ (&t nde" '.a.B At%o3% Ind#a #& t%e

+o"d& e#3%t% a"3e&t &tee '"od)e"1 #t&-'& &%a"e o$ 3o*a &tee ot't #&

&t# e"/ o+ #t #& "o3%/ t%e &ae a& U,"a#ne& &%a"e o$ +o"d &tee

'"od)t#on. C%#na1 t%e +o"d& *#33e&t &teea,e"1 '"od)e& nea"/ ten t#e&

a& )% a& Ind#a. In 2006 Ind#a& )"de &tee ot't o$ !5.6 ##on ton& +a&

F%#3%e" t%an #n 200! on/ #n C%#na +a& t%e 3"o+t% "ate )onde"a*/ %#3%e"

at 6.


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Goe"nento$ Ind#a1 M#n#&t"/ o$ Stee1 &tee.n#).#nB

FACTORS HOLDING BACK THE INDIAN STEEL INDUSTRY

20

YEAR SUPPLY #n tB GROTH #n B

-2 !.

2- 6.2 5.0:

-! 6.2 0

!-6 :.F2 :.2

6-5 2.! 20.0F

5-: 22.:2 5.5

:-F 2.: 2.F5

F- 2.F2 .2

-2000 25.: 2.

2000-200 2.: .

200-2002 0.5 .

2002-200 .5: .2

200-200! 5. :.!F

200!-2006 !0.06 0.55

2006-2005 !2.55 5.!6

2005-200: 66.!5 2.!

200:-200F 6F.2 6.6

200F-200 6.02 .6


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T%e 3"o+t% o$ t%e Ind#an &tee #nd&t"/ and #t& &%a"e o$ 3o*a )"de

&tee '"od)t#on )od *e een %#3%e" #$ t%e/ +e"e not *e#n3 %ed *a), */

a(o" de$#)#en)#e& #n $ndaenta a"ea&. Ine&tent #n #n$"a&t")t"e #& "#n3

a''"e)#a*/ *t "ea#n& +e *eo+ t%e ta"3et ee& &et */ t%e 3oe"nent de

to $#nan)#n3 '"o*e&.

E-8= ?:="

Po+e" &%o"ta3e& %a'e" '"od)t#on at an/ o)at#on&. S#n)e 200 t%e

Ind#an 3oe"nent %a& *een endeao"#n3 to en&"e t%at 'o+e" #& aa#a*e

Nat#on+#de */ 202. T%e de$#)#en)#e& %ae '"o'ted an/ $#"& +#t%

Hea#e" ene"3/ deand& to o't $o" '"od)#n3 ee)t"#)#t/ +#t% t%e#" o+n

Ind&t"#a 3ene"ato"&. Ind#a +# "e/ &>a"e/ on n)ea" ene"3/ $o" #t& 8t"e

'o+e" 3ene"at#on "e>#"eent&. In Se'te*e" 2006 t%e 6t% and a"3e&t

n)ea" "ea)to" to date +ent on-#ne. T%e n)ea" &%a"e o$ t%e ene"3/ #9 #&

#,e/ to "#&e to "o3%/ 26 */ 2060. Oe"a1 Ind#a #& #,e/ to *e t%e +o"d&

$o"t% a"3e&t ene"3/ )on&e" */ 200 a$te" t%e US1 C%#na and Ka'an.

P-:2? -;-38 -@ 2


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In Ind#a1 #n&$$#)#ent $"e#3%t )a'a)#t/ and a t"an&'o"t #n$"a&t")t"e t%at

%a& on3 *een #nade>ate a"e *e)o#n3 #n)"ean3/ &e"#o& #'ed#ent& to

e)ono#) deeo'ent. At%o3% t%e )ont"/ %a& one o$ t%e +o"d& *#33e&t

t"an&'o"t net+o",& J t%e "a# net+o", #& t+#)e a& e9tene a& C%#na& J #t&

'oo" >a#t/ %#nde"& t%e e$$#)#ent &''/ o$ 3ood&. T%e &to"/ #& "o3%/ t%e

&ae $o" 'o"t $a)##t#e& and a#"'o"t&. In t%e )o#n3 /ea"& a tota o$ USD 60 *n

#& to *e #ne&ted #n t"an&'o"t #n$"a&t")t"e1 +%#)% o$$e"& %3e 'otent#a $o" t%e

&tee #nd&t"/. In t%e ed# to on3 te" t%#& )a'#ta e9'end#t"e +# a/ t%e

$ondat#on& $o" &eae&& $"e#3%t t"an&'o"t.

FORE7ORD"

Stee #& an ao/ )on&t#n3 o&t/ o$ #"on1 +#t% a )a"*on )ontent *et+een

0.2 and 2.! */ +e#3%t C0J08eB1 de'end#n3 on 3"ade. Ca"*on #& t%e

o&t )o&t-e$$e)t#e ao/#n3 ate"#a $o" #"on1 *t a"#o& ot%e" ao/#n3

eeent& a"e &ed &)% a& an3ane&e1 )%"o#1 anad#1 and tn3&ten.

Ca"*on and ot%e" eeent& a)t a& a %a"den#n3 a3ent1 '"eent#n3 d#&o)at#on& #n

t%e #"on ato )"/&ta att#)e $"o &#d#n3 'a&t one anot%e". Va"/#n3 t%e aont

o$ ao/#n3 eeent& and $o" o$ t%e#" '"e&en)e #n t%e &tee &ote eeent&1

'"e)#'#tated '%a&eB )ont"o& >a#t#e& &)% a& t%e %a"dne&&1 d)t##t/1 and tene

&t"en3t% o$ t%e "e&t#n3 &tee. Stee +#t% #n)"ea&ed )a"*on )ontent )an *e ade

%a"de" and &t"on3e" t%an #"on1 *t #& a&o o"e *"#tte. T%e a9# &o*##t/

o$ )a"*on #n #"on a& a&ten#teB #& 2.! */ +e#3%t1 o))""#n3 at ! C

%#3%e" )on)ent"at#on& o$ )a"*on o" o+e" te'e"at"e& +# '"od)e )eent#te.

Ao/& +#t% %#3%e" )a"*on )ontent t%an t%#& a"e ,no+n a& )a&t #"on *e)a&e o$

t%e#" o+e" et#n3 'o#nt and )a&t-a*##t/. Stee #& a&o to *e d#&t#n3#&%ed $"o

+"o3%t #"on )onta#n#n3 on/ a e"/ &a aont o$ ot%e" eeent&1 *t

)onta#n#n3 J */ +e#3%t o$ &a3 #n t%e $o" o$ 'a"t#)e& eon3ated #n one

d#"e)t#on1 3##n3 t%e #"on a )%a"a)te"#&t#) 3"a#n. It #& o"e "&t-"e&tant t%an

&tee and +ed& o"e ea/. It #& )oon toda/ to ta, a*ot t%e #"on and &tee

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#nd&t"/ a& #$ #t +e"e a n3e ent#t/1 *t %#&to"#)a/ t%e/ +e"e &e'a"ate

'"od)t&.

1.> COMPANY PROFILE"

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1.>.1 MANAGEMENT TEAM

S.A-;6:2 BE(M;63;: E83-38) MBA

A- A-;6:2 BE(S7 M;63;: E83-38)

MS(I*?


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FIGURE 1.4.1.1 GATE !AL!E

1.4.$ BUTTERFLY !AL!E"

A *tte"$/ ae #& a t/'e o$ $o+ )ont"o de#)e1 t/'#)a/ &ed to

"e3ate a $#d $o+#n3 t%"o3% a &e)t#on o$ '#'e. T%e ae #& #a" #n

o'e"at#on to a *a ae. A $at )#")a" 'ate #& 'ot#oned #n t%e )ent"e o$ t%e

'#'e. T%e 'ate %a& a "od t%"o3% #t )onne)ted to an a)tato" on t%e otde o$

t%e ae. Rotat#n3 t%e a)tato" t"n& t%e 'ate e#t%e" 'a"ae o" 'e"'end#)a"

to t%e $o+. Un#,e a *a ae1 t%e 'ate #& a+a/& '"e&ent +#t%#n t%e $o+

t%e"e$o"e a '"e&&"e d"o' #& a+a/& #nd)ed #n t%e $o+ "e3a"de&& o$ ae

'ot#on.

A *tte"$/ ae #& $"o a $a#/ o$ ae& )aed >a"te" t"n ae&.

T%e *tte"$/ #& a eta d#&) onted on a "od. %en t%e ae #& )o&ed1 t%e

d#&) #& t"ned &o t%at #t )o'ete/ *o),& o$$ t%e 'a&&a3e+a/. %en t%e ae

#& $/ o'en1 t%e d#&) #& "otated a >a"te" t"n &o t%at #t ao+& n"e&t"#)ted

29


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'a&&a3e. T%e ae a/ a&o *e o'ened #n)"eenta/ to "e3ate $o+.

FIGURE 1.4.$.1& BUTTERFLY !AL!E

1.4.> BALL !AL!E"

A *a ae #,e t%e *tte"$/ ae1 one o$ a $a#/ o$ ae& )aed

>a"te" t"n ae&B #& a ae t%at o'en& */ t"n#n3 a %ande atta)%ed to a *a

#nde t%e ae. T%e *a %a& a %oe1 o" 'o"t1 t%"o3% t%e #dde &o t%at +%en

t%e 'o"t #& #n #ne +#t% *ot% end& o$ t%e ae1 $o+ +# o))". %en t%e ae

#& )o&ed1 t%e %oe #& 'e"'end#)a" to t%e end& o$ t%e ae1 and $o+ #&

*o),ed. T%e %ande 'ot#on et& /o &ee t%e ae& 'ot#on.


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T%e *od/ o$ *a ae& a/ *e ade o$ eta1 )e"a#)1 o" 'a&t#). T%e

*a a/ *e )%"oe 'ated to a,e #t o"e d"a*e.

FIGURE 1.4.>.1& BALL !AL!E

1.4.4 GLOBE !AL!E"

A Go*e ae #& a de#)e &'e)#$#)a/ a t/'e o$ aeB $o" "e3at#n3

$o+ #n a '#'e#ne1 )on&t#n3 o$ a oa*e d#&,-t/'e eeent and a &tat#ona"/

"#n3 &eat #n a 3ene"a/ &'%e"#)a *od/.

Go*e Vae& a"e naed $o" t%e#" &'%e"#)a *od/ &%a'e +#t% t%e t+o

%ae& o$ t%e *od/ *e#n3 &e'a"ated */ an #nte"na *a$$e. T%#& %a& an o'en#n3

t%at $o"& a &eat onto +%#)% a oa*e '3 )an *e &)"e+ed #n to )o&e o"

&%tB t%e ae. T%e '3 #& a&o )aed a d#&) o" d#&,. In 3o*e ae&1 t%e '3

#& )onne)ted to a &te +%#)% #& o'e"ated */ &)"e+ a)t#on #n ana ae&.

T/'#)a/1 atoated ae& &e &#d#n3 &te&. Atoated 3o*e ae& %ae a

&oot% &te "at%e" t%an t%"eaded and a"e o'ened and )o&ed */ an a)tato"

31


32/107

a&&e*/. %en a 3o*e ae #& ana/ o'e"ated1 t%e &te #& t"ned */ a

%and +%ee.

FIGURE 1.4.4.1 GLOBE !AL!E

1.4.5 CHECK !AL!E"A )%e), ae #& a e)%an#)a de#)e1 a ae t%at no"a/ ao+& $#d

#>#d o" 3a&B to $o+ t%"o3% #t #n on/ one d#"e)t#on. C%e), ae& a"e t+o-

'o"t ae&1 ean#n3 t%e/ %ae t+o o'en#n3& #n t%e *od/1 one $o" $#d to ente"

and t%e ot%e" $o" $#d to eae. T%e"e a"e a"#o& t/'e& o$ )%e), ae& &ed #n

a +#de a"#et/ o$ a''#)at#on&. C%e), ae& a"e o$ten 'a"t o$ )oon

%o&e%od #te&. At%o3% t%e/ a"e aa#a*e #n a +#de "an3e o$ ?e& and

)o&t&1 an/ )%e), ae& a"e e"/ &a1 'e1 ando" )%ea'. C%e), ae&

+o", atoat#)a/ and o&t a"e not )ont"oed */ a 'e"&on o" an/ e9te"na

)ont"o a))o"d#n3/1 o&t do not %ae an/ ae %ande o" &te. T%e *od#e&

e9te"na &%e&B o$ o&t )%e), ae& a"e ade o$ 'a&t#) o" eta.

32


33/107

FIGURE 1.4.5.1 CHECK !AL!E

1.4.# PLUG !AL!E"

P3 ae& a"e ae& +#t% )/#nd"#)a o" )on#)a/-ta'e"ed '3&

+%#)% )an *e "otated #nde t%e ae *od/ to )ont"o $o+ t%"o3% t%e ae.

T%e '3& #n '3 ae& %ae one o" o"e %oo+ 'a&&a3e+a/& 3o#n3

de+a/& t%"o3% t%e '31 &o t%at $#d )an $o+ t%"o3% t%e '3 +%en t%e

ae #& o'en. P3 ae& a"e 'e and o$ten e)ono#)a.

FIGURE 1.4.#.1 PLUG !AL!E

33


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1.4. DOUBLE PLUG !AL!E"

T%e&e t+#n '3 ae& a"e #dea &%t o$$ ae& $o" ao&t an/ ed#

e#t%e" nde" &ee"e o'e"at#on )ond#t#on o" #n %#3% e9'oe a"ea&. Vae&1

)o'#e& +#t% t%e ASME )ode& .T%e den o$ t%e *"#)ated t+#n-'3 ae

#& e"/ )o'a)t1 &'a)e and +e#3%t #& #n##?ed and +#t% $a)e to $a)e

d#enon& #dent#)a to a n3e '3 o" *a ae. A t+#n '3 ae& %ae

t%e CCR S/&te +%#)% ao#d& oe"'"e&&"e #n t%e )a#t/ *et+een t%e t+o

'3&1 #$ an ee"3en)/ J+#t% e9t"ee %#3% oe"%eat1 &%od o))".

FIGURE 1.4..1 DOUBLE PLUG !AL!E

34


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1.4. ANGLE !AL!E"

An an3e ae #& a $#d "e3at#n3 de#)e &ed #n '*#n3 and

#nd&t"/. It %a& #net and otet 'o"t& a#3ned at an an3e +#t% "e&'e)t to ea)%

ot%e"1 t%e o&t )oon an3e *e#n3 0 de3"ee&. T%e #net and otet 'o"t& )an

*e t%"eaded $o" )onne)t#n3 to 3aan#?ed &tee and #"on '#'e&1 o" t%e/ )an %ae

)o'"e&on $#tt#n3& $o" )onne)t#n3 to )o''e" '#'e&. %en an an3e ae #&

&ed a& a &%t-o$$ ae $o" "edent#a '*#n3 $#9t"e&1 #t #& )aed an an3e

&to' ae1 o" '/ an an3e &to'.

T%e"e a"e t+o d#$$e"ent ae e)%an#&& )oon/ &ed #n an3e

ae&. A )o'"e&on e)%an#& %a& a t%"eaded &te t%at t#3%ten& a +a&%e"

o" 3"ond (o#nt a3a#n&t t%e ae &eat to &to' $#d o" 3a& $o+ +%en t%e

%ande #& t"ned )onte"-)o),+#&e. An an3e *a ae1 on t%e ot%e" %and1 a&

a t#3%t-$#tt#n3 *a ade o$ eta o" 'a&t#) +#t% a %oe t%"o3% #t. 8#d 'a&&e&

t%"o3% t%e %oe +%en t%e ae #& o'en1 *t +%en t%e %ande #& t"ned

t%"o3% 0 de3"ee&1 t%e %oe a#3n& 'e"'end#)a"/ to t%e $o+ and #t &to'&.

35


36/107

FIGURE 1.4..1 ANGLE !AL!E

1.5 G-*? / S


37/107

) C%#na &tee 3"ade& G< &tanda"d

STANDARD GRADE

EN02-2 .051 .05261 .:6:

EN02-! .!0F1 .!!0F1 .!6F

EN02- .5220

ASTM A 25 C


38/107

- ID Co"e P"o$#e Len3t% 4 #dt%

- T%#),ne&&

G#de R#* T%#),ne&&

G#de R#* to R#* D#&tan)e

a T%#),ne&&

BONNET"

Oe"a Len3t%


39/107

- Inne" D#aete"

- T%#),ne&&

Yo,e a" - #dt%

- T%#),ne&&

a"e #dt%

- Inne" D#aete"

- T%#),ne&&

D#$$&e" ID

Seat R#n3 -


40/107

CHECK !AL!E"

BODY"

Oe"a Len3t%

S#de 8an3e -


41/107


42/107

a t%#),ne&&

PLUG"

Po"t - #dt%

- He#3%t

Oe"a - He#3%t


43/107

- Ote" D#aete"

- Inne" D#aete"

- T%#),ne&&

To' $an3e - Oe" D#aete"

- Inne" D#aete"

- T%#),ne&&


44/107

- Inne" D#aete"

- T%#),ne&&

S#de $an3e - Ote" D#aete"

- Inne" D#aete"

- T%#),ne&&

To' $an3e - Inne" D#aete"

Yo,e &eat - #dt%

- Len3t%

- T%#),ne&&

St$$


45/107

- T%#),ne&&

- 8a)e to 8a)e Oe"a Len3t%B

-


46/107

- T%#),ne&&

1.#.10 ISO PAD"

- Ote" D#aete"

-


47/107

-


48/107

- S#de 8a)e to $a)e

- a T%#),ne&&

1.#.1 LOCK RING"

- Ote" D#aete"

- Inne" D#aete"

- OAL He#3%t

- A" +#dt%

1.#.19 BRACKET"

- Inne" Len3t%

- Ote" Len3t%

- T%#),ne&&

- #dt%

1.#.$0 BODY CASTING HEADS"

8an3e - Ote" D#aete"

-


49/107

De$e)t& "ed)t#on +# *e one o$ t%e o&t '"o#n3 and #a*e &t"ate3/ and

#t +# a&o *e )a'a*e to )o'e ' t%e ee"3#n3 $t"e )%aen3e& Anton/ et a.1

2006B. S#9 S#3a )on)e't %a& *een +#de/ &ed #n an$a)t"#n3 &e)to"

$"o a&t 26 /ea"& a& )o'an/ #,e Moto"oa %a& *een #'"o#n3 #t&

'"o)e&&e& n)e F5 */ n3 #t& de$e)t "ed)t#on a''"oa)% E),e&1200B.

S##a"/ an$a)t"#n3 3#ant& #,e Gene"a Ee)t"#) and Hone/ e %ae

*een n3 #t a& )/)e t#e "ed)t#on too1 n)e 5 et a.1 20B. Ot%e"

+e-,no+n )o'an#e& #,e 8o"d1 Cate"'#a"1 O" ad/ o$ Lo"de& ed#)a

)ent"e1 LG and Sa&n3 et). a"e a&o '"a)t#)#n3 S#9 S#3a a& a >a#t/

#'"oeent te)%n#>e #n t%e#" "e&'e)t#e an$a)t"#n3 '"o)e&&e& $"o

. Ta*e )#te& a(o" +o",& o$ t%e "e&ea")%e"& "eated to a''#)at#on o$

S#9 S#3a #n an$a)t"#n3 &e)to" d"#n3 t%e 'a&t de)ade.

A$te" ana/?#n3 n#$#)ant )ont"#*t#on o$ S#9 S#3a a''"oa)% aon3

SME&1 an e$$o"t %a& *een ade to #'eent DMAIC et%odoo3/ #n non-

$e""o& ed# &)aeB $ond"/1 +#t%ot #3no"#n3 #t& e9#&t#n3 Ind#an

)on&t"a#nt&. It $"t%e" de/&t#$#e& a"#o& /t%& "e3a"d#n3 S#9 S#3a and

SME&1 &'e)#$#)a/ $o" t%e $ond"/ n#t.

T: $.1& A:3;


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CHAPTER&>

BASICS OF FOUNDRY

50

S No Author(s) Comp!" #U!it

Prm$t$rs A%hi$v$m$!ts

1 Henderson &Evans (2000)

General Electrico!"an#

$!"le!entationas a %alit#tool' edced

te c#cle ti!eat re"air so"s'

*nnal savin+o, -2 .illion/rocess

i!"rove!entdone

2 $n+le and oe(2001)

edi! siedeldin+ nit

"ti!iation o,eldin+ "rocess"ara!eters

oint stren+t isincreased .#26 and scra"or is redced.# 3

3 oes et al'(2002)

* .l.!an,actrin+SE

$!"rove te"rocess andredced tesell cracin+o, .l.s

Si+!a levelincreased ,ro!3'1 to 4'5

4 *nderson et al'(2006) * +ravit# diecastin+ nit astin+ scra"redced ,ro!23 to 11

40 redctionin!an,actrin+cost itannal savin+so, -72000 "'a'

5 in et al' (2008) ran.err#rins td'

$!"rove!ent in"acin+"rocess'

/ leveli!"roved ,ro!3011 to 178onl#' 17redction in"acin+ ti!e'

6 *nton# and

esai (2009)

ilson :ools Sorten te

eat treat!entti!e

o+l# -10000

"er #earsavin+s' 2redction inoverall eadti!e

7 Sin+ and;and


51/107

>.1 FOUNDRY"

A F*-= #& a $a)to"/ t%at '"od)e& eta1 )a&t#n3&. Meta& a"e )a&t

#nto &%a'e& */ et#n3 t%e #nto a #>#d1 'o"#n3 t%e eta #n a od1 and"eo#n3 t%e od ate"#a o" )a&t#n3 a$te" t%e eta %a& &o#d#$#ed a& #t

)oo&. T%e o&t )oon eta& '"o)e&&ed a"e a#n# and )a&t #"on.

Ho+ee"1 ot%e" eta&1 &)% a& *"on?e1 *"a&&1 &tee1 a3ne1 and ?#n)1

a"e a&o &ed to '"od)e )a&t#n3& #n $ond"#e&. In t%#& '"o)e&&1 'a"t& o$

de"ed &%a'e& and ?e& )an *e $o"ed.

>.$ PROCESSES OF A FOUNDRY"

PATTERN MA@ING

METHODING

MOULDING

MELTING

LA.$.1 PATTERN MAKING"

T%e a,#n3 o$ 'atte"n&1 )aed


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&,#& t%"o3% a''"ent#)e&%#'& and t"ade &)%oo& oe" an/ /ea"& o$

e9'e"#en)e. At%o3% an en3#nee" a/ %e' to den t%e 'atte"n1 #t #& &a/

a 'atte"na,e" +%o e9e)te& t%e den.

>.$.1.1 P.$.$ METHODING"

52

http://en.wikipedia.org/wiki/Castinghttp://en.wikipedia.org/wiki/Sand_castinghttp://en.wikipedia.org/wiki/Waxhttp://en.wikipedia.org/wiki/Plaster_of_Parishttp://en.wikipedia.org/wiki/Castinghttp://en.wikipedia.org/wiki/Sand_castinghttp://en.wikipedia.org/wiki/Waxhttp://en.wikipedia.org/wiki/Plaster_of_Paris


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T%e 'atte"na,e" o" 8ond"/ en3#nee" de)#de& +%e"e

t%e S'"e&1 3at#n3 &/&te&1 Co"e& and R#&e"& a"e 'a)ed +#t% "e&'e)t to t%e

'atte"n. %e"e a %oe #& de"ed #n a )a&t#n31 a core a/ *e &ed +%#)% de$#ne&

a oe o" o)at#on #n a )a&t#n3 +%e"e eta +# not $o+ #nto.

Soet#e& )%#& a/ *e 'a)ed on a 'atte"n &"$a)e '"#o" to od#n31

+%#)% a"e t%en $o"ed #nto t%e &and od. C%#& a"e %eat n,& +%#)% ena*e

o)a#?ed "a'#d )oo#n3. T%e "a'#d )oo#n3 a/ *e de"ed to "e$#ne t%e 3"a#n

&t")t"e o" dete"#ne t%e $"ee?#n3 &e>en)e o$ t%e oten eta +%#)% #&

'o"ed #nto t%e od.


54/107

>.$.> MOULDING"

M:*38 ?*1 a&o ,no+n a& /*-= ?*1 #& &and t%at +%en o#&tened

o" o#ed tend& to 'a), +e and %od #t& &%a'e. It #& &ed #n t%e '"o)e&& o$ &and

)a&t#n3. G-?* #& an a33"e3ate o$ &and1 *enton#te )a/1 'e"#?ed

)oa and +ate" . It& '"#n)#'e &e #& #n a,#n3 od& $o" eta )a&t#n3. T%e

a"3e&t 'o"t#on o$ t%e a33"e3ate #& a+a/& &and1 +%#)% )an *e

e#t%e" #)a o" o##ne.

T%e"e a"e an/ "e)#'e& $o" t%e '"o'o"t#on o$ )a/1 *t t%e a &t"#,e

d#$$e"ent *aan)e& *et+een od a*##t/1 &"$a)e $#n#&%1 and a*##t/ o$ t%e %ot

oten eta to de3a&. G"een &and #,e ot%e" )a&t#n3 &and&B #& &a/ %o&ed

#n +%at )a&te"& "e$e" to a& $a&,&1 +%#)% a"e not%#n3 ot%e" t%an *o9e& +#t%ot a

*otto o" #d. T%e *o9 #& &'#t #nto t+o %ae& +%#)% a"e &ta),ed to3et%e" #n

&e. T%e %ae& a"e "e$e""ed to a& t%e to' )o'eB and *otto d"a3B $a&,

"e&'e)t#e/.

G"een &and #& not 3"een #n )oo"1 *t 3"een #n t%e &en&e t%at #t #& &ed #n a

+et &tate a,#n to 3"een +oodB. T%#& d"/ &and )a&t#n3 '"o)e&& "e&t& #n a o"e

"#3#d od *ette" &#ted to %ea#e" )a&t#n3&. A ?* -22- #& a '#e)e o$

e>#'ent &ed #n $ond"/ &and te&t#n3 to a,e te&t &'e)#en o$ od#n3

&and */ )o'a)t#n3 *, ate"#a */ $"ee $#9ed %e#3%t d"o' o$ $#9ed +e#3%t $o"

t#e&. It #& a&o &ed to dete"#ne )o'at#*##t/ o$ &and& */ n3 &'e)#a

&'e)#en t*e& and a #nea" &)ae.

>.$.>.1 S;32 P--


55/107

'"od)e& a &tanda"d )o'a)t#n3 a)t#on to a '"e-ea&"ed aont o$ &and.

Va"#et/ o$ &tanda"d &'e)#en $o" G"een Sand and S##)ate *a&ed CO2B &and a"e

'"e'a"ed n3 a &and "ae" aon3 +#t% a))e&&o"#e&. T%e o*(e)t $o" '"od)#n3

t%e &tanda"d )/#nd"#)a &'e)#en #& to %ae t%e &'e)#en *e)oe 2 #n)%e&

%#3% '& o" #n& 2 #n)%B +#t% t%"ee "a& o$ t%e a)%#ne. A$te" t%e

&'e)#en %a& *een '"e'a"ed #nde t%e &'e)#en t*e1 t%e &'e)#en )an *e

&ed $o" a"#o& &tanda"d &and te&t& &)% a& t%e 'e"ea*##t/ te&t1 t%e 3"een

&and )o'"e&on te&t1 t%e &%ea" te&t1 o" ot%e" &tanda"d $ond"/ te&t&.

8a)#n3 &and1 e$#e&.An o*(e)t t%at %a& eted )o'ete/ #& oten.

T%e 2:#d at ato&'%e"#)

'"e&&"e. At t%e et#n3 'o#nt t%e &o#d and #>#d '%a&e e9#&t& #n e>##*"#.

T%e et#n3 'o#nt o$ a &*&tan)e de'end& &a/ &#3%t/B on '"e&&"e and #&

&a/ &'e)#$#ed at &tanda"d '"e&&"e. %en )onde"ed a& t%e te'e"at"e o$

55

http://en.wikipedia.org/wiki/Phase_transitionhttp://en.wikipedia.org/wiki/Solidhttp://en.wikipedia.org/wiki/Liquidhttp://en.wikipedia.org/wiki/Internal_energyhttp://en.wikipedia.org/wiki/Melting_pointhttp://en.wikipedia.org/wiki/States_of_matterhttp://en.wikipedia.org/wiki/Solidhttp://en.wikipedia.org/wiki/Liquidhttp://en.wikipedia.org/wiki/Standard_conditions_for_temperature_and_pressurehttp://en.wikipedia.org/wiki/Phase_transitionhttp://en.wikipedia.org/wiki/Solidhttp://en.wikipedia.org/wiki/Liquidhttp://en.wikipedia.org/wiki/Internal_energyhttp://en.wikipedia.org/wiki/Melting_pointhttp://en.wikipedia.org/wiki/States_of_matterhttp://en.wikipedia.org/wiki/Solidhttp://en.wikipedia.org/wiki/Liquidhttp://en.wikipedia.org/wiki/Standard_conditions_for_temperature_and_pressure


56/107

t%e "ee"&e )%an3e $"o #>#d to &o#d1 #t #& "e$e""ed to a& t%e /-38 3e #& de'endent on $a)to"& &)%

a& t%e eta *e#n3 eted1 t%e aont o$ oten eta "e>#"ed $o" t%e

'"od)t#on "n and t%e a"ea aa#a*e to %o&e t%e et#n3 e>#'ent. T%e"an3e o$ et#n3 e>#'ent t/'#)a/ &ed )an *e )ate3o"#&ed a& $oo+&

Ee)t"#) A") 8"na)e&

Ind)t#on 8"na)e&

Va) Ind)t#on et#n3

Hea"t% 8"na)e&

C")#*e 8"na)e&

C'oa 8"na)e&

Va) A") S, Met#n3 and Ca&t#n3

>.$.4.$ I*;


57/107

"e&t #n a e)%an#)a $o")e1 +%#)% &t#"& t%e oten eta. T%e *ene$#t& o$ t%#&

&t#""#n3 #n)de t%e '"od)t#on o$ a t%e"a/ and )%e#)a/ %oo3eneo&

et and e9)eent ao/ and )%a"3e a*&o"'t#on.

FIGURE >.$.4.$.1& INDUCTION FURNACE

>.$.5 POURING"

57


58/107

In a $ond"/1 oten eta #& 'o"ed #nto od&. Po"#n3 )an *e

a))o'#&%ed +#t% 3"a#t/1 o" #t a/ *e a&&ted +#t% a a) o" '"e&&"#?ed

3a&. Man/ ode"n $ond"#e& &e "o*ot& o" atoat#) 'o"#n3 a)%#ne& $o"

'o"#n3 oten eta. T"ad#t#ona/1 od& +e"e 'o"ed */ %and n3 ade&.

>.$.# LABORATORY TESTS"

T%e $oo+#n3 a"e &oe o$ t%e te&t& *e#n3 )a""#ed ot #n )%e#)a a*

M#)"o &t")t"e o$ S)"a'&

Co'"e&on &t"en3t% Pe"ea*##t/ and Mo#&t"e )ontent o$ Mod

4Co"e Sand.

C%e#)a )o'ot#on o$ Ca&t#n3&


59/107

. Pe"ea*##t/ a*##t/ o$ )o'a)ted od to 'a&& a#" t%"o3% #tB

!. Tota )a/ )ontent d&t )ontentB

6. A)t#e )a/ )ontent '"e&en)e o$ a)t#e *enton#te)a/ +%#)% )an

"ead#/ *ondB

5. Co'"e&e &t"en3t%

8o" 'a"aete"& 1 21 ! and 6 &tanda"d *, ate"#a &a'#n3 et%od& )an

*e a''#)a*e o" &a'#n3 )an *e done +#t% %e' o$ &and Me"1 &and &a'e"

and &and &'#tte" to do #t #n a &tanda"d#?ed anne".

>.$. FETTLING"

T%e $ond"/ Cean#n3 Roo #& )oe)t#on '"o)e&&e& +%e"e )a&t#n3& a"e

$#n#&%ed to eet t%e )&toe"& &'e)#$#)at#on&. On)e 'o"ed1 t%e od& a"e

ao+ed to )oo *e$o"e ne9t *e#n3 &ent to t%e &%a,eot. At t%e &%a,eot1 t%e

)a&t#n3& a"e &e'a"ated $"o t%e &and od. T%e &and #& &ent to a "e)aat#on

&/&te &o t%at #t )an *e "e&ed #n t%e od#n3 '"o)e&&. A& )a&t#n3& a"e

"eoed $"o t%e &%a,eot t%e/ a"e &ent to t%e )ean#n3 "oo +%e"e t%e/ a"e

$#n#&%ed to t%e )&toe"& &'e)#$#)at#on&.

P"o)e&n3 #n t%e )ean#n3 "oo #n)de& &%ot *a&t#n31 )t-o$$1 +ed#n31

%eat t"eat#n3 and #n&'e)t#on. De-3at#n3 #& t%e "eoa o$ t%e %ead&1 "nne"&13ate&1 and "#&e"& $"o t%e )a&t#n3. Rnne"&1 3ate&1 and "#&e"& a/ *e "eoed

n3 )tt#n3 to")%e&1 *and &a+& o" )e"a#) )t-o$$ *ade&. 8o" &oe eta

t/'e&1 and +#t% &oe 3at#n3 &/&te den&1 t%e &'"e1 "nne"& and 3ate& )an

*e "eoed */ *"ea,#n3 t%e a+a/ $"o t%e )a&t#n3 +#t% a &ed3e %ae" o"

&'e)#a/ dened ,no),ot a)%#ne"/. T%e 3at#n3 &/&te "e>#"ed to '"od)e

)a&t#n3& #n a od /#ed& e$toe" eta1 #n)d#n3 %ead&1 "#&e"& and &'"e1

&oet#e& )oe)t#e/ )aed &'"e t%at )an e9)eed 60 o$ t%e eta "e>#"ed

59

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to 'o" a $ od. S#n)e t%#& eta &t *e "e-eted a& &aa3e1 t%e /#ed o$

a 'a"t#)a" 3at#n3 )on$#3"at#on *e)oe& an #'o"tant e)ono#) )onde"at#on

+%en den#n3 a"#o& 3at#n3 &)%ee&1 to #n##?e t%e )o&t o$ e9)e&& &'"e1

and t%& et#n3 )o&t&.

>.$. HEAT TREATMENT"

Heat t"eat#n3 #& a 3"o' o$ #nd&t"#a and eta+o",#n3 '"o)e&&e& &ed to

ate" t%e '%/)a1 and &oet#e& )%e#)a1 '"o'e"t#e& o$ a ate"#a. Heat

t"eatent #noe& t%e &e o$ %eat#n3 o" )%##n31 no"a/ to e9t"ee

te'e"at"e&1 to a)%#ee a de"ed "e&t &)% a& %a"den#n3 o" &o$ten#n3 o$ a

ate"#a. Heat t"eatent te)%n#>e& #n)de annea#n31 )a&e %a"den#n31

'"e)#'#tat#on &t"en3t%en#n31 te'e"#n3 and >en)%#n3. A$te" de-3at#n3 and %eat

t"eat#n31 &and o" ot%e" od#n3 ed#a a/ ad%e"e to t%e )a&t#n3. To "eoe

t%#&1 t%e &"$a)e #& )eaned n3 a *a&t#n3 '"o)e&&. T%#& ean& a 3"ana"

ed#a +# *e '"o'eed a3a#n&t t%e &"$a)e o$ t%e )a&t#n3 to e)%an#)a/

,no), a+a/ t%e ad%e"#n3 &and. T%e ed#a a/ *e *o+n +#t% )o'"e&&ed a#"1

o" a/ *e %"ed n3 a &%ot +%ee. T%e ed#a &t"#,e& t%e )a&t#n3 &"$a)e at

%#3% eo)#t/ to d#&od3e t%e od#n3 ed#a $o" e9a'e1 &and1 &a3B $"o

t%e )a&t#n3 &"$a)e. Ne"o& ate"#a& a/ *e &ed a& ed#a1 #n)d#n3 &tee1

#"on1 ot%e" eta ao/&1 a#n# o9#de&1 3a&& *ead&1 +ant &%e&1 *a,#n3

'o+de" aon3 ot%e"&. T%e *a&t#n3 ed#a #& &ee)ted to deeo' t%e )oo" and

"e$e)tan)e o$ t%e )a&t &"$a)e.

>.$.9 'UALITY CONTROL"

Qa#t/ )ont"o #& t%e '"o)e&& o$ a&&"#n3 t%e '"od)t& +#t% no de$e)t& and

3ood >a#t/. Soe o$ t%e et%od& &ed $o" Qa#t/ Cont"o a"e

Ma3net#) Pa"t#)e In&'e)t#on

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Rad#o3"a'%#) te&t#n3

Ut"a&on#) te&t#n3

Penet"ant te&t#n3

V#&a #n&'e)t#on

D#enona #n&'e)t#on.

>.$.10 DESPATCH PACKING

8#n#&%ed '"od)t& a"e &o"ted1 ta33ed1 'a),ed and oaded $o" t"an&'o"tat#on#n t%#& a"ea. 8o" e9'o"t )&toe"&1 n-a)%#ned )a&t#n3& a"e 'a),ed #nto +ooden

)"ate& o" *o9e& de'end#n3 on t%e )&toe"& '"e$e"en)e. 8o" e"/ a"3e )a&t#n3&1

+ooden 'aet& a"e &ed. Ma)%#ned )a&t#n3& a"e 3#en '"ote)t#on )oe"#n3 #n

a)%#n#n3 &"$a)e to ao#d daa3e&. P"ote)t#e Ant#-R&t )oat#n3& a"e 3#en $o"

Ca"*on &tee and Ao/ &tee.

>.> TERMS USED IN MELTING AREA OF FOUNDRY"

C%a"3e

A 3#en +e#3%t o$ eta #nt"od)ed #nto t%e $"na)e.

C%a"3#n3 C"ane

S/&te $o" )%a"3#n3 t%e et#n3 $"na)e +#t% a )"ane.

C%a"3#n3 Doo"

O'en#n3 t%"o3% +%#)% t%e $"na)e #& )%a"3ed.

C%a"3#n3 8oo"

8oo" $"o +%#)% t%e $"na)e #& )%a"3ed.

C%a"3#n3 Ma)%#ne

Ma)%#ne $o" )%a"3#n3 t%e $"na)e1 'a"t#)a"/ t%e o'en %ea"t%.

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Con&tant Intent/ P/"oete"

U&e o$ a )o'a"#&on a' $#aent& 3o+ to e&t#ate eta te'e"at"e.

Co*&t#*e&

Mate"#a& )a'a*e o$ )o*&t#on #n$aa*e.

Co*&t#on

C%e#)a )%an3e a& a "e&t o$ t%e )o*#nat#on o$ t%e )o*&t#*e

)on&t#tent& o$ t%e $e +#t% o9/3en1 '"od)#n3 %eat.

Co*&t#on C%a*e"

S'a)e #n $"na)e +%e"e )o*&t#on o$ 3a&eo& '"od)t& $"o $e ta,e&

'a)e.

Co*&t#on E$$#)#en)/

T%e aont o$ %eat &e$/ aa#a*e d##ded */ t%e a9# aont

+%#)% )an *e #*e"ated */ )o*&t#on &a/ e9'"e&&ed #n 'e")enta3e.

Co""e)t#e E$$e)t#e Te'e"at"e C%a"t

A )%a"t on +%#)% #n$o"at#on )an *e 'otted "e&t#n3 #n an ad(&tent

te'e"at"e "ead#n3 o"e #nd#)at#e o$ %an )o$o"t.

C"#t#)a Po#nt& Te'e"at"e&B

Te'e"at"e& at +%#)% )%an3e& #n t%e '%a&e o$ a eta ta, 'a)e1 and

a"e dete"#ned */ t%e #*e"at#on o$ %eat +%en t%e eta #& )ooed and */ t%e

a*&o"'t#on o$ %eat +%en t%e eta #& %eated1 "e&t#n3 #n %at& o" a""e&t& on)oo#n3 and %eat#n3 )"e&.

De)ant

Po" $"o one e&&e to anot%e". Po" o$$ oten eta +#t%ot

d#&t"*#n3 t%e &d3e.

De-&)ae

Reoe t%e $#"e &)ae $"o t%e &"$a)e o$ )a&t#n3.

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64/107

8ond"/ Lade

A e&&e $o" %od#n3 oten eta and )one/#n3 #t $"o $"na)e to t%e

od&.

8ond"/ Ret"n&Meta #n t%e $o" o$ &'"e&1 3ate&1 "nne"&1 "#&e"& and &)"a''ed )a&t#n3&1

+#t% ,no+n )%e#)a )o'ot#on t%at a"e "et"ned to t%e $"na)e $o" "e-

et#n3.

Hand Lade o" S%an,

A &a ade )a""#ed */ one an.

Heat

A n3e $"na)e )%a"3e o$ eta to *e &ed $o" 'o"#n3 d#"e)t/ #nto

od )a#t#e& a %eat a/ *e a o$ 'a"t o$ a a&te" %eat.

Hee

Meta e$t #n a ade a$te" 'o"#n3 o" #n a $"na)e a$te" o" *et+een

ta''#n3.

Hod#n3 8"na)e

U&a/ a &a $"na)e $o" a#nta#n#n3 oten eta at t%e '"o'e"

'o"#n3 te'e"at"e1 and +%#)% #& &''#ed $"o a a"3e et#n3 n#t.

Hod#n3 Lade

Hea#/ #ned and #n&ated ade #n +%#)% oten eta #& 'a)ed nt# #t

)an *e &ed.

In)on&B

Pa"t#)e& o$ &a31 "e$"a)to"/ ate"#a&1 &and o" de-o9#dat#on '"od)t&

t"a''ed #n t%e )a&t#n3 d"#n3 &o#d#$#)at#on.

Ind)t#on 8"na)eAC et#n3 $"na)e1 +%#)% t##?e& t%e %eat o$ ee)t"#)a #nd)t#on.

Ind)t#on Heat#n3

P"o)e&& o$ %eat#n3 */ ee)t"#)a "e&tan)e and %/&te"e& o&&e& #nd)ed

*/ &*(e)t#n3 a eta to t%e a"/#n3 a3net#) $#ed &""ond#n3 a )o# )a""/#n3

an ate"nat#n3 )""ent.

In3ot

Ca&t#n3 to *e ate" $o"3ed o" %ot +o",ed. A&o1 a $o" &ed $o"

)onen#ent %and#n3 o$ )a&t #"on1 a#n#1 and ot%e" )oe")#a eta&.

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I"on-Ca"*on G"a'%#teB D#a3"a

A d#a3"a "e'"e&ent#n3 &ta*e e>##*"# )ond#t#on& *et+een #"on and

3"a'%#te '"e )a"*onB '%a&e oe" t%e ent#"e "an3e o$ #"on and &tee.

@e#n Te'e"at"e S)aeOne #n +%#)% t%e n#t o$ ea&"eent e>a& t%at o$ t%e )ent#3"ade

de3"ee and a))o"d#n3 to +%#)% a*&ote ?e"o #& 0 de3"ee&1 e>#aent to

-2:.5C.

@#oot ,VB

Un#t o$ ee)t"#)a 'otent#a e>a to 1000 ot&.

Lade

Meta "e)e'ta)e $"e>ent/ #ned +#t% "e$"a)to"/ &ed $o" t"an&'o"t#n3

and 'o"#n3 oten eta. D#$$e"ent t/'e& o$ ade& #n)de %and *1 )"ane1 *otto-'o"1 %od#n31 tea'ot1 &%an,1 and #'-'o".

Lade1


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Meta"3/

S)#en)e dea#n3 +#t% t%e )on&t#tt#on1 &t")t"e1 and '"o'e"t#e& o$ eta&

and ao/&1 and t%e '"o)e&&e& */ +%#)% t%e/ a"e o*ta#ned $"o o"e and ada'ted

to t%e &e o$ an.

M#)a S)%#&t

A t/'e o$ "e$"a)to"/ "o), &ed $o" #n#n3 )'oa& and ot%e" et#n3

$"na)e&.

No??e

Po"#n3 &'ot o$ t%e *otto -'o" ade.

No??e


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Pat)%#n3

Re'a#" o$ a $"na)e #n#n3 o" "e'a#" o$ a od )o"e.

Pee

8"ee "eoa o$ *"nt od#n3 &and $"o )a&t#n3.

Pen)# Co"e

A )o"e '"o(e)t#n3 to t%e )ent"e o$ a *#nd "#&e" ao+#n3 ato&'%e"#)

'"e&&"e to $o")e ot $eed eta.

Po"

D#&)%a"3e o$ oten eta $"o t%e ade #nto t%e od.

Po"#n3

8##n3 t%e od +#t% oten eta. T"an&$e""#n3 t%e oten eta $"o

t%e $"na)e to t%e ade1 ade to ade1 o" ade #nto t%e od&.

Po"#n3 ant#t#e& o$

"e'et#t#e )a&t#n3&.

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P"od)t#on ed#n3

An/ +ed#n3 )a""#ed ot d"#n3 an$a)t"#n3 *e$o"e $#na de#e"/ to

t%e '")%a&e". T%#& #n)de& (o#nt +ed#n3 o$ )a&t#n3 and $#n#&%#n3 +ed#n3.

P"3#n3E##nat#on o$ a#" and ot%e" nde"a*e 3a&e& $"o $"na)e& o" %eat#n3

*o9e&.

P/"oeta"3/

C%e#)a eta"3#)a '"o)e&& de'endent 'on %eat.

P/"oete"

An #n&t"ent $o" dete"#n#n3 eeated te'e"at"e&.

P/"oet"#) Cone

A &ende" t"#%ed"a '/"a#d ade o$ a #9t"e o$ #ne"a& #a" #n

)o'ot#on to t%at o$ )a/ o" ot%e" "e$"a)to"/ *e#n3 te&ted. Ea)% )one #&

a&ned a n*e" #nd#)at#n3 #t& $on te'e"at"e.

P/"oet"#) Cone E>#aent PCEB

An #nde9 o$ "e$"a)to"#ne&& o*ta#ned */ %eat#n3 on a t#e-te'e"at"e

&)%ede a )one o$ t%e &a'e ate"#a and a &e"#e& o$ &tanda"d#?ed '/"oet"#)

)one& o$ #n)"ean3 "e$"a)to"#ne&&.

P/"oet"/

A et%od o$ ea&"#n3 te'e"at"e +#t% an/ t/'e o$ te'e"at"e

#nd#)at#n3 #n&t"ent&.

Ra"e Ea"t% REB

An/ o$ a 3"o' o$ 6 #a" eta& +#t% ato#) n*e"& 6: to :. A&o

"a"e ea"t% eeent1 "a"e ea"t% eta1 ant%an#de &e"#e&1 n)oon eta&1

M#&)% eta.

Ra"e Ga&e&

T%e&e #n)de %e#1 a"3on1 neon1 ,"/'ton1 9enon and "adon.

Re-*ond#n3

Te" &a/ e'o/ed #n "e$e"en)e to add#n3 ne+ *ond#n3 ate"#a to

&ed od#n3 &and &o t%at #t )an *e &ed a3a#n to '"od)e od&.

Re)e##n3 Lade

A ade 'a)ed #n $"ont o$ t%e )'oa #nto +%#)% a eta #& ta''ed. Ita)t& a& a #9e" and "e&e"o#" and to &oot% ot eta $o+ to t%e 'o"#n3 a"ea.

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Re$"a)to"/

Heat-"e&tant ate"#a1 &a/ non-eta#)1 &ed $o" $"na)e #n#n3&

et). T%e >a#t/ o$ "e&t#n3 %eat. Mate"#a &a/ ade o$ )e"a#)&1 +%#)% #&

"e&tant to %#3% te'e"at"e&1 oten eta1 and &a3 atta),.

Re(e)t Rate

Rat#o o$ t%e n*e" o$ 'a"t& &)"a''ed to t%e tota n*e" o$ 'a"t&

an$a)t"ed1 e9'"e&&ed a& a 'e")enta3e.

Re#e$ S'"e

T%e te" &a/ "e$e"& to a &e)ond &'"e at o''ote end o$ t%e "nne" to

"e#ee '"e&&"e )"eated d"#n3 'o"#n3 o'e"at#on.

Re'a#" ed#n3

An/ +ed#n3 )a""#ed ot a$te" de#e"/ to t%e end &e"1 #.e.1 a$te" t%e)a&t#n3 %a& *een #n &e"#)e.

Ret"n&

Meta #n t%e $o" o$ 3ate&1 &'"e&1 "#&e"& o" de$e)t#e )a&t#n3& +%#)% a"e

't *a), #nto t%e et#n3 )/)e.

Ree"*e"ato"/ 8"na)e

Met#n3 n#t +#t% a "oo$ a""an3ed to de$e)t t%e $ae and %eat to+a"d

t%e %ea"t% on +%#)% t%e eta to *e eted "e&t&.

Ree"t

Re)/)ed &'"e&1 3ate&1 "#&e"&1 de$e)t#e )a&t#n3& and a)%#ne )%#'&.

Re/nod& N*e"&

U&ed #n %/d"a#)& and #n )a&t#n3 3at#n3 t%eo"/. A d#enone&& ae

d/na#) #&)ot/ dent/B de&)"#*#n3 t%e $a#"/ &dden &%#$t o$ $o+ $"o

a#na" to t"*ent. Re 2000 "e'"e&ent& t"*ent $o+. La#na" $o+ #&

&edo e9'e"#en)ed #n "nne" and 3at#n3 &/&te&.

R#dde

Hand o" 'o+e"-o'e"ated de#)e $o" "eo#n3 a"3e 'a"t#)e& o$ &and o"

$o"e#3n ate"#a $"o $ond"/ &and.

R#33#n3

Gate&1 "#&e"&1 oo&e '#e)e&1 et).1 needed on t%e 'atte"n to '"od)e a &ond

)a&t#n3.

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R#&e"

A "e&e"o#" o$ oten eta t%at t%e )a&t#n3 )an d"a+ $"o to o$$&et t%e

&%"#n,a3e t%at #& ta,#n3 'a)e a& t%e eta &o#d#$#e&.

Rnne" T"a'e?o#da &%a'ed '#e)e t%at "n& %o"#?onta/ to t%e od )a#t/ and

)onne)t& t%e S'"e *a&e to t%e 3ate&B.

Rnne"


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So#d#$#)at#on

P"o)e&& o$ eta o" ao/B )%an3#n3 $"o t%e #>#d to t%e &o#d &tate.

S'ot

A t"o3% t%"o3% +%#)% t%e eta $o+& $"o t%e $"na)e to t%e ade.

S'"e

A e"t#)a 'a&&a3e+a/ t%at ta,e& t%e oten eta $"o t%e 'o"#n3

*an to t%e "nne".

S'"#n3

Reo#n3 3ate& and "#&e"& $"o )a&t#n3& a$te" t%e eta %a& &o#d#$#ed.

Ta'

To +#t%d"a+ a oten )%a"3e $"o t%e et#n3 n#t.

Ta' Hoe

O'en#n3 #n a $"na)e t%"o3% +%#)% oten eta #& ta''ed #nto t%e

ade.

Tea'ot Lade

Lade +#t% e9te"na &'ot +%e"e#n t%e oten eta #& 'o"ed $"o t%e

*otto "at%e" t%an $"o t%e to'.

Te'e"at"e

De3"ee o$ +a"t% o" )odne&& #n "eat#on to an a"*#t"a"/ ?e"o ea&"ed

on one o" o"e o$ a))e'ted &)ae&1 a& Cent#3"ade1 8a%"en%e#t1 et).

Te'e"at"e1 Hod#n3

Te'e"at"e a*oe t%e )"#t#)a '%a&e t"an&$o"at#on "an3e at +%#)%

)a&t#n3& a"e %ed a& a 'a"t o$ t%e %eat t"eatent )/)e. T%e te'e"at"e

a#nta#ned +%en eta #& %ed #n a $"na)e1 &a/ '"#o" to 'o"#n3.

Te'e"at"e1 Po"#n3T%e te'e"at"e o$ t%e eta a& #t #& 'o"ed #nto t%e od.

Tene St"en3t% Ut#ate Tene St"en3t%1 UTSB

A ea&"e o$ t%e aont o$ e)%an#)a &t"e&& a ate"#a )an +#t%&tand

*e$o"e #t $"a)t"e&. Mea&"ed #n Pond& 'e" S>a"e In)% PSIB 1 o" t%o&and& o$

'ond& 'e" &>a"e #n)% @SIB.

Te&t


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Te&t L3

A 3 )a&t a& a 'a"t o$ t%e )a&t#n3 and ate" "eoed $o" te&t#n3 '"'o&e&.

T%e"o)o'e

A de#)e $o" ea&"#n3 te'e"at"e& */ t%e &e o$ t+o d#&#a" etan )onta)t t%e (n)t#on o$ t%e&e eta& 3#e& "#&e to a ea&"a*e ee)t"#)a

'otent#a +%#)% a"#e& +#t% t%e te'e"at"e o$ t%e (n)t#on. T%e"o)o'e& a"e

&ed to o'e"ate te'e"at"e #nd#)ato"& o" %eat )ont"o&.

T"an&$e" Lade

A ade t%at a/ *e &''o"ted on a ono"a# o" )a""#ed #n a &%an, and

&ed to t"an&$e" eta $"o t%e et#n3 $"na)e to t%e %od#n3 $"na)e o" $"o

$"na)e to 'o"#n3 ade&.

T"an&$o"at#on Te'e"at"eB Ran3eT%e )"#t#)a te'e"at"e at +%#)% a )%an3e #n '%a&e o))"&.

Vent

A 'at%+a/ '"o#ded #n t%e od to ao+ 3a& to e&)a'e.

Co'e

T%e to' %a$ o$ a %o"#?onta/ 'a"ted od.

Co"e

A &e'a"ate/ ade &and &%a'e1 &a/ *a,ed o" )%e#)a/ *onded1

#n&e"ted #n a od to $o" t%e #nde o$ a )a&t#n3 o" 'a"t& +%#)% )od not

ot%e"+#&e *e &%a'ed */ t%e 'atte"n.

D"a3

T%e *otto %a$ o$ a %o"#?onta/ 'a"ted od

Gate

T%e )onne)t#on to t%e )a&t#n3 )a#t/ t%"o3% +%#)% t%e oten eta

$o+&.

Pa"t#n3 L#ne

T%e #ne aon3 +%#)% a 'atte"n o" )o"e *o9 #& d##ded o" t%e d##d#n3 #ne

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*et+een &e)t#on& o$ a od.

>.4 METALS USED IN A FOUNDRY"

A#n#A#n# #& a )%e#)a eeent #n t%e *o"on 3"o' +#t% &/*o A and

ato#) n*e" . It #& a e"/ +%#te1 &o$t1 d)t#e eta. A#n# #& t%e

t%#"d o&t a*ndant eeent1 and t%e o&t a*ndant eta1 #n t%e Ea"t%& )"&t.

M:


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H#3%-Ao/ Stee

>erros allo# it !ore tan 12 ei+t "ercent o, non?car.on

additions'

Ine"t Ga&

A 3a& t%at +# not &''o"t )o*&t#on o" &&ta#n an/ )%e#)a "ea)t#on

e.3.1 a"3on o" %e#.

I"on

I"on #& a )%e#)a eeent +#t% t%e &/*o 8e and ato#) n*e" 25. It #&

a eta #n t%e $#"&t t"ant#on &e"#e&. It #& */ a&& t%e o&t )oon eeent onEa"t%1 $o"#n3 )% o$ Ea"t%& ote" and #nne" )o"e. Met#n3 'o#nt 16F C

Man3ane&e


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Mone

A %#3% n#),e ao/1 a''"o9#ate/ 5: N#1 2F C1 t%e *aan)e 8e1 Mn1

S# and ot%e" eeent&. Mone eta #& "e&tant to )o""oon and #& +#de/ &ed

to "e&t t%e a)t#on o$ a)#d&.

Mo/*den

A eta &ed +#de/ #n ao/#n3 o$ ot%e" eta&. It #& &ed a& %a"den#n3

eeent $o" &tee1 and $o" d#e-)a&t#n3 d#e&. T%e et#n3 'o#nt #& 21520C

!1:!F8B1 and t%e ato#) n*e" #& !2.

Mot%e" Meta

T%e oten ao/ (&t *e$o"e $#na &o#d#$#)at#on and $"ee?#n3 ot o$ t%e &o#d.

N#)%"oe

O9#dat#on-"e&tant ao/ 56 N#1 20 8e1 and 6 C".

N#),e

An eeent &ed $o" ao/#n3 #"on and &tee a& +e a& non$e""o& eta&

et#n3 'o#nt !66C 2568B. N#),e #& a&o a *a&e eta $o" an/ )a&t#n3

ao/& "e&tant to )o""oon and %#3% te'e"at"e o9#dat#on. N#),e& )%e#)a

&/*o #& N#. It& $o"a +e#3%t #& 6F.5 and t%e &'e)#$#) 3"a#t/ #& F.01 and

n#),e& et#n3 'o#nt 1!62C.

N#o*#

N#o*#1 $o"e"/ )o*#1 #& a )%e#)a eeent +#t% t%e &/*o N*

and ato#) n*e" !. It #& a &o$t1 3"e/1 d)t#e t"ant#on eta1 +%#)% #& o$ten

$ond #n t%e '/"o)%o"e #ne"a1 t%e a#n )oe")#a &o")e $o" n#o*#1 and

)o*#te. Met#n3 'o#nt 21!5 C

N#t"o3en

N#t"o3en1 &/*o N1 #& t%e )%e#)a eeent o$ ato#) n*e" &een. At

"oo te'e"at"e1 #t #& a 3a& o$ d#ato#) oe)e& and #& )oo"e&& and

75

https://www.google.co.in/search?biw=1366&bih=667&q=niobium+melting+point&stick=H4sIAAAAAAAAAGOovnz8BQMDgw0HnxCXfq6-gZFpsUlRupZOdrKVfnJGam5mcUlRJYSVnJgTn5qTmpuaV2KVm5pTkpmXrlCQn5lX8ici4cUW--sHDG1aquLN5tx44l82AQAUmkzhWQAAAA&sa=X&ei=AgszU8qwJcX_rAfe9YEw&sqi=2&ved=0CNEBEOgTKAEwGghttp://en.wikipedia.org/wiki/Chemical_elementhttp://en.wikipedia.org/wiki/Atomic_numberhttp://en.wikipedia.org/wiki/Diatomic_moleculeshttps://www.google.co.in/search?biw=1366&bih=667&q=niobium+melting+point&stick=H4sIAAAAAAAAAGOovnz8BQMDgw0HnxCXfq6-gZFpsUlRupZOdrKVfnJGam5mcUlRJYSVnJgTn5qTmpuaV2KVm5pTkpmXrlCQn5lX8ici4cUW--sHDG1aquLN5tx44l82AQAUmkzhWQAAAA&sa=X&ei=AgszU8qwJcX_rAfe9YEw&sqi=2&ved=0CNEBEOgTKAEwGghttp://en.wikipedia.org/wiki/Chemical_elementhttp://en.wikipedia.org/wiki/Atomic_numberhttp://en.wikipedia.org/wiki/Diatomic_molecules


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odo"e&&. N#t"o3en #& a )oon eeent #n t%e n#e"&e1 e&t#ated at a*ot

&eent% #n tota a*ndan)e #n o" 3aa9/ and t%e Soa" S/&te. On Ea"t%1 t%e

eeent #& '"#a"#/ $ond a& t%e 3a& oe)e #t $o"& a*ot F0 o$ Ea"t%&

ato&'%e"e. T%e eeent n#t"o3en +a& d#&)oe"ed a& a &e'a"a*e )o'onent o$

a#"1 */ S)ott#&% '%/)#an Dan#e Rt%e"$o"d1 #n ::2.

O"e

* !ineral ,ro! ic a !etallic ele!ent !a# .e e@tracted "roAta.l#

Pea"#te

A #)"o-)on&t#tent o$ #"on and &tee )on&t#n3 o$ ate"nat#e a/e"& o$

$e""#te and #"on )a"*#de o" )eent#te

Pa&te" o$ Pa"#&

A &e#-%/d"ated $o" o$ )a)# &'%ate ade */ nte"#n3 3/'& to

20C-0C 2!F8-2558B.

P%o&'%o"&

One o$ t%e eeent& #t& )%e#)a &/*o #& P. It& $o"a +e#3%t #& 2.2

&'e)#$#) 3"a#t/ .F21 and et#n3 'o#nt !!.C.

S##)on

An a*ndant eeent1 )%e#)a/ )a&&ed a& a non-eta1 eta"3#)a/ a

eta1 &ed e9tene/ #n $e""o& and non$e""o& ao/& et#n3 'o#nt !2C26.!8B.

76

http://en.wikipedia.org/wiki/Universehttp://en.wikipedia.org/wiki/Milky_Wayhttp://en.wikipedia.org/wiki/Solar_Systemhttp://en.wikipedia.org/wiki/Atmosphere_of_Earthhttp://en.wikipedia.org/wiki/Atmosphere_of_Earthhttp://en.wikipedia.org/wiki/Scotlandhttp://en.wikipedia.org/wiki/Daniel_Rutherfordhttp://en.wikipedia.org/wiki/Universehttp://en.wikipedia.org/wiki/Milky_Wayhttp://en.wikipedia.org/wiki/Solar_Systemhttp://en.wikipedia.org/wiki/Atmosphere_of_Earthhttp://en.wikipedia.org/wiki/Atmosphere_of_Earthhttp://en.wikipedia.org/wiki/Scotlandhttp://en.wikipedia.org/wiki/Daniel_Rutherford


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Tn3&ten

Stee-3"a/1 eta#) eeent1 ' F0C 558B &ed $o" ee)t"#) a'

$#aent1 9-"a/ t*e ta"3et1 and a& ao/ eeent #n %#3%-&'eed &tee&.

Vanad#

A +%#te1 %a"d1 eta#) eeent1 ' F00C 2:28B1 &ed a& an ao/ #n

#"on and &tee a 'o+e"$ )a"*#de &ta*##?e" and deo9#d#?e".

V#"3#n Meta P"#a"/ MetaB

Meta e9t"a)ted d#"e)t/ $"o t%e o"e not '"e#o&/ &ed.

#n)

A )%e#)a eeent %a#n3 &/*o n1 $o"a +e#3% 56.F1 &'e)#$#)

3"a#t/ :.!01 and et#n3 'o#nt !.!C.

#")on#

S#e"/-+%#te1 eta#) eeent1 ' 1F50C 1F08B1 a 'o+e"$

deo9#d#?e" +%en added to oten &tee.

CHAPTER 4

CASE STUDY

P"od)t -Ca&t#n3&

Mate"#a& - ASTM A$1# 7CB

ASTM A>51 CK>MCN

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St"at#$#)at#on ate"nate/1 $o+ )%a"t o" "n )%a"tB

T%e denat#on a"o&e #n 'o&t+a" Ka'an1 #n&'#"ed */ t%e &een $ao&

+ea'on& o$


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DMADV De$#ne&1 ea&"e&1 ana/?e&1 den&1 and e"#$#e& ne+ '"o)e&&e& o"

'"od)t& t%at a"e t"/#n3 to a)%#ee S#9 S#3a >a#t/. A S#9 S#3a '"o)e&&e&

a"e e9e)ted */ S#9 S#3a G"een #"eent&1 #n)"ea&ed )&toe" &at#&$a)t#on1 and

o"e "e#a*e '"od)t& and &e"#)e&. It #& a),no+ed3ed t%at S#9 S#3a )an *e

)o&t/ to #'eent and )an ta,e &ee"a /ea"& *e$o"e a )o'an/ *e3#n& to &ee

*otto-#ne "e&t&. Te9a& In&t"ent&1 S)#ent#$#)-Atanta1 Gene"a Ee)t"#)1 and

A#ed S#3na a"e a $e+ o$ t%e )o'an#e& t%at '"a)t#)e S#9 S#3a.

4.1.$.1 DMAIC 2


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'"e#o& '%a&e&.

P6? I" D/3

T%e '"o*e )an *e de$#ned a& C"a),& and ot%e" de$e)t& $ond #n )a&t#n3&.

P6? IIIII" M?- * A:=?

FIGURE 4.1.$.1.1 FISHBONE DIAGRAM FOR DEFECTS IN

CASTING

T: 4.1.$.1.1 CK>MCN ;?


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F38-

4.1.$.1.$ RT NSD

/ 7CB

;?


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F38- 4.1.$.1.4 RT NSD / CK>MCN ;?


86/107

T: 4.1.$.1.5 C?< :=?3? / CK>MCN C?


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H


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Ca&t#n3& a"e 'a)ed on &"$a)e 'ate o" &"$a)e ta*e +#t% an3e - ea&"#n3

#n&t"ent&. Va"#o& ea&"#n3 #n&t"ent& a"e e'o/ed $o" a $#"&t &et o$

)a&t#n3&1 &o a& to &tanda"d#?e &*&e>ent )a&t#n3&.

5.$ TESTING METHODS

5.$.1 PRESSURE TESTING"

Ca&t#n3 t%at #& &ed $o" )onta#n#n3 o" )one/#n3 #>#d&1 3a&e&1 &)%

t/'e a"e &*(e)ted to '"e&&"e te&t#n3. It #& te&ted $o" an/ ea,& t%"o3% t%e#"

+a&. Lea,& a/ *e dete)ted */ &*e"3#n3 t%e )o'ete )a&t#n3 nde" +ate"

$o" 3a& '"e&&"e& o" */ #&a #n&'e)t#on */ #>#d '"e&&"e&.

5.$.$ DESTRUCTI!E TESTING"

T%#& te&t #& done )an3 %a" to t%e )a&t#n3 #.e. */ de&t"o/#n3 #t. Va"#o&

te&t& #n)de $at#3e te&t&1 )o'"e&on te&t&1 )"ee' te&t& et).

5.$.> NON DESTRUCTI!E TESTING NDT"

He"e 'a"t& to *e te&ted a"e #n&'e)ted $o" #nte"na de$e)t& and &"$a)e

de$e)t& +#t%ot de&t"o/#n3 t%e )o'onent.

Va"#o& et%od& aa#a*e a"e

5.$.>.1M8#),1 )%ea' and e"/ &ent#e. Can on/ *e a''#ed to $e""o& eta& #,e

&tee1 )a&t #"on et)

P"#n)#'e

%en a eta 'a)ed #n a3net#) $#ed1 a3net#) $9 #& #nte"&e)ted */

t%e de$e)t

Ma3net#) 'oe& a"e #nd)ed on e#t%e" de o$ d#&)ont#n#t/. T%#& )an

dete)ted +%en a3net#) 'a"t#)e& a"e att"a)ted to+a"d& de$e)t#e "e3#on.

88


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Ma3net#) 'a"t#)e& '#e& ' #n de$e)t#e "e3#on.

In&'e)t#on o$ de$e)t

Gene"a/1)a""#ed ot #n 3ood #3%t. I$ no de$e)t& t%en "e3a" 'atte"n1 #$ '"e&en)e o$ de$e)t& t%en $9 #ne& d#&to"ted. Ma3net#) 'a"t#)e& &'"ead ot at

t%e 'o#nt o$ de$e)t& #nd#)at#n3 '"e&en)e o$ de$e)t.

F38- 5.$.>.1.1& M8


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T%e a*&o"'t#on o$ 3aa "a/& #& d#"e)t/ '"o'o"t#ona to t%e dent/ o$

and t%#),ne&& o$ t%e 'a"t. I$ t%e 'a"t %a& no de$e)t&1 t%e 3aa "a/& +# 'a&&

n#$o"/ t%"o3% t%e 'a"t. Ho+ee" #$ t%e"e a"e an/ de$e)t& &)% a& 'o"ot/

+%#)% ead& to %#3%e" dent/1 t%e 'enet"at#on o$ 3aa "a/& +# oe

t%"o3% t%e +%#)% &%o+& a& da",e" a"ea& on t%e $#.

Gaa "a/& te)%n#>e #& e$$e)t#e #n o)at#n3 )"a),& &a3 #n)on&

&%"#n,a3e '#'#n3 'o"ot/ *o+ %oe& '#n %oe& et). Gaa "a/& )an *e

&ed $o" #n&'e)t#on o$ )a&t#n3 #n a t/'e o$ eta&1 #,e &tee1 a#n#1

a3ne et).

F38- 5.$.>.$.1 R*38-63;


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F38- 5.$.>.$.$ R*38-63;


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F38- 5.$.>.$.4 I-3*32 19$ R*38-63;


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F38- 5.$.>.$.# R*3;.$.$& S:;U:


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Penet"ant te&t#n3 #& 00 'e"$o"ed on Sta#ne&& Stee1 D'e91 S'e"

D'e9 and N#),e Ao/ )a&t#n3&. A& t%e&e ate"#a& a"e non-a3net#)1 #t #&

done to #dent#$/ C"a),& and &"$a)e de$e)t&. ate" +a&%a*e and &oent

"eoa*e et%od& a"e *e#n3 '"a)t#)ed #n ARUNA ALLOY STEELS

PVT.LTD. Mo&t/1 Soent "eoa*e #& done on C&toe"& #n&'e)t#on

"e>#"eent&.

FIGURE 5.$.>.4.1& DYE PENETRANT TESTING

95


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96


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CHAPTER #

A!OIDING THE DEFECTS IN CASTING

M#d eta.

Po&*e Ca&e& O9#de $#& +%#)% od3e at t%e &"$a)e1 'a"t#a/a",#n3 t%e 'at%& o$ eta $o+ t%"o3% t%e od.

97


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R2*3?"

In)"ea&e od te'e"at"e

Lo+e" t%e 'o"#n3 te'e"at"e

Mod#$/ 3ate ?e and o)at#on $o" 'e"anent od#n3 */ 3"a#t/ o"

o+ '"e&&"eB

T#t t%e od d"#n3 'o"#n3

In d#e )a&t#n3 a'o" *a&t o" &and *a&t od &"$a)e& +%#)% a"e

'e"'end#)a"1 o" nea"/ 'e"'end#)a"1 to t%e od 'a"t#n3 #ne.

I;2:ate "#3#d#t/ o$ 'atte"n& and 'atte"n 'ate&1 e&'e)#a/ +%en

&>ee?e '"e&&"e& a"e *e#n3 #n)"ea&ed.I;:?3? - S


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ANNE+URE

!ISION

Sa$e1 En#"onenta/ $"#end/ and de'enda*e o"d Ca&& Stee

8ond"/ an$a)t"#n3 a)%#ned ae )a&t#n3& $o" &ee"e and )"#t#)a

a''#)at#on #n )o'e9 ate"#a&.

MISSION

Cont#na/ de#3%t t%e )&toe" +#t% >a#t/ and on-t#e de#e"/ $o"

$o"3#n3 on3 te" &&ta#na*e +#n-+#n 'a"tne"&%#'&.

Cont#na/ #'"o#&e e$$e)t#ene&& o$ ana3eent to &t"en3t%en t%e

&/&te and $o)& 'eo'e on data d"#en de)#on ana/& and '"o*e

&o#n3.

Cont#no&/ #ne&t and deeo' 'eo'e +#t% )o"e &,#& to #'"oe

)o'eten)/ and o"3an#?at#ona #noeent. En%an)e )a'a*##t#e& and #ne&t #n ne+ te)%noo3/ to #'"oe

'"od)t##t/ and &''/ $#n#&%ed '"od)t& $o" &ee"e and )"#t#)a

a''#)at#on&.

20

- La"3e&t C2A Ca&t#n3 2!= 600 GTV +e#3%#n3 61600 @3

an$a)t"ed &))e&&$/

- 5 St"a#ne" *od#e& +#t% &%o"t de#e"/ &''#ed $o"

ARAMCO @a"an Ga& P"o(e)t

- Stee Vae a)%#n#n3 $a)##t/ +#t% H/d"o Te&t 'to 2!=

2600 4 5= 00 &ta"ted

- 00 C"#e Rad#o3"a'%/ Co 50


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ANGLE


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103


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104


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ORGANIATIONAL STRUCTURE

106

Electricalecanic

eltin+$ncar+e

/rodcti

on

>ettlin+$ncar+e

aintenance

Sto"e&

S"ervisors & orers o,

all de"art!ents in a

Patte"n

&%o' #n-

)%a"3e

Mod#n3

4 P"o)e&&

)ont"o #n

-)%a"3e&

Met#n3 4

8ett#n3 In-

)%a"3e&

Qa#t/

Cont"o In

)%a"3e

Pa),#n3 4

De&'at)%

In)%a"3e

HR ADMININISTRATIONB

KMD

AMD

MD

P")%a&e 4

Ad#nHR MATERIALSB


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A Project Report on Cost Reduction in Melting- A SQC and Six Sigma Approach

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Transcript of A Project Report on Cost Reduction in Melting- A SQC and Six Sigma Approach