Case Study of Foundry

At G&B Metalcasting Pvt. Ltd

Sieve the sand properly and pour it into the Muller mixer with help of Charger(Bucket)

Sand Preparation

Add Bentonite Powder and Water in Sand as shown in table.NEW SAND(KG)

BENTONITE(KG)

WATER(LIT.)

200 30 8

100 15 4

OLD SAND(KG)

BENTONITE(KG)

WATER(LIT.)

200 10 6

100 5 4

Mix the sand properly up to 5-7 min. and take it out from outlet in trolley and pass it through sammum ariater for fine sand.

1) Place the pattern on machine

2) Put guide pins and fix it by nut tightly

Pattern installation

3)Add parting paste (yellow color) at parting line of pattern .

4) Put ejector pin on m/c

5) Put empty mould box and do proper setting of ejector pin .

6) Add parting agent on pattern

1) Place the mold box on match plate properly and make

ejectors pin setting.

Mould Preparation

2) Sieve the prepared sand for the facing of the component and fill the box with filling sand vibrate once and then backfill it and press it after placing wooden ply on it.

3) Eject prepared mold box and clean it with air gun and put core in it if required.

4) Prepare upper mold as directed above but we have to drill riser by drill m/c and clean riser also with the help of air gun.

5) Insert the closing pins and align lower and upper mold with the help of closing pins on conveyer.

Start the furnace (electric or oil fired) wait till it get warm and then fill the crucible by 60-40% of ingot and Scrap Alloy.

Melt Treatment

Wait for melt total alloy in crucible after melting it measure the temp.

If it is near to pouring temp. Add titanium boron tablet and red flux in it because of which all impurities in the form of dross will float on melt.

Coat the ladle before using and remove all the dross. Do degassing up to 10min with the help of impeller, & after that take it out

and clean it.

Add modification powder(blue) and stir it properly and remove final floating dross to clean the melt.

Warm the casting ladle before casting, remove oxide layer before pouring and pour in mold box at an optimum speed.

1) Melting cost.

Melt wt- 140 kg Melting Time – 3.5 hrs Weight of casting in Box – 4.9 kg Weight of casting after grinding – 0.80 kg Boxes poured in one Heat – 27

2) Core No of cores /hour - 30 No of Persons – 2 Time required for1 core to prepare – 2.5 min

Statistical Data for screw down valve(3105)

3) Sand Preparation

Time required for 27 boxes – 3 hours No of Persons – 2 Time required to make sand for 1 box – 7 min

4)Moulding

No of Boxes / hour – 11 No of Persons – 4 Time required for 1 Box – 5.5 min

5) Melt Treatment

Melting Time – 3 hrs Time for degassing and cleaning of melt – 30 min Ingredient – Titanium boron tablet & red flux. Weight – 600 gm & 1 kg respectively. Wight of Feedol powder – 3 kg

6) Pouring

Pouring time for 1 Box – 40-50 sec Pouring time for 27 boxes - 20 min No of Person - 1

7) Knock Out

Time required for knocking out of one twin casting – 3 min No of twin castings knock ed out / hour – 20 No of person – 1

8) Cutting Time required for cutting 1 twin casting - 2 min No of cutting twin castings / hour – 30 No of person – 1

9) Grinding Time required for grinding of 1 component – 3 min No of pieces grinded / hour – 20 No of person - 1

10) Final grinding

Time required for final grinding of 1 piece – 1.2 min No of pieces finally grinded / hour – 42 No of person – 1

11) Shot Blasting

No of components shot blasted / hour – 200

12) Plant capacity

No of moulds poured / day- 80

Actual Time Required for making 1 screw down valve (3105)

1) core - 4 min 2) Sand - 7 min 3) Mould box – 5 min 4) Melt Treatment & Pouring – 1 min 5) Knockout – 3 min 6) Grinding – 3 min 7) Final Grinding – 1 min

Total - 24 min

1) Core sand – Rs 5/kg For 1 core 1.5 kg sand required. Hence, Cost= Rs 7.5

2) Bentonite – Rs 5/ kg For 1 component 0.5 kg required. Hence ,Cost= Rs 2.5

3) Hardener - Rs 105/ kg For 1 core 12 gm hardner required. Hence ,Cost= Rs 1.26

Actual cost of screw down valve (3105) at G&B Metalcasting Pvt Ltd.

4) Activator – Rs 165/ kg For 1 core 12 gm activator needed. Hence , Cost= Rs 1.98

5) Amine –Rs 200/ kg For 1 core 15 gm activator needed. Hence , Cost= RS 3.0

6) Aluminium Aloy – Rs 165/ kg For 3105 1 kg Required. Hence, Cost = RS 165

7) Sleeve – Rs 18 /piece 1 sleeve needed for 2 components. Hence , Cost = Rs 9

8) Furnace- 40 kw Runs for 3 hour – 120kwh 1kwh =10 Rs. Hence ,Cost= 1200 Rs(For 54 parts=27 Boxes). For 1 Part ,Cost = Rs 22

9)Compressor – 22 kw Runs for 3 hours – 66 kwh 1kwh = 10 Rs Hence, Cost= 660 Rs(For 54 parts=27 Boxes). For 1 part, Cost = Rs 12

10)Ceraflux –Rs 22/ kg 1 kg needed for 54 components (27 boxes) For 1 part, Cost= Rs 0.4

11) Titanium Boron –Rs 255/ kg 600 gm needed for 54 components (27 boxes) Hence, cost = 153 Rs for 54 componts Hence, Cost = Rs 2.83

12)Feedol powder – Rs 125 / kg 3 kg needed for 54 components Hence ,Cost = Rs 6.96

Total = RS 235

THE END