PREVAIL CASTING PVT. LTD. WELCOMES DATE: SEPT. 20, 2006

PREVAIL CASTING PVT. LTD.

WELCOMES

DATE: SEPT. 20, 2006

OVER VIEW OF INVESTMENT CASTING

(LOST-WAX PROCES)

DEVELOPMENTS PROCESS

Conversion of Paper drg to AutoCAD drg

Raster drg Vector drg

3-d Model (Sand Casting ) provided by Customer to be converted to investment casting.

3d model converted to suit Investment Casting requirements.Advantage : 1. Machining Allowance Reduced.

2. Pilot Holes provided on P.C.D for flanges to reduce machining time.

Wax pattern – 3 Patterns made from 3 different tools and assembled for next operation.

Design of Die for Aluminum Core and Cavity using I-DEAS software

Tool path generation designed by using Unigraphics Software to be transferred to Vertical Machining Center after verification

Tool path verification on Unigraphics Software

Machining of core die ON 5-AXIS VMC(MAKE : DECKEL MAHO-GERMANY)

Inspection of Die with precision measuring instruments.

Inspection of Surface finish for the Die

Modification of Die : Originally punch was fixed to the side plate causing practical problem while removal of wax

pattern from the die. Now its modified by separating punch from the side plate

Injection of Wax into the dieOpened Die with injected wax

pattern.

Assembly of wax pattern with gate, runner and riser

First Layer of Ceramic Coating

Coated wax pattern withapprox. 10 to 14 coats

De-waxing of ceramic coated shell by dipping into liquid

wax

De-waxed shell

Samples taken during heat for chemical testing on

spectrometer along with strip containing heat no.

Grinding of Sample for spectro analysis

Testing of sample on spectro Spectro result for chemical analysis

Tested Scrap Tested Sample

Tapping of molten metal in to the ladle

Pouring into ceramic shells

Knock-out of ceramics from casting

Weld Cutting of Gates & Runner of the casting

Heat Treatment: Solution Annealing

Grinding and Velvet Polishing

Microstructure analysis performed on Olympus Microscope equipped with digital camera analysing the structure by using automatic image analyser software to determine % of ferrite & Austenite

Physical Tesing by using UTM and Extensometer attached to the Computer.

Test Piece

Computerized Extensometer giving graph of Stress Vs Strain

Removal of Gate and Runners on Lathe Machine Grinding of Gate

Fettling & Cleaning of Casting

Sand Blasting

Dye Penetration Test

Visual Inspection of Casting

Hydro Testing of casting

Testing of Surface Finish

Casings in Sand Blasted Condition

THANKS….