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Indian Foundry Journal

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Vol 61  No. 11  November 2015

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indianfoundry. Sinha CFO Writes 54 15 IIF Annual Awards 2015 : Nominations Invited 77 NEWS IFEX 2016 & Cast India Expo 19 Member Exclusive : Brakes India Ltd.O. East Kolkata Township P. 11  November 2015 ..11 November 2015 Energy Conservation : Ferrous Foundry An Innovative Melting Technique for Energy Conservation in Ferrous Foundries – R.700 107 Phone : +91 (033) 2442 4489 / 7385 z Fax : +91 (033) 2442 4491 E-mail : journal@indianfoundry. 335. Jain 45 Editorial 11 History of Metal Castings : Past.org Indian Foundry Journal 5 Vol 61  No.org z Website : www. Rajdanga Main Road.CONTENTS President’s Communiqué 7 Vol. 64th Indian Foundry Congress NCTS News : Case Study IIF in Media 87 21 61 News from IIF Regions & Chapters Statistics 123 Udyog Aadhaar Memorandum for MSMEs 125 95 62 CET News zInplant Price Trend of Foundry Raw Materials 115 News & Trends 75 107 Workshop for Workers & Supervisors : z Sand Quality and Testing z Mould. Present & Future Castings in Human Civilisation – N.61 No. Both Green Sand & Dry Sand Workshop on : z Upgrade Your Foundry Forthcoming Events 135 Advertisers’ Index 142 The Institute of Indian Foundrymen “IIF Center”. Kolkata . P. Making. K.

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It also has liberated      .President’s Communiqué The Sharing Economy and the Foundry Industry A phenomenon has been taking root in the developed economies in the recent years. This business model known as aggregation. That is the use of IT and the Internet to disrupt the traditional business models. is challenging established businesses and cosy cartels while leaving the regulators feeling powerless.

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It has also created asset light businesses. providing the consumers with Convenience.    earnings potential. valued in multi-billions.   . in a rather short period. At the same time.

So much so.  This leads us to the question: What is this Phenomenon and What is the Sharing !"     # ‘‘ The Foundry Industry should be prepared for a big disruption in this market! . reduces the pollution levels and lowers cost and thereby lowering the burden on society. Uber. This is a case of the use of technology to share movable assets i. This is especially true about the Millenials (youngsters in their twenties). Ola and other similar services which have revolutionised intra-city transportation by their convenience. that in the metropolitan cities of the world.roads and parking. $%. it is no longer required or fashionable to own a car. Our Industry has to be aware of the Effect of the Sharing Economy.. This sharing helps in reducing the burden on Infrastructure . Making the service come to the customer.e. availability and reliability.

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world over. is dependent on the automotive. which we can conveniently ignore? The Foundry Industry. agriculture.!'   affect us or is it only a Fad. The Foundry Industry should be prepared for a big . These segments account for over seventy per cent of the demand. construction and goods carriers amongst others.

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  Look at the fact that an average automobile is only being utilised twenty per cent of the time in a day. the  % . Similarly. in the Intra-City Goods Transportation Segment.

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In the Infrastructure Sector. The sharing economy or the aggregators can. In agriculture. increase the effective  %   /*  .  %  /0  %   is idle. the equipment utilisation factor is not more than thirty per cent. waiting for loads. the equipment utilisation factor is again twenty per cent. hypothetically.

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market for the above assets. This can lead to reduction in demand and growth rates in
the immediate future, till the market is able to absorb the additional capacity released
by the Aggregation Model. It will be healthy in the long run, by providing cost-effective   

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infrastructure light and employment generative . environmentally light. In conclusion. with many local and global players either entering with new models or duplicating successful models elsewhere. our Industry has to be aware of the Effect of the Sharing Economy./ This can and is happening very fast. It is asset light. in the near . It may have a small negative impact in the demand in the short run. However.

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11  November 2015 . $%1 K. Samaraj Indian Foundry Journal 7 Vol 61  No.  of our Industry. which in turn will lead to prosperity for the Foundries.

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Eastern Region Mr. Paknikar - Member Greetings of the Season! I am sure all of you celebrated the festivities with family and friends to usher in a prosperous year ahead. Kolkata 700 107. N. Sinha - Member Mr. Baidyanath Dutta Executive Director. A. In keeping with the theme and the mood – IIF Journal Team pays salutations and warm regards to the Unknown Foundrymen. K. Indian Foundry Journal From the ancient Pillars/Bells & Bridges – a time has come when designing of castings through 3D images and converting them straight into casting forms have become a reality. Material in this publication cannot be reproduced whether in part or in whole. Foundrymen should strive hard towards Technology Upgradation and projecting Indian products and brand to the rest of the world – this should be our mantra as we look beyond the festivities. FIC Mr. N. Surajit Datta - Member Chief Financial Officer. The IIF is not in any way responsible for the result of any action taken on the basis of the advertisement published in the journal. All these and many other foundries’ wonder products stand proudly today as glorious symbol of our mother industry that has stood the sands of time. Mukherjee - Director. Dr. One of the extraordinary feats that I myself witnessed is the Iron Bridge at Telford. NCTS Invited Members Mr. IIF Mr. but have come out with some master-pieces such as the Iron Pillar at Qutub Minar premises in Delhi or the Moscow Bell / Philadelphia Bell. IIF is working closely with the Government to make this happen – a Technology Upgradation Fund for the Foundries. B.org o All correspondence on Editorial Matters. P. Saxena - Chairman. o IIF reserves the right to reject advertisements. without the consent of IIF. Goel - Member Mr. These upgradations shall also impact savings in Energy cost. V. S. Pradeep Mittal - Chairman Northern Region Dr. This issue is dedicated to the History of Castings over the centuries and I thank Dr. Lal Chopra - Member Prof. who through the last 5000 years have not only kept the technology of castings going. K. P. The Ministry has been kind in rationalising Duty Drawback Rates for Castings and they have also received approval of the Cabinet for Interest Equalisation (Subvention) for Pre & Post-shipment to the tune of 3%. CET Mr. Technology and Quality Upgradation are the two important attributes in enhancing competitiveness for any manufacturing industry. which has been published in this issue. Ravi Sehgal - Editor Fellow Foundrymen & Friends. Ravi - Associate Editor Mr. 11 • November 2015 . These festivities and meeting elders in the family take us back to our childhood. B. England – a bridge made completely out of Cast Iron with a span of 100 feet.O. 335. Anand - Director. S. K. S. Unsolicited articles and transparencies are sent at the owner’s risk and the publisher accepts no liability for loss or damage. Enjoy the year and happy Casting Times ahead!! Ravi Sehgal Editor 11 Vol 61 • No. Subscriptions and Advertisements should be addressed. Dewan D. Rajdanga Main Road. G. endured wars and famines and serves as historical monuments of the Evolution of Man & Technology over the centuries. Technology is moving at a very rapid pace. Anil Agashe - Director. IIF - Convenor Dr. M. Speaking of the rapid pace of Technological advancements – there is an urgent need of Technology Upgradation at most of the 4000 odd foundries in India. K.Editorial Board Editorial Mr. Ramachandran - Member Dr. improve productivity and capacities and most importantly improve the quality of lives of the people working in the foundry. Banerjee - Member Dr.. S. ‘IIF Center’. o The views and opinions expressed or implied in the INDIAN FOUNDRY JOURNAL are those of the authors and do not necessarily reflect those of IIF. built over 200 years ago. Velankar - Chairman Western Region Mr. Narasimhan - Member Dr. With a majority of them under MSME sector – the Government needs to set up a separate fund to assist foundries to upgrade themselves in order to fulfil the international and domestic demands. which would go a long way in the promotion of casting exports. Sinha for having compiled all his research into an interesting presentation. Mr. Nithyanandan Devaraaj - Chairman Southern Region Articles/Write-ups (soft copy) may be forwarded to : journal@indianfoundry. The Institute of Indian Foundrymen.P. East Kolkata Township P. With a review of history of Castings and keeping manufacturing alive to keep the country’s youth power and efficiency to the fore. H.

Tata Steel IIF NATIONAL COUNCIL (2015-16) OFFICE BEARERS President Mr K Samaraj Vice President Mr Anil Vaswani Hon. NMCC z Mr B Muthuraman. Vice-Chairman. 2015) 12 Vol 61  No. 11  November 2015 ` 175/- For SAARC Countries US $ 120 For Other Countries US $ 155 Indian Foundry Journal . Chairman. Secretary Mr Sanjay Shroff Hon. Treasurer Mr Amish Panchal Immediate Past President Mr Vikas Garg Elected Members Mr D S Chandrashekar Mr K Samaraj Mr Jayant Shah Mr Devendra Jain Mr V P Premkumar Mr S Kuppusamy Mr Pradeep Mittal Mr N Viswanathan Mr Sanjay Shroff Mr Anil Vaswani Mr Amish Panchal Mr P A Patel Mr P D Chaubal Mr Dipak Kumar Ghosh Mr Sashi Kumar Jain Mr K C Mathew Mr Yatin P Shah Mr M K Thakur Nominated Members Eastern Region Mr S K Saxena Dr Goutam Sutradhar Dr Ashok Kumar Vaish Western Region Mr M H Velankar Mr Suresh Chavan Mr Anant Bam Mr S B Misra Mr P D Pant Mr Sham Arjunwadkar Mr R V Gumaste Southern Region Dr Nithyanandan Devaraaj Mr N Ramasamy Mr T Kandaswamy Mr R Suresh Kumar Mr K E Moidu Mr C Ravi Chandramouli Mr R Parag Bhandare Mr R Chellapan Northern Region Mr Kanishka Jain Mr Surendra Verma Mr Vineet Jain Mr Viney Luthra Co-Opted Members Ms Sudha Kurupp Mr Ayan Banerjee Mr R K Mehta Mr Sunirmal Dutta Past Presidents’ Council Mr Jagat Shah Mr Naresh Garg Dr H Sundara Murthy Mr Harsh K Jha Ms Reena Bhagwati Mr Vikas Garg [All Other Past Presidents are Invitees to the NC] Subscription Rates of Indian Foundry Journal For 12 Issues : Free Single Copy: Unregistered Post ` 2100/- Foreign : Registered Post ` 2800/- IIF Member Inland : (With effect from April 1.THE INSTITUTE OF INDIAN FOUNDRYMEN Affiliated Member of the World Foundry Organization [Founded 1950] Patron-in-Chief Dr V Krishnamurthy.

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telephony and travel will become expensive from Sunday with the Government imposing 0. 2006.10. MIIA Indian Foundry Journal 15 Vol 61  No. The Finance Ministry has clarified that the Swachh Bharat cess will not apply on those services for which payments have been received prior to November 15 and invoices raised before November 29. So in the remaining months of this fiscal till March 31. The Swachh Bharat cess would be levied only on the portion of taxable services (after abatement) and will go towards funding of the cleanliness drive. the Ministry said it would be calculated on the abated value or value arrived as per the Service Tax (Determination of Value) Rules.3.5 per cent Swachh Bharat cess on taxable services which is expected to yield about Rs. Eating out. This means that service tax on restaurant bills will go up from 5.5 per cent on all taxable services. AIII.6 per cent to 5. service tax rate will go up from 14 per cent to 14.800 crore to the exchequer in the remaining months of the fiscal. it expects to collect around Rs.8 per cent following the levy of 0. Surajit Datta FCA. I shall highlight on the imposition of Swachh Bharat cess @ 0.5 per cent cess will translate into a tax of 50 paise only on every Rs.5% on all taxable services with effect from November 15. the cess would yield about Rs.5 per cent Swachh Bharat cess. FCMA. 2015.CFO Writes Dear Members and Readers. With the imposition of the cess. The decision to impose 0. 2016. In this issue.3. The Finance Ministry has also clarified that the Swachh Bharat cess will not apply on those services for which payments have been received prior to November 15 and invoices raised before November 29.800 crore to the kitty.100 worth of taxable services. 11  November 2015 . According to the Government. Explaining the provisions for the levy of cess.000 crore from Swachh Bharat cess for full year.

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Sharmad Residency.org Shunpur Dasnagar (Jagacha) Howrah .org Sonai Hall.: (022) 2659 1303/1308 E-mail: greatermumbai@indianfoundry. Shrenik Park. P. 3rd Floor.org E-mail: nagpur@indianfoundry. N. Pune .411 038 Phone : (020) 25422902/25437374/65004705 E-mail : ncts@indianfoundry. : (011) 29960601 E-mail: delhi@indianfoundry. First Main Road.org 706. G. Surajit Datta Chief Financial Officer Tel.net. Tel. Rajdanga Main Road.org E-mail : jamshedpur@indianfoundry. Tughlakabad Institutional Area The Ushus Uptown.org NAGPUR E-mail: bhopal@indianfoundry. Baidyanath Dutta Executive Director Tel.: (044) 4218 7119 E-mail: chennai@indianfoundry. Fax : 033 2442 4491 E-mail : admin@indianfoundry. Karve Road.org CHENNAI COIMBATORE The Ushus Uptown.4383999. Anand Director. Chairman zMr.THE INSTITUTE OF INDIAN FOUNDRYMEN SECRETARIAT IIF Delhi Office Foundry Informatics Centre 67.O. Bandra-Kurla Complex Bandra (East). Flat No.org E-mail: kerala@indianfoundry.: (033) 2442 7386 (Direct LL) E-mail : cfo@indianfoundry.org 706. Karve Road. : 033 2442 4489/7385. C-Block.86.org E-mail: batala@indianfoundry.O. East Kolkata Township P. Telefax : 033 2442 4491 E-mail : cet@indianfoundry.org E-mail: belgaum@indianfoundry.org CHAPTERS UNDER WESTERN REGION VADODARA BHOPAL INDORE RAJKOT 207. S.110 062 Tel. Rajdanga Main Road.86.. Flat No. Tughlakabad Institutional Area. : (011) 29960601.org Dr. 3 Plot-122. New No. Char Rasta.. N.org IIF Head Office IIF Center 335.org HYDERABAD KERALA E-mail: hyderabad@indianfoundry. BPC Road Vadodara .region@indianfoundry. 104. Puliyakulam Main Road. N. Director IIF Center. Erandwana.org CHAPTER OFFICES CHAPTERS UNDER EASTERN REGION KOLKATA HOWRAH JAMSHEDPUR RANCHI IIF Center 335.org. Chennai-600 102. Tel. Pune .org E-mail: ranchi@indianfoundry.O. “Elysium Central” (opp to Carmel Garden School). : (033)6451 4046 (Direct LL) E-mail : kolkata@indianfoundry. E-mail: coimbatore@indianfoundry.: (022) 2659 1303/1308 E-mail : western. Mumbai – 400 051 Tel.org Mr. 11  November 2015 . 291. Tel.390 020 E-mail: vadodara@indianfoundry. Tughlakabad Institutional Area New Delhi . : (011) 29960601 E-mail : northern.org Indian Foundry Journal CHAPTERS UNDER SOUTHERN REGION BANGALORE BELGAUM E-mail: bangalore@indianfoundry. 335.O. Kolkata – 700 107 Tel. : (033)6451 4046 E-mail : eastern.org Flat No. Shilavihar Colony.1/B Neminath Nagar (Satyakam) Cooperative Society Housing Ltd. Behind Hotel Olivia. IIF-NR & FIC. : (011) 29960601 E-mail : iiffic@bol.: (033) 2442 7384 (Direct LL) E-mail : ed@indianfoundry. Rajarampuri. Silver Coin. 11th Lane.org Mr. H. Rajdanga Main Road. Anna Nagar East. 2nd Floor. S. New Delhi . 104. Director Flat No.org 43 Vol 61  No.org AHMEDABAD GREATER MUMBAI KOLHAPUR PUNE The Korner Plot No.org E-mail: chandigarh@indianfoundry. Ahmedabad E-mail: ahmedabad@indianfoundry. A.110 062 Tel.641 045. Coimbatore .org JAIPUR E-mail: jaipur@indianfoundry. K. C-Block.. E-mail : membership@indianfoundry. Chennai-600 102.711 105 E-mail : howrah@indianfoundry. Rajdanga Main Road.411 038 Phone : (020) 25422902/25437374/65004705 E-mail: pune@indianfoundry. 3..org SHIMOGA E-mail: shimoga@indianfoundry.: (044) 4218 7119 E-mail : southern. Sinha.org CENTRES OF EXCELLENCE National Centre for Technical Services (NCTS) Centre for Education & Training (CET) Mr. Sharmad Residency. S.org. Arjunwadkar.. Tel. 4th Floor. Kolkata -700 107 Tel. Erandwana. Ramanathapuram. Behind Hotel Olivia. Madhava. Tirth Enclave. New No. East Kolkata Township P. Telefax : (011) 29958028 E-mail : fic@indianfoundry. East Kolkata Township P. 291. Madhava.org New Delhi . East Kolkata Township P. Mukherjee. : 0422 . : (033) 2442-4489/7385. Mumbai – 400 051 Tel. Plot-122. Anil Agashe.org E-mail: agra@indianfoundry.110 062 Tel.org 67.org Mr. Shilavihar Colony. Kolkata – 700 107.org E-mail: indore@indianfoundry. Bandra Kurla Complex Bandra (East). First Main Road Anna Nagar East. Unit.region@indianfoundry. Kolkata – 700 107 Tel. Tel..in REGIONAL OFFICES East West North South IIF Center 335.org CHAPTERS UNDER NORTHERN REGION DELHI AGRA AJMER BATALA CHANDIGARH 67.region@indianfoundry.region@indianfoundry.org 2nd Floor. Satellite Road.B-3B.org E-mail: rajkot@indianfoundry. 3rd Floor. Kolhapur-416008 Telefax : 0231 2521105 E-mail: kolhapur@indianfoundry.org E-mail: ajmer@indianfoundry. E-mail : journal@indianfoundry.. Chairman z Mr.

    3  & * Eastern J . 2015 Those members who have paid their Annual Subscription for 2015-16 and beyond have been included  D<  .THE INSTITUTE OF INDIAN FOUNDRYMEN Membership Strength as on October 31.

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  L L '  & 9 99 L  XY   =4. Z L L L L &  Q * L && Total 51 0 0 12 22 9 29 110 19 12 264 Foreign  + + + + + +  & + + * Northern < & L L Q & * L * L L &Q   [ L L L * ' L  X L L '   B.% + L L L 9 L * & L  &+   D?. ' & 'Q X + '9   H .

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%% *X L L ' X 9 Y 'Y L * &+   Western ]% % ZX L L 9 9 &   L L Y   B.  ' L L L L L L ' L L +   #. . < * L L * &  9 &+ L L ** Total 175 3 4 52 57 32 82 378 652 13 1448 .

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 Q  L X 9  ' '' +  Z+   _< *+ L L & * L &   L 9Z   ` * L  * Y * 9 9* L & +'   D[K  9' L L 9 X & 9 9X  L +Y Total 278 1 1 39 48 17 58 410 12 9 873 531 4 5 136 165 68 201 1065 691 37 2903 Grand Total    #  #%      ..

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Vol 61  No. 11  November 2015

Indian Foundry Journal

energy consumption in Indian ferrous foundries is much more  % . Dept. ITM University. Gwalior E-mail : rkjain1192@yahoo.in This paper is aimed to study the energy consumption in Indian ferrous foundries and to investigate measures for energy conservation. As per the survey conducted and reports published by several national and international agencies. are depleting fast. Jain Professor. The natural sources of energy coal. oil. K.QQRYDWLYH0HOWLQJ7HFKQLTXHIRU (QHUJ\&RQVHUYDWLRQLQ)HUURXV)RXQGULHV R.ENERGY CONSERVATION FERROUS FOUNDRY $Q. of Mechanical Engineering. gas etc.co.

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) These experimental investigations on the rotary furnaces produced excellent results. Dayalbagh Educational Institute (DEI). and at Faculty of Engineering. Agra (a self-deemed university. Dayalbagh. installed at S.Harbhajan Singh Namdhari Enterprises. conducted a series of experimental investigations on the self-designed and developed Rotary furnaces. The experimental  . Agra for production of cylinder heads and auto parts. which are accrued here. Nunihai. industrial estate.

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which varies from 200 kg/hr to 2 tonnes/hr. which are driven by electric geared motor. The drums and cones . oxygen enrichment. Introduction Rotary furnace consists of a horizontal cylindrical drum. ^z/|^{/ Keywords : Rotary furnace. The length and diameter of the drum depend upon capacity of furnace. TERI (The Energy and Resources Institute). This drum is mounted on rollers. preheated air. Two cones. energy consumption. LDO (Light Diesel Oil). one side of which is welded to the drum.

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 % mortar and refractory bricks. 1: Layout of rotary furnace. Indian Foundry Journal One of the cones accommodates the burner. which can  +. Fig.

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A covered oil tank containing LDO is located at a height    . A tap hole is made approximately in the centre of the drum. Charging of material is done through the tap hole and other cone. whereas the pouring is done through tap hole only.  accommodates the duct for heat exchanger.

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and is connected to the burner through pipeline with
suitable diameter and control valves. A pump is installed
to force the oil at desired pressure to the burner. Layout
of furnace is shown in Fig. 1.
Baker[1] explained the working of Rotary furnace.
Baijayanath, and Panigrahy[2] explained that most of the
units are crippled with usage of rudimentary techniques.
The Indian foundry industry needs optimisation of
energy consumption. Pandey, Singh and Sinha[3] 

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as it reduces melting time and emission levels. Singh„^†
advocates the use of newer and cleaner technology for
environmental and energy conservation. Aswani[5] has   

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in melting alone. The furnace operation needs attention
of skilled operators to minimise rejection and energy
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Vol 61  No. 11  November 2015

ENERGY CONSERVATION FERROUS FOUNDRY losses. Arjunwadkar and Pal[6] stressed the use of energy-ef+     %& / $0* ‰  ] %„z† reports have shown that energy consumption in Indian ferrous foundries is much more above the required limit. it is possible to achieve energy conservation in Indian foundries. EPRI Centre[9]  %      . Basu. Chaudhuri and Roy„`† conclude that with judicious applications and implications of correct energy auditing and monitoring techniques.

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required for combustion of fuel.  Š‡{ of sensible heat. This sensible heat can be recovered by using suitable heat exchanger and preheating air. upto temperature of ‹z‡0/ *  .

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    €z kWh/tonne. Secretary General. Andrew Turner[10]. World Foundry Organization (WFO) stressed upon improving the melting techniques in foundries by recovering and %  %  .

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to replace additional air system. Khan and Fartag[11] strongly believe that energy conservation can effectively be achieved only by utilising effective heat exchangers. Mesbah. as they are important components for processes where energy conservation is achieved through enhanced heat transfer. in oxygen-enhanced combustion. scrap. cores and reduce the casting defects by employing suitable techniques. Seung[12] have used the fuel-lean re-burn system. It has maintained fuel lean conditions in the furnace. Kim. which reduces energy    +/ Œ[13] developed high +  .

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Malik„|^† have advocated  . lost as sensible heat through the gas especially in high temperature applications like metal melting in hot brick chamber. Singh and Chandra.

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Experimental Investigations Experimental Investigation 1 A. The %. of air. Operating furnace under existing conditions of operation The furnace was operated without oxygen enrichment and preheating of air as per existing conditions. proper sealings etc.

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more air was required.  started from room temperature. %      .

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In subsequent heats.    melting rate were less.     . but time and fuel consumption were more. the air was reduced.

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   melting rate increased. Observations taken during %   . whereas the time and fuel consumption decreased.

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2. Melting Operation The process of melting the charge is carried in following steps: (1) Preheating of oil and furnace (2) Charging (3) ~ ^Ž$ €Ž*‘Ž’. B. \]X“_/_‡^z kWh/litre). Graphical Representation The graphical representation of energy consumption without oxygen enrichment of preheated air is shown in Fig.

0 1220./ Fig.0 ^‘/‡‡ `z/‡ ‡/^‹€ Š‘‡/` |Š^‡/‡ ‹‡/Š^ 1325.0 ||z€/‡ ‹‡/‡^ 1350. Fuel litre.0 ‹‡/^€ 1310.0 ^z/‡‡ 90.2 : Energy consumption under existing conditions of operation.  Fuel (lit/kg) Melting rate (kg/hr) Excess air m3 Excess air % Flame temp.0 ‡/^€‡ 255.3 1290.00 92. Heat No. 11 November 2015 Indian Foundry Journal .0 30.0 ^€/‡‡ `‹/‡ ‡/^|€ 266.0 ‹‡/^| |‹|^/‡ ^/^€z 3 3 2.0 ^/||‡ 46 Vol 61  No.0 ‡/^‘‡ Š^‡/‡ 1320.0C Energy kWh/ kg 1 1 2.0 ^‘/‡‡ `‘/‡ ‡/^‹‡ 266. Rpm Time min.0 ^/€€‘ 2 2 2.0 50.10 |‹‹^/‡ ^/Š€_ 5 5 2. Table-1: Energy Consumption of Furnace without Oxygen Enrichment of Preheated Air Sl.0 ^/‹‡` ^ ^ 2. No.

ENERGY CONSERVATION FERROUS FOUNDRY Total Energy Consumption Graphical Representation Effect of operating furnace without oxygen enrichment of air on total energy consumption The graphical representation of energy consumption Š‡{  .

% %  % .

Ž% in Fig. The total energy consumption consists of energy consumption in(1) Melting the charge (2) Fuel consumption unit (3) Plant and equipment ^Ž ’. 3.

rotating furnace at optimal rotational speed temperature. &   (5) Shot blasting machine. energy consumption Fig. Experimental Investigation 2 Effect of 20% excess air with compact heat exchanger. The total energy consumption (kWh/tonne) is given in Table-2.3 :  .

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Again experiment was carried by further reducing excess .% %  exchanger.

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preheating LDO  z‡0C. Experimental Investigation 3     |‡{   .  at optimal rotational speed 1.0 rpm. The observations taken during experiment are given in Table-3.

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Particulars Energy consumed Total energy consumption 1        \]X “ ^|€ ^|€_/_‡^z“^||‡/^€‡'%ƒ Litre/tonne ^||‡/^€'% 2 Fuel combustion unit ‡/z^‘' 10.323 kWh ŽX+ . rotating furnace at optimal rotational speed on energy consumption Table-2 : Total Energy Consumption (kWh/tonne) when Furnace Operated without Oxygen Enrichment of Preheated Air Sl. No.

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1 ‹z`/‡ Š/_z|^ 10 1590. experiment was carried out by further reducing   .290 z‘‡/‡ 20.5656 2 1530.0 1.0 30. Flame Temp.0 ‹^/‡ 59. Excess Air Excess Air hr Cons.0 ‹/Š‘`€ 6 |€‘`/‡ 1.0 ‹z/‡ ‘^/‡ ‹Š^/‹ 0.1 ‹‡^/‡ 3.0 36.0 €`/‡ 363.ENERGY CONSERVATION FERROUS FOUNDRY Table-3: Effect of 20.0 39.1199 ` |€z`/‡ 1. Rotating Furnace at Optimal Rotational Speed of 1.0 ‹^/‡ 60.0 ‹Š^‹ 0.0 63.0 ‹z/‡ 66.1 329.0 ‹‡z/‘ ‡/‹^€ 930.0 ^|/‡ zŠ/‡ 293.300 z``/‡ 20.330 `z‡/‡ 20.0 rpm.0 61.360 995.0 ‹`/‡ ‘`/‡ ‹|€/z ‡/‹^‡ 905.0 333.9 0.9 ‹z‡/‡ 3.0 352.0% Excess Air with Compact Heat Exchanger.1695 z |€z‡/‡ 1.0 0.6 0. 0 C Rpm Time min.0 ^‡/‡ z‡/‡ 300.0 20.350 _z‡/‡ 25.0 69.0 ‹/‹‘z€ 5 1550.0C litre/kg  Energy Cons.3 0.0 1.0 ‹^Š/` 0.5 316.2 332.315 `ŠŠ/‡ 20.0 1.0 20.0 ‹`€/‡ Š/_Š|` 11 1620.9 ‹^‡/‡ 3.0 0.0 ‹^`/‡ 3.320 `‹€/‡ 19.0 1.0209 9 |€`‡/‡ 1.0 ‹/^|z| ^ |€^€/‡ 1.0 ^‡Š/‡ Š/`zŠ‹ Melting  Preheated Preheated Preheated Rate kg/ Fuel Excess Air.0 33.295 z`€/‡ 20. m3 % Temp.0 35.0 1.305 z_€/‡ 19.3 320.0 ‹/^‘‘‘ 3 |€^‡/‡ 1. on Energy Consumption Heat No. kWh/kg Again. Fuel litres 1 1510.9 0.0 352.

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Effect of Oxygen Enrichment of Preheated Air on Energy Consumption of Furnace Hence. it is thought to optimise the combustion volume by reducing the amount of preheated air and supplying oxygen externally. gradually reducing air to its theoretical requirement      .Ž% /^/ time shall be required for reaching a certain temperature. Several experiments were conducted.

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0 ‹`z/‡ ‡/Š`‡ ‘z‡/‡ 10.9 ^Š‘/z z€/^ z 1.0 352.0 56.9 ^€_/‡ z€/‹ 2 1.0 ‹z€/‡ ‡/Š`‡ Š/zz‹ ‹`/€ 6.1 ^‡€/‡ Š/`ŠŠ` 6 1693.0 ‹^/‡ 59.00 56. consump consum m3 % m3 % lit/kg kWh/kg 1 1.0 396. air cons kg/hr.0 1.0 6.0 31.0 363.0 56.0% Excess Air with Compact Heat Exchanger. Flame Temp.0 393.6 6.0 6.0 33. cons air cons.0 ‹_‹/^ 0.9 ^^‹/‡ z€/^ 5 1.295 `|‡/‡ ||/^ ‹`^/‡ Š/_Š|` 2 1656.0 ^€^/‡ |z€Š/‡ 31. on Energy Consumption Sl.0 ‡/Š`‡ Š/zz‹ 39. Fuel litres Melting Rate kg/hr.50 €^/‡ ‹`€/‡ ‡/Šz‡ Š/‘z^ ‹`/‡ 6.0 ^|`/‡ |zŠŠ/‡ 32.0 32.0 ^|‡/‡ |z|‡/‡ 33.0 ‹z€/‡ ‡/Š`‡ ‘`‡/‡ 10.0 32.260 Š/€z€ 36. No.0 ^€`/‡ |z€^/‡ 30.ENERGY CONSERVATION FERROUS FOUNDRY Table-4 : Effect of 10.9 ^‹^/€ z€/‹ 6 1.0 €`/‡ ‹z‡/‡ ‡/Š`€ z_‡/‡ 11.9 ^€|/‡ z€/^ ^ 1.00 53.0 0.0 ^|Š/‡ Š/zz‹‹  Preheated Preheated Preheated Fuel Excess Air Excess Excess Air Cons.9 0.0 10. 0 C.0 ‹`z/‡ 0. m3 Air% Temp. Rotating Furnace at Optimal Rotational Speed of 1.0 33.0 32.0 Š/`ŠŠ` 3 1666.0 ^^_/‡ |z^‘/‡ 31.9 ^€_/‡ z€/‹ 3 1. kWh/kg Table-5 : Effect of 6.265 Š/‘Š^ ‹z/‡ 6.50 52. 1 |‘^^/‡ 1. Rpm Time min.0 ^‘‡/‡ |z€€/‡ 30.9 ^Š‘/€ z€/^ Total Energy Consumption    .50 52.00 56.260 Š/€z€ 36.0 ^Š`/‡ |z‹‡/‡ 32.0 1.0 1.9% Oxygen Enrichment of Preheated Air on Energy Consumption Heat Rpm Preheated Flame No.0 ‹z€/‡ ‡/Š`‡ Š/zz‹ 39. air temp temp 0 0 C C Time min Fuel Melting   Oxygen Oxygen Preheated Preheated litre rate fuel Energy cons.3 392 .0 €`/‡ ‹z‹/‡ ‡/Š`Š z€€/‡ 10.5 6.0C litre/kg  Energy Cons.1 ^‡z/‡ Š/zz‹‹ z |z‡z/‡ 1.0 Rpm.0 Š/z_‹| ^ |‘z`/‡ 1.0 €z/‡ ‹`Š/‡ ‡/Š`€ 690.5 €z/‡ ‹z`/‡ ‡/Š`€ zŠ€/‡ 10.00 55.6 ‹_`/‡ Š/`ŠŠ` 5 |‘`^/‡ 1.

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No. Particulars 1 Fuel consumed in melting LDO=260 Litre/ tonne.9% oxygen enrichment of air Sl. Oxygen = 36.50/ 200m3/ “|`Š/€ 3/ tonne 2 Fuel combustion “|/`‘€ '% ^/z^‡'% unit .ENERGY CONSERVATION FERROUS FOUNDRY Table-6 : Total Energy Consumption (KWh/ tonne) when furnace operated with 6.

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Fan-heat Š‡/`€z'%ƒ exchanger 1HP tonne atmosphere side and 0.4% oxygen enrichment of preheated air on energy consumption Again the experiment was repeated further reducing   . ‹_‹/^^ kg/hr = c.7-8.5 HP furnace side ^ Total Energy Consumption #  z/^`/^{  enrichment on total energy consumption is given in $ z/ Effect of 7.

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ID Fan 5 HP b. Comparison of Energy Consumption The comparison of energy consumption. 6. z/ ||/‹z‘'% Pollution Control ‹/z‹'% Equipment: ‡/z^‘'%“ ^/^z‘'% a. as per experimental investigations is shown in Fig. Motor 1 HP . on energy consumption is shown in Fig.

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5 = theoretically required |‡‡/^€'% air.62 kWh   ‘|/||‘^/__{   x 0.4-8.9 2160. preheated up  ^z‘/‡0C. 1 Particulars Energy Total Energy Consumed Consumption Fuel consumed in Š‡`_/_‡^z Š‡‘‡/|z '%   z/^ `/^{ “ Š‡‘‡/|z |‡‡/^€'%“ oxygen enrichment kWh 200. No.ENERGY CONSERVATION FERROUS FOUNDRY Table-7 : Effect of 7. using compact heat exchanger).4% Oxygen Enrichment on Total Energy Consumption Sl. LDO = Š‡`/‡.

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6 ^ 1 ^^`/‡ |z‘Š/‡ 31.7-8.0 ‘Š/^ 3 1 ^‹z/‡ |z€€/‡ 32.5 ‹_‹/^^ ^^/‘ 0.0 ^Š‡/‡ ^Š‡/‡ |‘/‘‘{ Reduction (e) Annual Energy consumption kWh ^|zŠ/‡‹‘‡ Š`zŠ/‹‹‘‡ Šzz‹/‹‹‘‡ Šz||/‡^Š‡ ŠŠ‡€/‡^Š‡ = 1.225 Š/ŠŠ` ^‘/‡ `/| 310.4% oxygen enrichment % Savings compared to without oxygen enrichment (a) Fuel/heat litres `‹/‡ €`/‡ 56.5 ‹_‹/^^ ^‹/` 0.060 ^‡/‡ z/z Š_^/‡ ‘^/_ Table-9 : Effect of Oxygen Enrichment of Preheated Air on Energy Consumption Particulars Without oxygen enrichment With 20% excess air With 10% excess air With 6.1 ‹_`/‘z ^|/‘ ‡/Š‡` 2.1 ‹_`/‘z ^Š/‡ 0. cons.0 ‘‹/^ ` 1 ^z^/‡ |zz‘/‡ ‹‡/^ ‹_^/z‹ ^Š/_ ‡/Š|^ 2.0 ^‹/€ ^z/€_{ (b) Spec.235 Š/‹Šz ^_/‡ `/^ 319.4% Oxygen Enrichment of Preheated Air on Energy Consumption Heat Rpm Preheated Flame Time Melting Fuel  Energy Oxygen Oxygen Preheated Preheated fuel Cons.0 ‹z€/‡‡ ^`/‡ ‡/Š^‡ Š/‹zz ^_/‹ `/‹ 319. rate kg/ litres cons % air cons air cons % 0 0 C C hr.ENERGY CONSERVATION FERROUS FOUNDRY Table-8 : Effect of 7.0 360.219 2.1 2 1 ^‹‡/‡ |z€Š/‡ 32.210 Š/‡z_ ^|/€ `/‡ 295. kg.0 63.0 ‘Š/` 5 1 ^‘€/‡ |zz‡/‡ 31.0 ‹`z/‡‡ ^€/‡ 0.3 6 1 ^z‡/‡ |zzŠ/‡ 30.223 Š/Š‡` ^€/‡ `/| 309.0 ‹z€/‡‡ ^z/‡ 0. No. 1 1 ^Š^/‡ |z^€/‡ 32.0 52.169 ^€/‡ `/‹ 302. fuel.5 ‹`‡/_€ ^€/` 0. air temp temp Min.0 61.290 ‡/Š`‡ 0.3 z 1 ^zŠ/‡ |zz‹/‡ 30.0 ‘^/€ 10 1 ^z‘/‡ |zz`/‡ 30.03 x 106 “‡/__` “|/|‹`|‡6 = 0.7-8.0 360.260 ‡/Š‡` ^_/`z{ (c) Energy kWh/tonne ^|zŠ/‡ Š`zŠ/‹ Šzz‹/‹ Šz||/‡ 2205.6 9 1 ^z€/‡ |zz`/‡ 30.0 ^z/|^{ (d) Annual production tonnes 360.0 ‹z€/‡‡ ^‘/€ 0.926 6 6 10 10 x 106 z/z`/^{   .501 x = 1.0 63. litre/kg ‡/^|€ 0.232 Š/Š_z ^`/‡ `/‹ ‹|z/‡ 62.119 ^‹/‡ `/| Š_z/‡ 63.229 Š/Š‘` ^‘/` `/Š 313.9% oxygen enrichment With 7. cons lit/ kWh/ m3 m3 kg.

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C. *  .. ‡/€z€|‡6 Baijya Nath. Panigrahi. Hummer Press Ltd. Energy Conservation Options Among Indian Foundries-A Broad Overview. 52 Vol 61  No. 11 November 2015 2. London-2nd Edition.

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Indian Foundry ™.€‹`ŽŠ‡‡z /Šz‹‡/ ‹/ "/ ‰/ ’  0š % % –/ ”/ %  +  Energy Measures in Steel Foundry.

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Minimizing Electrical Energy Expenses. K. Aswani.ENERGY CONSERVATION FERROUS FOUNDRY 5. *  . G.

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of India and IIF.. H. Carbon Credits. Energy Savings. Prosanto Pal et al. Arjunwadkar.Opportunities and Challenges for *   . 6.^`|‡ŽŠ‡‡Š /Š‹Š_/ Product Development Centre. Ministry of MSME. PPDC. 2010. Govt. Agra. Feb-2. S.

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* . Khan. A Review on Micro Channel Heat Exchangers and Potential Applications. Amir Fartag. €^|‡Ž Š‡‡` /‹‹‹z/ 11. Mesbah. G..

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Castings in various shapes have been for use for centuries.2). Kolkata Introduction The human civilisation has progressed from Stone Age to present days. The historians and archaeologists say that castings existed in 5000 BC.HISTORY OF METAL CASTINGS PAST. When liquid metal is poured in a mould cavity made of . PRESENT & FUTURE &DVWLQJVLQ+XPDQ&LYLOLVDWLRQ N. Sinha Director. P. but no authentic proof has been found. However. A mineral copper pendent was found in northern Iraq that dated `z‡‡Œ(1. Foundry & Metallurgical Services. today we know that castings existed more than 5000 years ago (3300 BC). There has always been the need for metallic forms in the shape of castings.

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Indian Foundry Journal . Railways and aerospace castings.2b) was found in Mohenjodaro. Fig. the alloy was made harder and the castings made was stronger. Iron Age (1200 BC . which was easily available and having low melting temperature could be melted in small earthenware pots with charcoal. they are all due to development of castings. India dating back to 3000 BC. Another statue of copper.1200 BC) : Bronze Age originated in Turkey. The casting development started in Middle East and then the technique was spread to Egypt. Mesopotamia and (b) Dancing Girl-3000 BC. and at the domestic front. The historians have suggested casting's development period as : Bronze Age (3300 . In early days. castings were used for hunting and personal safety items like arrow head. 11  November 2015 (a) (b) Fig 2 : (a) Frog. A copper head casting in an axe was found in the hand of oldest mummy OTZI in 3300 BC (Fig. a dancing girl^Ž (Fig. Mohenjodaro. India. The early castings 54 Vol 61  No.1). A copper statue of frog(3) from Mesopotamia was found dating back to 3200 BC (Fig. iron products were cast thousand years later which included gun barrels and bullets. castings have been a constant companion. In Europe. With development of steel. automobile. Then by melting in crucibles and pouring into Industrial Age (1600 AD onwards): Also known as the age of technical revolution. it was discovered that by adding tin in copper. which could be sharpened better for hunting and making various other items for personal safety use. Mongolia. Apart from decorative castings. From the days of metallic head of the arrow for survival to present days of industrialisation. Iran and Iraq which are known as cradle of civilisation. hammered knives. oldest casting-3200 BC.1600 AD) : The Chinese mastered the technique in 1000 BC. were made of copper. engineering. 1 : Oldest Mummy OTZI had a Hammer with Copper Head-3300 BC.2a). The early metallic shape was made by hammering copper. which they used for mass production of cast tools and farm equipments. China and India. cast iron was widely used for machine tools and household articles. Later when tin was found. rocketry. casting demand increased in automobile. % %    % +   of aerospace. This age saw the increased demand for cast products.

5 : %   . as it is done in investment castings today (Fig.5). Fig. The progress in casting technology is aptly illustrated by the evolution of investment casting process for the production of ancient Chinese non-ferrous artifact(5) to its adaptation for sophisticated ferrous castings for their defence armament applications.HISTORY OF METAL CASTINGS PAST. PRESENT & FUTURE lost wax moulds. which was made by wax pattern and clay moulds.

Iron Pillar Fig. 4 :*. History of Metal Castings Fig 3: Lost wax castings.% „1]|‹^€–] Wt 616 g].

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High Phosphorus content. Built during the reign of Chandragupta II. the mummy from 3300 BC carried a copper age z  . Indian Foundry Journal Castings led to the progress of each civilisation z OTZI.  ] %‹‹‡–]„z~•% Rust Resistant. even after 1500 years it has not rusted].

OTZI. the oldest mummy had an axe with cast copper head z 3200 BC . Iran and Iraq z Iron Age (1200 BC onwards) : Chinese mastered the foundry technique in 1000 BC z Industrial Age : 1600 AD onwards Important Finding of Castings in Ancient Periods 3300 BC .A frog cast in copper found in Mesopotamia z 3000 BC .– zz‡‡Œž‹‹‡‡ŒŽ#     by copper age z Bronze Age (3300 BC – 1200 BC) : Bronze age originated in Turkey.A dancing girl casting in copper found in Mohenjodaro.Weapons and cult objects were found in Middle East and in India z z‡‡Œ. India z 3000 BC .

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daggers were made in stone moulds which increased the production and quality of castings. Mn. Swords.HISTORY OF METAL CASTINGS PAST. CrMo HIGH & SUPER ALLOYS z z z z z z WOOD CHARCOAL COAL OIL FIRED GAS FIRED ELECTRIC – INDUCTION – ARC LASER The early Bronze castings were used for domestic purposes but soon it found place in armoury. Moghul King Babur invaded India |€Š‘ +. PRESENT & FUTURE CHRONOLOGICAL DEVELOPMENT OF CASTINGS MANUFACTURING PROCESSES CASTING MOULDING MATERIALS z z z z z z z LOAM SAND BENTONITE CO2 CEMENT SAND RESIN SAND SHELL SAND CERAMICS MOULDING PROCESSES z z z z z z z z z z z z z z z z z CLAY CASTINGS z HORSE MANURE/CLAY z CASTING z STONE MOULDS z WAX PATTERN z SAND CASTING z DIE CASTING SHELL MOULDING z INVESTMENT CASTING V PROCESS PERMANENT MOULDING CENTRIFUGAL CASTING HAND MOULDING SWEEP MOULDING MACHINE MOULDING CONTINUOUS CASTING DISAMATIC 3D SAND PRINTED CASTING METALS MELTING COPPER BRONZE CHILLED IRON GREY IRON MALLEABLE IRON STEEL SS. Heavy cannons were made of brass and used in wars.

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The other casting marvels are the Iron pillar(6) 330 AD Qutub Minar. it has not rusted /^Ž/  ~    |Šz| % %        gun powder. Delhi. by Raja Jai % ™ . The world’s largest cannon was made in India. Even after 1500 years in open.%% he won the war.

In 1061.|zŠ‡/zŽ/* % €‡  %‹‡  barrel 20 ft and needed four elephants to pull it. Chinese made ]*.

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PRESENT & FUTURE suspension hangers are made  .HISTORY OF METAL CASTINGS PAST.

The biggest bell in Moscow was   |z‹€    % |_‘/€ tonnes (Fig.9). in Benjamin Huntsman`Ž % +    |`Š_   %  +. Bell castings are must for churches./*|z`| and still in use everyday.

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It could also sustain impact. 57 Vol 61  No. Manganese steel soon found application in mining and crushing industry. it found further application for railway track and chain wrap for excavators and military tanks (Figs. 10 : Railway Bogie and Wheel.   |Š{   Ž/ ~ steel had the special property of work Indian Foundry Journal hardening and could last longer than carbon steel under severe wear conditions.10 & 11). 11  November 2015 . Later with the invention of railways. Fig.

Kieth Millins invented Spheroidal Graphite Iron (SG iron) which has strength and ductility of steel.12) and machine tool industry. castability and damping properties of cast iron. PRESENT & FUTURE Fig. Castings from a few grams to z‡ %   ". Fig. * |_^‹ ~r.HISTORY OF METAL CASTINGS PAST. 11 : Manganese Steel Crossings. machining. SG iron found universal application in auto (Fig. 13 : ADI Gear Box.

The castings of recent past and present have made some engineering marvels which make us wonder where we would have been without the castings./ Further research on S. three-cylinder steam engine(9) at Kelham Industrial ~  % +       |_‡€  ] Œ. Iron. The River Don.G. 14 : Cylinder block in C. iron led to the development of Austempered Ductile Iron (ADI) and compacted graphite Fig. G.

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Indian Foundry Journal . 11  November 2015 Fig. 15 : River Don Engine./|^Ž/ 58 Vol 61  No.

350 tonnes has been m   % +   .11) in the world. 16 : Fat Bomb Shell Production in Foundry. PRESENT & FUTURE Fig.HISTORY OF METAL CASTINGS PAST. The largest steel castings(10.

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350 tonnes. Birmingham. 21 & 22).) Fig. 18 : Blood Hound Rocket Car. moulding machines and core shop (Fig.K. U. Fig. sand plant. 17 : Biggest Steel Castings in the world./ Fig. (Courtesy : Newby Foundry Ltd. 20. 19 : 3D Printed Pattern. The powder metal and laser melting can also bypass the melting furnace.. by % +  .

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Blood Hound rocket car and our modern household appliances. Kimura Group. Vol. 3.. 11  November 2015 ^/ ~  ". Tylecote. F . R. 21 : 3D Sand Mould.Source Internet. History of Metal Casting Industry. A. References 1. Supersonic planes. 2. z‰/|_z‹\ / Simpson Bruce L. K. Fig. History of Casting Industry. PRESENT & FUTURE Fig. where we would have been without Bullet Trains. which are assembly of castings. Casting Copper and Bronze in Stone Moulds. Chakrabarti for his valuable suggestions and help. Japan 05 . ] ’ *\–|__z/ 60 Vol 61  No. Acknowledgement The author wishes to thank Prof. At times I wonder. Bulletin of Historic Metallurgy Group.HISTORY OF METAL CASTINGS PAST.. 22 : Aluminium Casting from 3D Sand Mould.

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but without substantial increase in the quantity of good castings delivered to the customer. –%%%% . initiated through KAIZEN activities.NCTS News Case Study Quantity Up but Quality went Down Problem Continuous improvement projects. Ductile iron pouring on automated moulding line showed intended results in the number of moulds made every day. hit upon an idea to increase ladle capacity as a means of improving productivity in mouldpouring.

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There were no delay and the moulding line had an uninterrupted run. $% %  .  %    +    pouring-productivity. The Changed Process The incremental volume in liquid metal per ladle afforded 3 additional moulds to be poured over the previous practice of 7 moulds per ladle.

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There was a rise in pinhole defects (seen upon machining) and deterioration in nodule shape in standard test coupons from last moulds. Increased Indian Foundry Journal diameter exposed more of the metal to radiation heat loss and the three extra moulds poured accounted for additional heat loss through conduction as well. the last mould poured and was therefore considered as a compliant to quality system protocols. In a validated gating system. such substantial losses in metal temperatures are unwelcome and ductile iron is prone to %  . One corrective step was taken to increase residual magnesium to a higher band width that took care of nodularity issue but pinhole tendency persisted. What went Wrong? When the capacity of the ladle was enhanced. the diameter as well as the height increased.

Solution $%   %  +   . Problem Solving Clearly the corrective action was to eliminate this additional drop in temperature and ensure that the three extra moulds poured were well within previously established band width. indicated a drop of 100C compared to the temperature at the seventh mould from the smaller ladle.   / Measurement of temperature. when the tenth mould was poured with the bigger ladle.

61 Vol 61  No. to minimise conducted heat loss z Light weight insulating cover on the ladle to contain radiation heat loss Remarkably.    %  following improvements were incorporated: z Provision of a thin layer of ceramic blanket between the steel shell and the refractory lining. the fade of magnesium too came down and it was then possible to operate with original parameters for residual magnesium for achieving required nodularity. 11  November 2015 .

11  November 2015 Indian Foundry Journal .IIF IN MEDIA 62 Vol 61  No.

11  November 2015 .IIF in Media Indian Foundry Journal 63 Vol 61  No.

11  November 2015 Indian Foundry Journal .IIF in Media 64 Vol 61  No.

DVD – 114 Aluminium High Pressure Die-Casting 3. CD . Details of Each sheet available on Website 2. DVD . High Manganese Steel Casting 325 each 4. 3.107 Efficient Aluminium Melting Practices (English/Hindi) 2. DVD – 113 Analysis of Defects in Aluminum Castings – Compendium of Case Studies 3. Efficient Cupola Design and Operation 200 each 2. DVD -109 Shell Moulding Process 11.101 Melt Quality Control & Productivity in Foundry 700 each 3. CD .400 each 3. payable at Pune. DVD -110 Investment Casting Process – Defect Control Instructor 4. Sharmad Residency.900 Per set 2. A.400 each 14. R. Inclusions. The above prices are for India only.106 Interactive CD on Manufacturing Techniques & Heat Treatment of S. D.600 each 13. DVD . CD . 4. Discontinuities. Pattern Design – Practical Guidelines 460 each 5 Green Sand Practices For Defect-Free Casting – Mr. No. Green Sand Preparation and Control – Mr.e.500 each 17. Sheelavihar Colony. G.100 each 6.400 each 10. Above prices are inclusive of packing and forwarding charges for IIF Members & Technical Institutes. CD .103 Computer-based programme on Microstructures of Cast Iron 3. S.104 Temperature Measurements & Instruments and Thermal Analysis Techniques 2.000 each Books 1. 2. DVD . Pinhole Porosity and others in Ferrous as well as Non-Ferrous Casting 3. in favour of “The Institute OF Indian Foundrymen NCTS”. Set of Two DVD (Part 1 to 3 & Part 4 to 7) Introduction to Casting Defects: Blow Holes. NCTS INFO SHEETS Full set of 120 Nos. CD . DVD – 115 Inoculation of Cast Irons . : +9120 2543 7374 / 2542 2902 z E-mail : iifncts@iifncts.400 each 16.102 Efficient Cupola Operation & Productivity in Foundry 4.400 each 15. Off Karve Road.400 each 700 each 5. DVD -111 Divided Blast Cupola – Process & Technology 2. Krishnamoorthy 500 each 3.105 Green Sand Moulding Practices (alongwith Technical Booklet) 2. Product Description Price (`) 1. Shrinkage.411038 (INDIA) Tel.org Indian Foundry Journal 65 Vol 61  No. Subramanian 650 each Technical Information Sheets 1.W.org PRICE LIST CDs/DVDs Sl. Material will be sent by courier on receipt of payment. Website : www.400 each 8.Science and Practices 2. 11  November 2015 . DVD – 112 A Journey Through Cold Box Process 3. DVD – 116 Green Sand Moulding Technology – Emphasis on Sand Control 2. Scab.100 each 7.000 each 12.800 each 9.108 Gravity Die-Casting Techniques for Aluminium Casting 3. July 2015 NATIONAL CENTRE for TECHNICAL SERVICES The Institute of Indian Foundrymen 104. IIF members will get 20% discount on list price on presenting membership number. Please send at par cheque / D.800 per set Terms and Conditions: 1.f. Pune .iifncts. Iron 3.

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11  November 2015 Indian Foundry Journal .68 Vol 61  No.

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70 Vol 61  No. 11  November 2015 Indian Foundry Journal .

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11  November 2015 Indian Foundry Journal .74 Vol 61  No.

75 Indian Foundry Journal Vol 61 ¢ No. LAM Coke. Pig Iron. Al Ingot US Cents/lb FOB China Port Ferro-Chrome NOTE : Freight from China to India Port is about 60-80 USD PMT for container load. USD/Tonne FOB China Port Ferro-Mn NOTE : Freight from China to India Port is about 60-80 USD PMT for container load. 11 ¢ November 2015 . USD/Tonne Ex Plant China Ferro-Si / Pure Mg NOTE : Freight from China to India Port is about 60-80 USD PMT for container load.Price Trend of Foundry Raw Materials Ferro-Chrome. Steel Scrap. Ferro-Si / Pure Mg. Ferro-Mn.

11 ¢ November 2015 Indian Foundry Journal .Price Trend of Foundry Raw Materials MELTING STEEL SCRAP IN ` PER KG INCLUSIVE OF EXCISE PIG IRON IN ` PER KG INCLUSIVE OF EXCISE ` / KG LAM COKE ` / KG PRICE OF AL INGOT ` / KG 76 Vol 61 ¢ No.

2016 z Coimbatore to IIF members based on nominations received under various categories. 2014 to 31st March. Pune (open only to company members) Criteria for Selection (i) Qualitative and quantitative improvement in the last 3 years and various steps taken to increase production by adopting advanced technology. 2015) „ LAKSHMAN RAO KIRLOSKAR AWARD – for Foundry of the Year Sponsor: Kirloskar Oil Engines. 15 points (ii) Qualitative and quantitative improvement in the last 3 years and various steps taken to increase productivity by reduction of man-hours. Unless otherwise stated. of accidents during the year 10 points (ix) HRD promotion efforts 10 points Total : 100 points Nominations for this award should be accompanied by a    .IIF Annual Awards Nominations are invited for ANNUAL AWARDS of The Institute of Indian Foundrymen for the year 2015 Awards will be presented at the 64th Indian Foundry Congress January 29-31. 2015 (Last date for receipt of Nominations is December 20. the period considered for the Awards is 1st April. 15 points (iii) Energy savings effected with energy audit (enclose energy audit report) 10 points (iv) Waste reduction by effecting waste management – criteria value of savings 10 points (v) 10 points Innovative technology (vi) New process controls introduced 10 points (vii) Quality management for overall quality improvement 10 points (viii) Safety management – No.

moulding/core making. pouring. sand conditioning.   adequate explanatory notes covering each of the above criteria.e. melting. fettling. b) At least 6 colour photographs showing excellence in various aspects of the foundry i. 11  November 2015 . Indian Foundry Journal 77 Vol 61  No. heat treatment viz plant & equipment and foundry products.

life member. 11  November 2015 15 points iii] The policy and practice of the foundry in obtaining Safety Data Sheets from the supplier for each chemical used in the foundry. 10 points Total: 100 points Nominations for the award should be forwarded to IIF. transportation etc. construction.IIF Annual Awards „ Gargi Huttenes – Albertus – Green Foundry of the year Award Sponsor: Gargi Huttenes-Albertus Pvt Ltd. 10 points v] Details with photographs of the area inside and outside the foundry building clearly indicating the actions taken for developing greenery. i) ii) iii) iv) v) vi) vii) viii)  for 5 points vii] Measures introduced to reduce/ prevent noise pollution. Please submit the following: a) List of equipment installed with technical details and photographs b) Methods adopted for record keeping & reporting. Nominations for Foundryman of the Year award should be accompanied by    .HO by the Company where the person is currently employed. copy of current consent and copy of yearly or half-yearly statement for the previous year as submitted to the concerned authorities i] The foundry should have taken steps to install Pollution Control Equipment to improve the quality of air and water. R. including    ix) HRD Promotion Efforts 10 points 10 points 10 points 10 points 15 points 15 points 10 points 10 points 10 points Total: 100 points 78 Vol 61  No. fellow member or employee of a company member and (a) should be at least a Diploma-holder with a minimum of 10 years of experience related to the foundry industry or employee of a company member (b) should have a minimum of 15 years experience of which at least 5 years should be in the foundry industry. Santhanam Memorial Award – for Foundryman of the Year ii] The foundry should submit waste of greenery to foundry operational     10 points a) Steps taken to reuse/recycle spent foundry materials/wastes and/          accrued 5 points vi] Evidence of commitment of top management to environmental protection in terms of an environmental policy and environmental management system. 5 points The nominee for Foundryman of the Year Award should be a member. Please enclose. Mumbai (open only to company members) Minimum Qualifying Criteria The foundry should have consent to operate from the State Pollution Control Board. 10 points viii] Foundry should submit healthcare and welfare measures adopted for personnel. Ratio Criteria for the award will be contribution to: Process Improvement Material Substitution Use of New Technology Cost Reduction Increase in Production Increase in Productivity Energy Savings Quality Improvement. the following management: details b) Method of waste treatment and disposal 5 points c) Energy conservation activities 5 points Total: iv] Actions taken in eco-friendly packaging of both incoming and outgoing products. 15 points K. 10 points ix] Foundry should submit safety measures that have been put in place and training of personnel to handle emergency measures in case   10 points x] Use of alternate energy resource building.

Indian Foundry Journal .    adequate explanatory notes covering each of the above criteria and highlighting the individual contribution made by the nominee under each of the criteria. Photographs (optional) may be submitted to substantiate the nomination for the award.

4.e. 7. 2. 2015. weightage will be as per Annual Sales Turnover i.IIF Annual Awards „ IIF REGION OF THE YEAR AWARD – Awarded by IIF company members. 10. 2014 to 30th June. Nominations should be sent by the Chairman or the Hon. Secretary of the Region to IIF-HO vi) Technical Activities Criteria for the award i) a) Organised one Seminar/Workshop relating to the Presidential theme 5 points (a) For conducting Regional Council Meetings (1 point per meeting) minimum 1 meeting per quarter 5 points max b) Ensured Chapters under its jurisdiction have conducted technical activities 5 points (b) For conducting Regional Council Meeting at other than . 10 points max The period for this award is 1st July. except student Members =1. Weightage for others.

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assistance provided to conduct the Congress wherever it is held 5 points Total: 100 points The proposal for nomination should cover a brief write-up on each of the above points. Please submit documentary evidence 5 points b) Ensure timely submission by the Chapters under its jurisdiction 10 points max Sub-total: 15 points max iii) Chapter Activities a) Ensured that Chapters have conducted technical meetings 5 points b) Ensured that Chapters had held regular Chapter council meetings 5 points ix) Each Region should promote public relations with the Government Departments and also hold regular press conferences bringing to light the problems faced by the foundry industry.  (1 bonus point per meeting) 5 points max c) In-plant technical lecture or technical lecture organised in educational institutions by Region or by Chapters under its jurisdiction 5 points Sub-total: 10 points max ii) Annual Report and Annual Audited Accounts a) Timely submission by the Region Sub-total: 15 points max 5 points vii) Attendance at NC meetings by nominated members of the Region (Chairman. particularly relating to availability of input materials. reduction of power tariff etc. 11  November 2015 . Indian Foundry Journal 79 Vol 61  No. other nominated members) — proportion of attendance 5 points viii) Technical services rendered for quality improvement. 5 points c) Ensured that Chapters have submitted Monthly Activity Reports in the regularly prescribed form for the month within 7th of next month 5 points Sub-total: 15 points iv) National Foundry Day Celebration a) On 17th August or within a week before or after 17th August 6 points x) Sub-total: 10 points max v) Membership Growth Membership growth over the year in percentage will be calculated giving due weightage to type of member. central levies like excise. customs duty on capital goods. decreased rejection etc. increased productivity. import of scrap. For Submission of Technical Proceedings Submission of Technical Proceedings of seminar conducted by Region or by Chapters under its jurisdiction at HO 5 points b) Quality of National Foundry Day and Social Gettogether 2 points c) Chief Guest for NFD must be a person of stature in industry/Government 2 points Service to foundry industry xi) Indian Foundry Congress Participation in terms of delegates/technical presentations/souvenir and mobilisation of other resources. energy savings. Hon Secretary.

Mumbai The period for this Award is 1st June. 2014 to 31st May. 2015 vi) CET/Technical Activities a) Lectures arranged: ½ point per lecture 4 points max The Chairman or the Hon Secretary of the Chapter concerned should send the nomination to IIF-HO with details of criteria as stated below: i) a) Timely submission of Annual Audited Accounts to HO 10 points b) Timely submission of Annual Report to HO b) Lectures by outstation speakers within the Chapter or arranged outside the Chapter’s jurisdiction: 1 point per lecture 2 points max  5 points  # $%  .IIF Annual Awards „ VISWAMITRA KAPUR MEMORIAL AWARD – for IIF Chapter of the Year Sponsor: Gargi Industries.

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Module II: Diploma. except student members = 1 Award to be given in two categories: Large and Small Chapters. 2. 80 Vol 61  No. 7.''*   vernacular: 2 point per lecture 6 points max d) Full day/two or more days seminar/workshop/clinic Sub-total: 15 points max ii) 6 points max Timely receipt of Monthly Activity Reports (in prescribed form supplied by the HO) by 7th of the following month Each such report will earn 1/2 point 6 points max e) Promoting CET’s Modular Educational Programme (Module I: Pre-Diploma. 4. Weightage for others. except student members =1 10 points Sub-total: 10 points max Only one visit in each quarter will be considered Technical Service rendered to Foundries ix) Formation of Student Groups Formation of Student Group with at least 2 programmes 5 points Total 100 points Chairmen or Hon Secretaries of the Chapters should send details with a brief write-up of each of the above criteria „ MEMBERSHIP GROWTH AWARD FOR IIF CHAPTERS – Awarded by IIF The period for this Award is 1st January 2015 to 31st December. 10. For company members. 2015 Membership Growth over the year will be calculated in numbers giving due weightage to type of member. For company members. weightage will be as per Annual Sales Turnover i. Service should be provided to at least two foundries Sub-total: 15 points max iv) Celebration of National Foundry Day a) Celebration of NF Day on August 17th or within a week before or after August 17th 6 points b) Quality of NFD programme & social get-together 4 points (Chapters must present mementos to members completing 25 years) 5 points viii) v) Works Visit a) Each visit within the Chapter’s territory 2 points (max 6) b) Each visit outside the Chapter’s territory 2 points (max 4) Sub-total: 10 points max Membership Growth Membership growth over the year in percentage will be calculated giving due weightage to type of member. 2.7.e. weightage will be as per Annual Sales Turnover i. lower rejection.e. Weightage for others. 11  November 2015 Indian Foundry Journal .10.4. Module III. Post Diploma and Module IV: Examination): ½ point per student registered in CET education courses iii) a) Chapter Council Meeting (1/2 point for each meeting with a ceiling of one each month) 4 points max b) Attending Regional Council meetings by Chapter Chairman and Hon Secretary (1/2 point for each meeting) 5 points max 12 points max Sub-total: 30 points max vii) Activities in this area are expected to encourage improved working methods/processes leading to savings through increased yields. cost reduction etc.

In the event of the Committee    . April 1st. 2015.IIF Annual Awards „ BEST TECHNICAL PAPER : OTHER THAN NON-FERROUS AWARD – Awarded by IIF The best technical paper will be adjudged from the papers (other than non-ferrous) published in the Indian Foundry Journal during the period. 2014 to March 31st. Award will be given in two categories: FERROUS and GENERAL The Awards are intended to be a recognition for outstanding contribution.

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Reprints from IFC/ WFC/SEMINARS/CONFERENCES will not be considered.      recommend any award for the year. „ YOUNG FOUNDRYMAN OF THE YEAR AWARD – Awarded by IIF Nominee for Young Foundryman of the Year Award shall be from Industries that are members of IIF. He or she nominated for the Award should be:  +    ' .

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The criteria for the award will be for excellence in combination of the following: a) Process/Quality Improvement 10 points b) Material Substitution 10 points c) Use of New Technology 10 points d) Cost Reduction 10 points e) Increase in Production 10 points f) Energy Savings 10 points g) Books/papers published (details of journals) 10 points h) Exposure to Foreign Organisations 10 points i) Participation/Paper presentation in National and International j) SOLI COMMISSARIAT BEST PAPER AWARD (Silver Medal) For the best Technical Paper presented at the Congress. the author making the presentation will be given the Award. size/ weight produced using any casting process. any end-application. Both content and presentation will be taken into account in deciding the award. If the paper has more than one author. SG iron or steel casting > ' .  8 9  8      should have a minimum of 8 years of experience related to the foundry industry. b) The maximum age limit for the eligible candidate will be 40 years. Reprints from IFC/ Seminars 10 points WFC/SEMINARS/CONFERENCES will not Awards received. Total : 100 points „ CASTING OF THE YEAR AWARD (SHOWCASE YOUR COMPANY’S CASTING CAPABILITY) – Awarded by IIF Eligibility a) Participation is open to all Indian foundries b) Foundry/owner of foundry must be a member of IIF c) Casting may be of any metal. The awards will be given in two categories: 1) Ferrous: Cast iron. if any 10 points be considered.

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(The applicant has to rebook the casting at his own cost). 81 Vol 61  No. b) If required. the casting will have to be sent to the designated location at the cost of the applicant. Judge(s) of the panel or their representative may visit the foundry to inspect the casting. displays and for publication in the Indian Foundry Journal. if necessary. 11  November 2015 . c) Applications from small-scale units will have to be accompanied by a copy of   d) Photographs received along with the application may be used by IIF for tradeshows. market Terms a) Application should be accompanied with details of the casting and photographs from three angles.

the following     .IIF Annual Awards „ EXPORT EXCELLENCE AWARD – Awarded by IIF Criteria This award is categorised into large/ medium/small-scale industries For the purpose of awards.

The following details should be provided along with the nomination : a) Tonnage and type of castings produced.000 tonnes and above. 2.000 . 3.        d) Products exported in tonnage and value.000 tonnes per annum. B] Products manufactured by the Foundry should cover automobiles/ tractors/defence and other engineering industries. medium-scale and small-scale foundries in terms of total sales value / volume.      categories: A] 1. all foundries should provide data of export for a period of 3 years.10.500 . f) Nominations should be sent along with either the published annual report/    . b) Quality control for participating in the export promotion/ exhibition. clearly indicating the growth rate of exports on a year- to-year basis — 15-20% for largescale. Small-scale Foundries All foundry units whose tonnage of production is 2.000 tonnes per annum. e) Countries to which exports are made.20. Medium-scale Foundries All foundries whose tonnage of production is 10. C] Eligibility Criteria Nomination for any category a) The minimum export turnover for a large-scale foundry is Rs 100 crore and above b) For a medium-scale foundry it is Rs 25 crore to Rs 100 crore c) For small-scale foundry it is Rs 1 crore to Rs 25 crore d) Of the three categories. Large-scale Foundries All foundry units which are in operation and whose annual production is 20.

This report should contain points not covered by the questionnaire. Please do not repeat what is already addressed in the questionnaire. Nagpur (for excellence in quality). „ JAYASWAL NECO QUALITY AWARD Sponsor: Jayaswal Neco Industries Ltd. A] This award is being instituted from the year 2009. ii) A brief self-assessment report highlighting the high points of the various initiatives taken by your organisation and the results achieved. Self-assessment report should be restricted to 10 pages of A4 sheet including graphs. if any.       evidence of annual production/export performance. 11  November 2015 D] Guidelines for preparing the application  \ ^ _`{   \  `  \          data in the form of graphs. bar charts substantiating claims made.  \      . The award will be given to a foundry which achieves outstanding quality performance during preceding 12 months. B] The criteria for award consists of the following considerations: 1) Quality Performance 2) P r oc es s Ma n a g e me n t I m pr ov em e n ts 3) Energy Conservation & Management 4) Shop-Floor Practices C] The application will be in two parts: i) Reply to the enclosed questionnaire. 82 Vol 61  No. photographs and other supporting documents.

innovations in casting design resulting in weight reductions. These may be for quality of product.  has received Awards for good performance. \ |'       application is sent  \    \ |'    . service. cost reduction. delivery. ease of handling etc. enclose letters of appreciation from customers. reduction of machining times. if any. Please enclose copies and photographs commemorating these events. The following required information is applicable to one manufacturing plant and therefore data pertaining to that plant only must be submitted.

E-mail \ |'     ~ 9 .Designation.  } the company is part of a corporate group)  \ |'~ 9 corporate group           \ |'the chief executive (site) . e-mail \  9 .Mobile number. phone. mobile number. fax.

Cr.€ \ ' \  %  9 }‚@?`?ƒ  Rs.) \ †  '' '   commercial production \ %|' \ _$_''   \ ‡'   .

1 History and background of the organisation @‚ ! . \ | }ˆ‰ 0.0 Company Outline Please provide a brief write-up covering the following points: 0.

4 Major achievements and milestones in the life of the company 0.  € 0. partnership.5 Type of foundry: Jobbing/captive 0. family-owned.3 Whether joint stock company.6 Alloys and alloy families/ technology used Indian Foundry Journal . owner/ manager type 0.

7 @Š 1.1 Customer^  ‡' Quality Performance:25 points Customer Satisfaction Does the organisation have a formal system for capturing  '' € 1. In-house Rejection 1.4 What is the system you have in place for resolving customer ' € What are the proactive steps to a) Reduce customer complaints b) Prevent recurrence of complaints c) Horizontal deployment of corrective & preventive actions.3 Please provide data on the rejection values and trends for the above break-up 1. coremaking. processwise viz defects as-cast.1. moulding.2.1.1.1 Give detailed data & break-up of in-house rejection viz melting. 1.1. provide case histories –if any to support the above 1.0 1.1.     € ^ explain the system 1. during machining.2.IIF Annual Awards 0.2 Is a customer complaint analysis done customer-wise. delivery-related. fettling ‹  .

3 Cost of Quality 1.    trends over the months and years wherever possible.1 Does your organisation measure.0 Evaluation by Customers: 15 points 2.2 Explain the efforts to reduce inhouse rejection 1. please attach copies of the reports 2. citations received from customers starting from current year going backwards 2.    8 € Œ    € 2.2. 1. monitor overall cost of quality.3.3 Please provide summary of audit  .1 List out the awards.2 Do your customers rate your ˆ }8 " " 9€  so.

2 3.3.1 3.1. Please provide copies of Indian Foundry Journal 3.1.3 3.4 3. support to vendors by way of training.1 3.2 3.2 3.3 4.1 3.0 3. bentonite and other  '€ Please provide copies of a few specimens and list of all the items for which these systems are in use Do you recognise performance of good vendors by way of awards.1.        conducted by your customers.4. technical   €".3 3. vendor meets.3.0 improvement actions initiated by you and customers’ observations on these Process Management / Improvements: 20 points Vendor Management Do you have a criteria for vendor  € Does your organisation have internal standards/acceptance criteria for raw materials & other supplies coming from unorganised sector viz sand.2 3.4.1 3.4.

Environment Management Processes Does the organisation have    9  . which have resulted in    ' Improvements in Manufacturing Processes Give examples which have resulted in reduction of rejection both in-house and at customers’ end during machining. Process Improvements Improvement in Casting Design Give examples of improvements made.9  Low-Cost Automation Give examples of low-cost automation.

€ List some steps and achievements by the company What are systems of waste sand €ˆ .

0 5.2 4.1 4.3 Does your organisation have a long-term energy management / conservation plan covering for eg various energy inputs used .1 6. ' € Do you have norms units per heat/batch.coke/ furnace oil/electrical energy from grid.   9 '  € Provide a list of pollution control equipment and Equipment for recycling consumables Energy Management:15 points Please answer yes or no for each of the questions listed below and give a brief write-up covering all aspects and whatever data you can share.2 6. per shift. process heat.3 4. heat treatment.5 4.1 5.0 6. self-generation/renewable  € Have you laid down energy consumption norms operationwise say for melting.2 5.6 5.3 6. per tonne of ' '€ Does the company have metrics to monitor energy consumption at various stages as well as overall units per tonne of despatch and energy consumption as a  .4 4. 4.

€ Does the company analyse the electrical energy bill in terms of unit consumption. low power € Have you got energy audit conducted for your organisation and undertaken improvement    € Shop-Floor Practices: 5 points Does your organisation follow 5S € What are the methods adopted to 9 ƒ€ Illustrate with photographs the effectiveness of the implementation. Employee Involvement: 10 points Do you have a suggestion '€ Œ   '  suggestions per employee per € Do you have small group activities  '9'   * € Do you have a safety committee  99 . additional levy for maximum demand.

near'    .K€ˆ '  the trend of accidents.

11  November 2015 . € Œ steps do you take for employee   9€ Total : 100 points 83 Vol 61  No.

IIF Annual Awards „ CHANDRAN MENON MEMORIAL AWARD FOR APPLIED RESEARCH & INNOVATIVE TECHNOLOGY Sponsor: Menon & Kolhapur to encourage actively pursue applied  9   .

processes. metallurgical engineering. quality preceding the nomination with focus standards. processes 8 ' "  '  * . 1. 2. Should have at least 5 years experi       $  research institution /engineering college/polytechnic with foundry technology as part of mechanical/ 4. Menon Ltd. foundrymen to research and       Criteria for selection The nominee for the award shall be a scientist / technologist / practising foundryman and member of IIF. energy savings including on foundry materials. metalcasting. Should have made outstanding contribution towards the advancement of metal casting Nomination should be supported by: or technology based on original a) Report of the work carried out by K       9'    the nominee during the 5 years new materials. 3.

 and equipment. technological excellence. The new developments should have   9      " ' . b) Summary of achievements for the eligibility of the award.

commercial d) A list of papers along with prints exploitability. c) At least 3 references of the people the immediate user requirements who know the nominee and his leading to cost savings. improved work. published by the nominee. Should have published papers e) Any other information relating to in foundry journals/presented in pending patents. performance. „ FOUNDRY KAIZEN AWARD (Open to IIF Company Members only) M     ''  . commercial use of foundry congresses/workshops/ technology developed in support of seminars-National/International. nomination.

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 competitive in the global scenario. Area for Kaizen: Slide 3-4 Kaizen theme / problem description / problem  . IIF would like to recognise   ‡{  ''            % excellent work done inside foundries is otherwise hidden. if not given a good exposure.

minimisation. management practices. energy savings.    X* '$   Slide 5-7 Data collection and root cause analysis  ŒŒ     the problem. changeover time Slide 10-11 Countermeasure implementation and ' ' "    '9' " . |'    ' ‡{ ''    Mention the real root cause of the problem the areas of: Slide 8-9 Kaizen idea and countermeasure / solution Foundry operations. downtime minimisation. rework The action plan attempted to eliminate the root cause. yield improvement. The idea mooted by the employee to be mentioned logistics loss improvement.

Guidelines: Nominations have to be submitted as a power point format as follows: . countermeasures been implemented. Provide appropriate photographs to show the before product development initiatives in terms of weight reduction and after status. Since when have the and increased strength.  '9' " sustenance use of new materials to enhance performance of cast products.

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11  November 2015 Slide 12 Horizontal deployment    .   |  ‡{  9   implemented. Slide 2 Kaizen Team Names of the key persons involved 84 Vol 61  No.

the number of places it was       Slide 13-14 #  .‡{ and if so replicated.

Indian Foundry Journal . of slides should not be more than 15 in any case.$ Indicate the qualitative and quantitative savings that  ‡{   Slide 15 Kaizen sheet No.

Root cause analysis 10 points 3. 2. Time taken to implement 10 points 5. Nominations should be submitted in soft copy as well as hard copy.IIF Annual Awards Evaluation Criteria: Nominations will be evaluated on the basis of: 1. Savings – monetary/time/process/qualitative 20 points 6. Implementation success and sustenance 20 points 7. Clarity of the problem and its severity 10 points 2. All nominations must be as per the prescribed guidelines only. 4. Team / Individual contribution 10 points Total 100 points Rules: 1. Each company member can send only one nomination 3. Solution 10 points 4. ' * . Horizontal deployment 10 points 8. Only company members can send their nomination.

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Nominations should include the enclosed Foundry . <> . 6.  +  old.

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„ 5S EXCELLENCE AWARD (Open to IIF Company Members Only) 4. Organisation structure for 5S Objective 5 points Many Indian foundries are successfully adopting 5S practices. 6. 5. IIF may depute a team to visit the foundry to evaluate the nomination.*    can also be downloaded from www.org 7. 5S vision statement and objectives The fully implemented 5S practices result in increased morale.indianfoundry. Waste disposal procedures and efforts to      "  "  8     follow sound environmental practices   '   'K   .

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IIF has initiout of 5S initiatives ated the 5S Excellence Award. Nominations should be submitted in soft copy as well as hard copy. in the form of a trophy. will be awarded to the winner company members in three categories Rules: \'  20 points 20 points 20 points 10 Points 100 points 1. Interested company members should send a assessment form along with supporting documents. \#. \‰  '  self 2. Sustenance plan Categories of Award Total : The 5S Excellence Award. 9.   To motivate and recognise the member companies.

if any 5 points 10 points 5 points 3. Companies falling under MSME category must submit their . 5S manual. 5 areas) 3.  Evaluation Criteria Nominations will be evaluated on the basis of: 1. Stages completed 5 points 2. Photographs of before and after “5S” (min.

   4. Please send the enclosed Self Assessment Sheet duly .

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 5. All nominations should be submitted in four sets. IIF may depute a team to visit the foundry to evaluate the nomination. addressed to: Executive Director THE INSTITUTE OF INDIAN FOUNDRYMEN !" ‘’’ƒ"  . two hard copies and two soft copies in CD/DVD.

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Indian Foundry Journal 85 Vol 61  No. 11  November 2015 .

86 Vol 61  No. 11  November 2015 Indian Foundry Journal .

0HPEHU([FOXVLYH “Auto Component Industry is shining example of the vision. . 120 km from Chennai. Narasimhan BRAKES INDIA LIMITED FOUNDRY DIVISION B rakes India established its Foundry Division in 1981 at Sholingur. adaptation and overwhelming cost competitiveness” – V.

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K. %  grown to the level of 140.A. The product-mix focuses on safety critical parts such as Brake Calipers. Japan. Torque Plates. Turbo Charger components. Powertrain components and Compressor parts. ~   Œ. France. Sweden.S. the thrust destinations being Germany. Steering Knuckles. seven Disamatic moulding lines and a Künkel Wagner High Pressure Horizontal Moulding line with state-of-the-art equipment and in-house Pattern and Die Shop with CAD / CAM / CAE facility. Engine Components. South Africa and U. Brakes India Foundry specialises in the manufacture of Ductile Iron castings in the Sand Foundries.000 MT in 2014-15. Exports constitute 50 per cent of the turnover. has a Permanent Mould facility. U. Brakes India Ltd.

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Cultural advantages and our Indian Foundry Journal history in Foundry Technology. Consolidation of the industry will be more pronounced. / IIF: How do you sketch the country’s Foundry scenario? V. Adaptability to the changing circumstances is very important. Innovation in our DNA. Productivity has to be increased manifold with adequate automation. For example: Cheap labour. Quality will be the key factor. Availability of educational and training facilities. Narasimhan : In the “new normal” our competitive advantages of the past will not be relevant. IIF: What are the strengths and weaknesses of India’s Foundry sector? VN : Strengths: Committed workforce. lack of economy of scale with fragmentation of the industry. failure to modernise ahead of time. less employability of the youngsters. Demography. Weaknesses: Very low productivity. IIF: To what extent Indian castings are acceptable in the global market? VN : $% .

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with the advent of modern. 87 Vol 61  No. the image is changing especially due to the efforts put in by the Foundry Industry in the Automotive and Auto Component Sectors. However. mechanised foundries. 11  November 2015 . expectations on the Quality and Delivery front.

Quality    .Member Exclusive IIF: How quality conscious are Indian foundrymen? VN : Indian Foundrymen overall are yet to realise that quality is the single most important criterion for the success and the future of foundry industry.

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IIF: Mention the major internal as well as external challenges faced by the foundries in India and what are the ways out? VN : Internal challenges: Cascading nature of taxes and duty structure. is instilling a sense of purpose into the minds of Foundrymen. prevalence of widespread corruption and %         . Entry barriers specially in the areas of exports are blessing in disguise. IIF : Brakes India’s role in the auto component sector in India and abroad.

to improve communication and establish a sense of reliability and +  %    . External challenges are our lack of competitiveness. inability to qualify through entry barriers.  %  +      %  make up for the lost time are the internal challenges.

The rate of growth on the export front bears testimony to the above./ IIF: What is the present status of the country’s auto component industry? VN : Auto component industry is shining example of the vision. adaptation and overwhelming cost competitiveness coupled with high level of Quality. what should be the relationship among castings buyers and suppliers? VN : $% . IIF : According to you.

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11  November 2015 VN : Brakes India’s Vision was to export at least 50% of the turnover to the West and achieve benchmark Quality. 88 Vol 61  No. Daimler and –   . It should be clear that nobody is doing anybody a favour. That we have found acceptance with BMW. +          dependence must be established. simply somebody is providing a service and somebody is compensating for it.

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IIF: Achievements and Awards won by Brakes India. VN : Deming Prize for TQM. Best Supplier Awards from International Customers. which has facilitated the increase in our turnover by 25 times in 20 years. %    on the quality front is something that we are proud of. Special Award for the Practice of TPM besides First Category and Consistency Award earlier. IIF: Environmental consciousness of the Company and policy adopted in this respect. VN : We recognise the society as an important stakeholder . establishing a name for ourselves all over the world.

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Futuristic and innovative HR policies have been the key.  front especially in the area of Green Manufacturing needs to be mentioned. Foundry industry is supposed to be . IIF : HR and Health & Safety Policy of the Company. VN : Human Resource is very important for Brakes India and it is the reason for the progress made by the Foundry.

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new markets and new territories. VN : We will continue to grow organically.  in substantially improving the quality of work-life in the Foundry by imaginative approach going beyond occupational health and safety. IIF : Future roadmap of Brakes India. Indian Foundry Journal . We have already set up 3 manufacturing facilities and the endeavour will be to work towards new products.

11  November 2015 .Indian Foundry Journal 89 Vol 61  No.

90 Vol 61  No. 11  November 2015 Indian Foundry Journal .

where Foundry is a 1.Examination on Foundry Technology – WINTER (DEC. 2015) Production / Manufacturing etc. Module-I Eligibility : Class 10 passed of 10 + 2 schemes or & &+/ Registration : Eligible candidates are to register  %     ~  * .

Student Question Bank : Last year’s question papers are available against payment of `50/. student will receive Syllabus and Study  Materials of all the 10 subjects. are not required to have any practical  .for each paper or `900/.per set (inclusive of mailing charges). Module-II subject.drawn in favour of “The  Institute of Indian Foundrymen” payable at Kolkata. 2. Students willing to register have to send a DD of `2.+ / Once registered. Examination Fee : ` 100/.000/.for TEN papers at a time.

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Schedule of Examinations : 7 to 11 December.for appearing in FIVE papers under one Section at a time. Kolkata .org equivalent with Physics. (Direct) 40630074 E-mail : cet@indianfoundry.  Practical Experience : Ž $ .org / cet1@indianfoundry. All Communications to be Addressed to : The Institute of Indian Foundrymen Centre for Education and Training ‘IIF CENTER’. CET” payable at Kolkata in advance as per requirement. 2015 Last Year’s Question Papers : Available on Payment of ` 50/.`1000/to get his/her Registration Numbers.for each paper or `2500/. 335 Rajdanga Main Road East Kolkata Township P.700 107 Ph : (033) 2442-4489 / 7385.per year (inclusive of mailing charges).indianfoundry.O. Examination Fee : `600/. Note : All Demand Drafts are to be drawn in favour of “The Institute of Indian Foundrymen. Chemistry and Mathematics.org Website : http://www..

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11 ¢ November 2015 ./ (b) Engineering Graduates in Metallurgy / Mechanical / Candidates appearing in Module-I Examination are eligible to write in Vernacular. 91 Indian Foundry Journal Vol 61 ¢ No.

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com. + 91 90999 69217 94 Vol 61 ¢ No.mehta@shreesponge. Tel. Vadodara. 2830636.com. shreesponge@yahoo. Website : www.   6/1. POR-391 243.shreesponge. 11 ¢ November 2015 Indian Foundry Journal . Dist. GIDC Estate. marketing@shreesponge.com Mobile : +91 98240 47078.com E-mail : ankit. : 2830132. Fax : 2830131.

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11  November 2015 .Indian Foundry Journal 103 Vol 61  No.

11  November 2015 Indian Foundry Journal .104 Vol 61  No.

11  November 2015 .Indian Foundry Journal 105 Vol 61  No.

106 Vol 61  No. 11  November 2015 Indian Foundry Journal .

CET NEWS Inplant Training Workshop for “Workers and Supervisors” P roduction of quality castings complying to  .

 + .

 .

 standards using latest technologies requires use of modern sophisticated equipments. an IIF centre of excellence organises in-plant training workshops regularly where domain experts from industry as well as academies deliberate on various foundry operations and give practical tips to  . The Centre for Education & Training (CET). Migration to higher technologies call for better quality of manpower. Only skilled and educated workforce can run such state-of-the-art machines.

  %   %   % % .

 .

 .

These in-plant workshops have already become popular %  . face in their day-to-day activities.

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Leakage in castings was a serious issue. 2015. incorrect pouring temperature and degree of nucleation. Director.80% sulphur-0. Course Coordinator and Mr. hot tears and other defects are likely to occur where thicker sections meet thinner sections. N.  their workers/supervisors. CET had been at Britannia Engineering Works where they observed the production process and castings with different types of defects. Mr. 2015.50%. Some of their observations were as under: Castings at Britannia are made of IS:210. G. internal porosity. Grade FG 200 with compositon: Carbon-3. P. Sinha.15% and phosphorus-0.20–3. slight sponginess at heavy section normally does not result in leakage. The expert faculties noted that unsoundness of castings at Britannia was due to combination of one or more of the following factors: Expansion in soft moulds.2% (max.0. Chairman.). S. Mukherjee. Shrinkage. 2015 Sand Core Making (CO2 and Resin Bonded) July 1. are sending repeated requests for holding such workshops in their plants. Sasmal made his in-depth presentation on the above topic at the company’s conference hall of Britannia Engg. 2015 Remedial Actions for Reduction in Casting Defects July 15.60-0. high pouring temperature.8–2. silicon-1. gas-tight castings cannot afford the slightest defect. underfeeding. $%    . manganese. 2015 Discussion/Interaction Sand Quality and Testing June 17. Gautam Banerjee. Workshop on “Sand Quality & Testing” Mr. however. 2015 Mould Making both Green Sand & Dry June 24. 2015 On June 10. In case of water-tight castings. K. pressure-tight against gases and liquid. Castings are with uniform wall section thickness. Dr. Works on June 17.600. 2015 Melting of Cast Iron in Induction Furnace July 8. higher rate of phosphorus. 2015 Test July 22.3%. CET organised the following 7 days in-plant training workshops at Britannia Engineering Works: Topic Date Observation of Casting Defects and June 10. unsuitable chemical composition.

 +.

     .

 types of sand like zircon sand. 107 Vol 61  No. advantages and disadvantages. This would lead to lesser rejection rate. He explained their basic properties. The presentation was made in an interactive manner Indian Foundry Journal when the speaker observed that the foundry could easily switch over to green sand moulding from dry sand moulding. 11  November 2015 . chromite sand etc. He also covered different sand testing methods and described the procedures for checking suitability of sand for mould making.

These castings were defect-free. G. the faculty dwelt upon Hand Moulding: Floor with only cope  %    . 2015.CET NEWS Workshop on “Mould Making. 2015 were shown to the faculty Mr. G. Both Green Sand & Dry Sand” This in-plant workshop was organised by CET at Britannia Engineering Works on June 24. Considering the existing mouldmaking processes. Banerjee and CET Director Mr. Castings produced in green sand mould following the suggestions that had been made at the earlier workshop held on June 17. Mukherjee.

   %    .

Mr. CET-Shimoga Seminar on “Upgrade Your Foundry” C ET and Shimoga Chapter of IIF in association with DISA India Ltd. Sodium silicate family including sodium silicate-ester. in his presentation outlined the global casting industry scenario. sodium silicate – di    /¬%  ¬   ¬ Investment casting. Simultaneous jolt-squeeze machines. the technocrat has to study the casting design and make necessary corrections. Vijay Naidu. No-bake moulding – both two-part and three-part. organised this seminar on Oct. Vacuum moulding. Thereafter. Mr. Banerjee discussed various steps of designing moulds and cores. Dry sand moulding. Chairman. with skeleton pattern and pit moulding. Mr. 17. M. He touched upon High pressure moulding line. Dry sand core moulding. 2015 at Country Club. Further. Banerjee discussed different sand moulding systems like Green sand moulding. Managing Director of DISA India Ltd. Banerjee explained the operations of Jolt rollover machines. While throwing light on machine moulding. Shimoga. IIF-Shimoga Chapter while delivering welcome address called for supplying modern foundry equipments at affordable cost so that foundries with increased competitiveness can access international markets. He then discussed the points to be considered while working out mould joint. He referred to the rules to be followed while choosing the position of casting in the mould. Mr. Mr. According to him. He then explained vertical and horizontal processes of producing castings. Flaskless moulding and High pressure moulding lines. N. Suresh. if required. Banerjee also dwelt on Jolt type moulding and Jolt squeeze type moulding machines. Mr. He described vertical .

   .

 +  % %  %.

The third speaker detailed on shotblasting machines. sand plant. $%   . horizontal process is preferable.N. DISA India Ltd. for complicated cores. Mr. the speaker said. Satyanarayana V. sand conveying system and 108 Vol 61  No. Vice President. However.˜    respect of productivity enhancement leading to cost reduction. 11  November 2015 shotblasting system. He referred to DISA’s offer of complete end-to-end solution for moulding line.. He also dwelt on typical Disamatic foundry and Disamatic 030 that uses top-end vertical technology affordable to Indian foundries. made his presentation on Arpa moulding machine of different sizes with the average productivity ranging from 30 to 60 moulds/hr.

.

+  .

 & .

 .

Secretary. %  participants. Mr. Hon. IIF-Shimoga Chapter offered vote of thanks. Indian Foundry Journal .V. G. Kiran Kumar.

Indian Foundry Journal 109 Vol 61  No. 11  November 2015 .

11  November 2015 Indian Foundry Journal .110 Vol 61  No.

Indian Foundry Journal 111 Vol 61  No. 11  November 2015 .

112 Vol 61  No. 11  November 2015 Indian Foundry Journal .

Indian Foundry Journal 113 Vol 61  No. 11  November 2015 .

114 Vol 61  No. 11  November 2015 Indian Foundry Journal .

3D measurement. foundry as well as general engineering. Maus srl has also entered into joint venture with Palmer Manufacturing & Supply Inc. services and software to a vast range of manufacturers within the disciplines of 3D scanning. With the coremaking technology from Fritz Hansberg and the moulding line technology from Savelli. the group’s presence would further be strengthened in key markets like Europe. of Canada. feet aluminium casting facility and $450 million for expansion of their existing operation in Valley East Industrial Park. Maus would complete its portfolio as a full global solution provider for foundries. dental. In April 2015. medical. Kamtek to Open New Aluminium Casting Facility Kamtek of USA. CNC machine tools and a range of measuring arms. integrated Renishaw touch probe capability so that it can be used as a traditional touch probe device or as a high-tech laser scanner. Birmingham at more than 200. which and has re-invested heavily in the  %  +.a. feet. reverse engineering. Kamtek acquired Ogihara Metrolog X4 i-Robot software. a leader in automatic grinding and vertical turning.. Their technology can also be used for heritage applications. a touch-and-scan represents investment of $473 robotic inspection cell powered by million. Alabama operation including opening of a new aluminium casting facility for meeting the demand of automakers for lighter parts. a manufacturer of moulding lines and sand plants for green sand foundries and Fritz Hansberg. a producer of no-bake foundry equipment with a well-recognised presence in the foundry industry in USA. to consolidate and expand their brand as well as sales network in North America. All laser scanners of Kreon incorporate a unique. a manufacturer of core making equipment of Italy. is planning to invest $530 million for expansion of its Birmingham. would acquire both Savelli s. The new aluminium casting facility and the expansion programme would demonstrate their commitment to customers including MercedesBenz and Volkswagen. Caldeaz Manufacturing Technologies of South Africa. As the foundry equipment industry is concentrating. The new arrangement would provide foundry automation and machining equipment. also known as rapid prototyping. As part of their latest expansion programme. A new version of its 7-axis Ace measuring arm has also been announced. Kreon Technologies is a pioneer in 3D non-contact measurement technology providing complete noncontact measurement solutions for quality control. In the joint venture agreement. whose parent company is Magna International Inc. a provider of 3D engineering solutions through products. A range of 3D scanners are included in their products which can be integrated on 3D CMMs.000 sq.p. and 3D printing. non-contact measurement tracking solution. the company would invest $80 million in the new 148. surface inspection and rapid prototyping throughout the entire design and manufacturing process for industries like automotive. aerospace. share of Maus and Palmer is 70:30. Their current Kreon recently launched AirTrack operation in Jefferson County robot solution.. USA and China and position it as a reference point for the industry.NEWS & TRENDS Foundry Caldeaz to Partner with Kreon of France Maus to Acquire Savelli and Fritz Hansberg of Italy Maus.000 sq. Solutions of the company help manufacturers to reduce production times and bring their products in the market faster eliminating errors as well as increasing productivity and quality. reverse engineering. has formed a new strategic partnership with Kreon Technologies of France for the growth of their 3D scanning capabilities.

  .

115 Indian Foundry Journal Vol 61  No.     operation over the years. 11  November 2015 .

Automobile BMW to Invest More in India of petrol and diesel for meeting   .

    +  Š‡Š‡/ Fuels meeting Euro IV or Bharat  ŒŽ*¡ +.

2020. BS-IV fuels contain 50 parts per million (ppm) sulphur whereas BS-V and BS-VI grade fuel contain 10 ppm sulphur. localisation of their products because Delhi. BS-IV auto fuels are being supplied in whole of northern BMW is planning to increase their India covering J&K. Uttarakhand.   supplied throughout India by April 2017 and BS-V or Euro-V grade fuel by April 1. At present. investment in India to improve Himachal Pradesh. Punjab. Haryana. parts of Rajasthan and Western         .

Rest of the country has BS-III The company has already invested grade fuel. Odisha. Karnataka.490 crore in India apart from Telangana.+/ UP. Union Territories 0/‘^‡. Rs. Goa. Kerala.

.

+ .

    .Haveli. / of Daman and Diu. Dadra and Nagar According to the company’s Make. Anadaman and Nicobar in-India strategy. 2017. level of localisation would get BS-IV fuel from 1st April would be increased from 50% at 2016 and the rest of India would present. stepping up from assembly receive supply from 1st April.

Feasibility studies are units. Their Chennai plant has a transport fuel (CNG) in cities is being capacity of production of 13.000 to 40.000 units transportation fuel for inter-city .000 encouraged. also going on for using LNG as a A volume of 30. use of gas as in India. / $%  To reduce pollution and greenhouse are focusing on premium products gas emissions.

 .

&.

Indian condition is more favourable to them than that of China.   %      movement of heavy vehicles. production capacity and they are prepared for the same. In future. Brazil and Russia. Long-term investment planning is also there. they may start exporting from India. Hinduja to Invest $1 India to Introduce Billion in Africa Euro VI Emission Hinduja Group has committed to invest $1 billion in Africa in the next Norm by 2020 +  .

 .

mid and long-term. A revised Auto Fuel Policy development of the country across %  +%%    three different time horizons – short. X . infrastructure VI emission compliant petrol and etc. trading. chemical. Investment will take place diesel by 2020. introduction of BS-VI fuels by 2020. to cut carbon in a phased manner to suit the emission.   India is planning to shift to Eurooil.

+ .

  .

 .

&.

80.000 crore in upgrading quality .     With this ‘Go Africa’ strategy. the Rs.

which is the second largest bus and truck maker in India. Exports contribute 15% to the turnover at present which might increase to 33% over %    %. would increase bus as well as truck exports to the continent from the present 12.000 units to 25.000 units over the next three years. = %    –% Leyland.

  .

Ford to Design in India Ford is looking at designing a new  %   * / *  %  +. Hinduja Group is present across various countries in sectors like automobiles. technology etc. energy. infrastructure. banking./ – + part of this growth is expected to come from Africa.

The company would design the new Fiesta at their research and development (R & D) as well as engineering facilities in Chennai. 11  November 2015 Indian Foundry Journal . the company has already been showcasing Indian automobile manufacturing at a global scale with exports of 60% of the vehicles. To use India as their design centre would surely enhance ranking of India in global automobile manufacturing. product engineering. The company would enhance investment in India for capacity expansion at their Chennai plant as well as establishing a new and global engineering and technology centre.  automobile major to design a vehicle in the country. which is expected to be launched in 2017 to cater to the domestic as well as export markets. Global Business Service operations in the areas of IT. 116 Vol 61  No. With two manufacturing facilities in India at Sanand and Chennai. data analytics and manufacturing would also be there.

2% share during January-June Around 200 projects involving 2015. Strengthening the interface among  . 9. pig iron from India during JanuaryJune 2015 was Thailand at 1.51.Development and demonstration of technologies for common use by cluster of industries.2% of total exports of pig iron from India.000 of technologies for Government tonnes sharing 22. Taiwan z Development and demonstration was in the second place at 88. accounting for 39.8% followed by %       Saudi Arabia at 35.181 tonnes.296 tonnes with projects.

R&D establishments and establishments.     + Govt. both in public and academic Institutions has been private sectors. Policy industry. have so far been proposed by the Department of supported by the Department  +   * .

 0  .

% involving DSIR’s share of Rs.100 crore ]*0Ž    %  + .

The projects cover products commercialisation. in total project cost of around Rs.250 crore. and processes in various industries An    .

+  .

.

Course comprises 20 sessions of 2 hours each between 6 pm to 8 pm. In June 2015. with a decline of 19. for the development and machineries. Saudi Arabia was at third place at 5000 tonnes.dsir. “Niryat Bandhu @ Your desktop” in earthmoving export-import business has recently z Providing catalytic support metallurgy.822 tonnes during May 2015. Taiwan was the top importer of pig iron from India. This programme is likely to serve the objectives of both ‘Digital India’ and ‘Skill India’. increasing competitiveness procedure are available in www. Details of eligibility criteria for Bandhu Scheme of the Directorate need-based technologies for applicants as well as application General of Foreign Trade (DGFT). which is 67% higher compared with exports of 70. z Development of a new or improved process resulting in establishing a process know-how etc.17. leading to industrially useful applications. view. Project Proposals z Technology development projects should aim at development of a new product or process with attractive market potential. DGFT has joined hands with Research & Development Technology Development and Demonstration Program of DSIR z    Programme for Exports and Imports Sector of Interest z For any sector. Objective of the Niryat Bandhu Scheme is to reach out to new and gov. Pig Iron Exports from India Hit High in June 2015 Pig iron exports from India hit the highest level in 15 months in June 2015 at 1. participants would be . accounting for about 18% of total Indian pig iron exports. potential exporters to make them z For strengthening the able to get into international trade Business & Trade interface among industry. Nature of Proposals Supported z Development of new or improved product resulting in prototype development.77.2%. This online programme would enable them to learn the essentials of export-import business through direct transmission of the lessons on their desktops. Courses have already begun from October 2015. industrial machinery been launched under the Niryat demonstration of innovative etc. z Priority technology development projects of PSUs.421 tonnes during January-June 2014.989 tonnes. A digital resource library would be available to them online. Second largest export destination of India’s pig iron was Thailand at 21. R&D as well as boost exports from India.  Objectives including mechanical engineering.85. z Absorption and upgradation of imported technology. Online question-answer sessions would also be there for addressing the concerns with experts from IIFT. On successful completion of the programme.in among industries. Largest importer of Indian Institute of Foreign Trade (IIFT) for launching an innovative online programme for exporters and entrepreneurs.618 tonnes. compared to cumulative exports of 4.181 tonnes. Cumulative pig iron exports from India during January-June 2015 were 3. establishments and academic With the objective of “Skill India’ in Institutions.

 .

+ š% ]"$ and IIFT. Online registration can be done at http://niryatbandhu.in 117 Indian Foundry Journal Vol 61  No.iift. 11  November 2015 .ac.

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Indian Foundry Journal 119 Vol 61  No. 11  November 2015 .

11  November 2015 Indian Foundry Journal .120 Vol 61  No.

11  November 2015 .Indian Foundry Journal 121 Vol 61  No.

11  November 2015 Indian Foundry Journal .122 Vol 61  No.

95 2219.14 227.03 Singapore 174.58 321.24 Korea RP 107.96 1046.83 436.44 146.16 193.94 87.44 50.52 363.49 Turkey 116.54 115.10 Thailand 62.04 -1.50 Brazil 60.47 845.80 76.3% which is higher than the fall in India’s total engineering exports by 12.3 Share of Top 25 Countries (%) z Out of top 25 countries.25 UAE Country Japan 66.40 834.41 -23.20 419.00 -12.34 856.47 2.40 Nepal 54.50 -9.74 3.11 -62.29 -20.69 128.92 France 77.53 -35.07 2.61 -20.67 843.50 -28.55 118.49 654.38 -56.17 1130.01 -69.34 South Africa 103.35 -29.75 -37.79 Nigeria 85.52 -33.73 The Netherlands 73.32 -21.50 110.24 59. Indian Foundry Journal 123 Vol 61  No.49 517.65 Bangladesh 120.36 347.29 47.33 425.25 99.80 610.01 -40.26 869.52 -13.15 409.48 Mexico 148.6%.11 1177.86 186.96 731.27 7.37 22329.06 September 2015 (US$ Million) September 2014 (US$ Million) USA 561.90 -26.97 Belgium 95. 11  November 2015 .86 86.95 -16.17 153.36 Saudi Arabia 113.85 459.91 620.31 -13.77 1087.56 Germany 184.22 -30.13 -13.43 -35.22 -16.54 -8.75 4.57 97. z During April-September 2015.07 -12.99 35136.STATISTICS Engineering Exports from India During April-September 2015 – Top 25 Destinations (Country) Growth % AprilSeptember 2015 (US$ Million) AprilSeptember 2014 (US$ Million) Growth % 709.26 609.82 Sri Lanka 154.40 670.87 3583. only 4 countries namely Malaysia.35 6329.60 4790.62 Indonesia 74.4 30720.57 -16.53 1467.52 785.80 Total of Top 25 Countries 3335.20 1324.99 -4.28 655.66 531.7 72.62 140.72 147.16 345. the top 25 nations account for 72.82 -3.67 25753.43 1439.80 China 214.92 687.29 Total Engineering Exports 4719.41 2913.78 -19.33 -13.21 431.47 755.18 506.73 583.12 69.83 85.98 86.70 417.23 UK 198.66 -0.74 -22. The Netherlands and Belgium recorded positive growth in September 2015.19 3737.7% of the total. during April-September 2015.36 371. z Indian engineering exports to USA continues to be the highest with negative growth both in September 2015 and AprilSeptember 2015.99 181.26 1057.78 -1.39 1311.50 -23.67 687.33 -33.42 1402. growth rate of the top 25 countries taken together recorded fall in exports by 13.70 Italy 122.52 -13.98 190.7 75.19 -22.6 70.48 -2.99 756.01 642.13 864.10 631.75 -33. z Out of 218 destinations for exports of Indian engineering goods.79 520.84 306.90 73.19 -9.77 Malaysia 84.21 -60. South Africa.55 Iran 50.7 73.46 -12.06 -25.84 -17.33 2044.38 532.

124 Vol 61  No. 11  November 2015 Indian Foundry Journal .

gov.46 Belgium 5.13 z z USA remains the topmost destination for exports of auto components and parts from India with share of more than 22% during April-September 2015.13 -42.67 20.23 99.23 61.61 -29.03 -10. Govt. has notified the Udyog Aadhaar Memorandum (UAM) under the MSMED Act.in by the concerned MSME unit.54 20.16 2.86 82.23 -39. The detailed notification and Applicable Forms can be downloaded from the link: http://msme.01 473.68 61.94 -7.91 97.55 Italy 10.31 -34. it shall not be mandatory but it is preferable for them also to file the same. Small and Medium Enterprises (MSME). of India in order to promote ease of doing business for MSMEs.88 2.22 Bangladesh 10. However.26 -2.39 55.8% respectively of India’s exports of auto component and parts during April-September 2015.30 67.05 -47.35 8.76 Turkey 34. 2576(E)] dated 18-09-2015.70 Spain 4.67 204.91 2.19 92.11 52.39 20.nic.in/Web/doc/ GazetteNotification2576. Turkey and Thailand achieved the second and third positions importing 8.76 41.45 43.46 12.14 44.66 2.38 4.98 22.15 7.25 The Netherlands 3.75 21.84 83.10 3.18 -7.87 -4.61 Mexico UAE Nepal 4.01 Export Destination September 2015 (US$ Million) September 2014 (US$ Million) Exports to World 328.99 47. 11  November 2015 .pdf Exports of Auto Components from India During April-September 2015 Growth % AprilSeptember 2015 (US$ Million) AprilSeptember 2014 (US$ Million) Growth % 378.24 -0.07 -21.56 Nigeria 2.87 82.36 460.29 87. 2006 vide Gazette Notification [SO No.68 -3.77 Sri Lanka 5.56 113.53 -22.87 3.92 7.57 18.07 -2.58 -14.87 26.14 1.77 -12.49 UK 15.39 -10.98 -18.68 19. Indian Foundry Journal 125 Vol 61  No.07 31.98 2. for the MSME units having EM-I or EM-II or SSI registration prior to MSME Act 2006.76 9.85 USA 71.73 33.02 63.41 17.65 16.44 30.63 Thailand 16.32 23.99 31.50 91.93 107.56 47.8% and 4.74 26.45 103.41 10.57 12.22 26.12 2082.28 Brazil 12.50 182.21 16.31 2252.45 5.25 -13.53 73. The filing of UAM can be done online on http://udyogaadhaar. A one-page simple Registration Form for online filing of UAM has been introduced which replaces the filing of Entrepreneur’s Memorandum Part I&II.Udyog Aadhaar Memorandum for MSMEs Online Filing The Ministry of Micro.71 -26.72 Germany 16.99 106.

99% min Antimony Trioxide : 75 / 25% 99% min 99.co. C : 5-8% MC MC Cr : 50-55%.05% / 0.09323160250. Shalaj Gupta 09375033830 mandi@phoolchand.85% min Megnesium 99.09869214950.09324612137. Rajesh J. Khandelwal .PHOOLCHAND BHAGATSINGH ESTD.com E-mail : faridabad@phoolchand. Aakash S. Secondary Zinc Ingot 98.in 126 Vol 61  No. C : 0. Si :38% min Ferro Sulphur Silico Manganese S : 50% min Mn : 60% min. Mahavir J. Shameer Babu : 09381060001 (Coimbatore) Mr.com Contact : Mr.261074 Fax : 011-2351 1182 Fax : 044 .15% max /0.5% min 99.7%min Tin Metal Sn : 99.35% max Si : 0.7% min Aluminium Alloy Al : 85%.z www.5% max P : Si : 1% max /3% max P : C : 0. Al : 1. 11  November 2015 Indian Foundry Journal .9% min Manganese Briquettes 97% min Nickel Oxide : 75 % min.5% max/1.01% max /0. "]. Mr.8%min 99.09820080250/09323880250.com Contact : Mr.=#z  + Perlite Ore SiO2 46%min Ferro Silicon Zirconium Si : 70% min. Sanjiv B.5% Zinc Metal Zn : 99. Si : 40% min Zr : 15% min.15% max '!^_`j#+ Chromicte Sand Cr2O3 '.95% min Titanium Scrap Ti : 99% min Ahmedabad Branch Menganese Metal Lamps Molybdenum Metal Selenium Metal (Powder 200 mesh/Granules) 99. Si : 40% min Mg : 8-10%. Mr. LC Mn : 70% /80%.261073 Phone : 011-2351 1194 /2351 3657 Fax : 02718 .65% min Aluminium Ingot Al : 99. Santosh Khandelwal (Chennai) Mr.97% min Cerium Misch Metal Manganese Flakes 99. P : 0. G. Si: 15% min Ferro Silicon Ferro Silicon Magnesium 71%min {<"z|'}+ FC : 90% min Base Metals & Alloys Antimony Bismuth Calcium Aluminium Alloy Minor Metals 99. MC Mn: 70% /80%. .5% max. Ramesh : 09443062100 9310611122 / 9313611008   !" #$'*+#.1%max. Mr.72%. Rajiv B. Jain .1% max /0.35% max 0. \=. C : 2% max Ferro Niobium 63% min LC LC Cr : 60% min.1% max Ferro Titanium 30 .1957 Reliable Source for : Noble Alloys & Ores Ferro Alloys Calcium Silicide Lumps/Granules/ Powder Ferro Aluminium Ferro Boron Ferro Chrome Al : 30% / 35%min B : 15% min Ferro Molybdenum 57% min HC HC Cr : 60% min.09820189931/ 09321044897.9% min Cobalt Oxide Silicon Metal (553/441/3303/2202) Delhi / Faridabad / Mandi Branch 70% min Si : 99% min Chennai Branch Phone : 02718 .2590 3006 E-mail : ahmedabad@phoolchand.4% max 0. P : 0. Jain .03% / 0. C : 0.9% min Chromium 99% min Cobalt Lead Ingot Pb : 99. Khandelwal . Al : 2%max 50% & 80% Moly Oxide 57% min Ferro Manganese HC Mn: 70% min. Ajay Gupta 9811084240 / 9313281075 Mr.com E-mail : chennai@phoolchand.<=>???>!'?@@+[@??? Contact Person : Mr. Khandelwal .35% Nitrited Low Carbon Ferro Chrome Cr : 60% min. N :8-10% Ferro Vanadium 68 .65% min Arsenic 99. . Si : 10% Copper Phosphorus 85 / 15% Nickel Metal Ni : 99.1% max Mg : 5-7%.phoolchand. Mr.

STATISTICS Engineering Exports from India .Destinations (Regionwise) (US$ Million) Engineering Exports from India .Regionwise Share April-September 2015 April-September 2014 [Source : EEPC] Indian Foundry Journal 127 Vol 61  No. 11  November 2015 .

128 Vol 61  No. 11  November 2015 Indian Foundry Journal .

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11  November 2015 Indian Foundry Journal .130 Vol 61  No.

Indian Foundry Journal 131 Vol 61  No. 11  November 2015 .

11  November 2015 Indian Foundry Journal .132 Vol 61  No.

11  November 2015 .Indian Foundry Journal 133 Vol 61  No.

11  November 2015 Indian Foundry Journal .134 Vol 61  No.

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..... 350 z Energy Efficiency & Pollution Control ....................................... 200 z Repair and Reclamation Technology of Casting .................. 350 z Resin Binders & No-bake Related Equipments ......... 450 Technology of Iron Casting (B-9) [E-Ia] ............................. 350 z Gating System Design for Steel Casting ..............Vol..................STUDY NOTE AVAILABLE FOR PRACTISING FOUNDRYMEN CET WORKSHOP STUDY MATERIALS Casting Defects ` z Analysis of Casting Defects .................................. 350 Metallurgy of Cast Alloys (B-6) ....... 350 Principles of Methoding & Casting Design (B-2) – Vol........................Silicate Moulding Process ........... 350 Repair/Welding/Machining z Application of Welding in Foundry Casting .. 550 Moulding z A Guide of Sand Control Practice in Ferrous Foundries.......................... 350 Physical Metallurgy for Ferrous and Non-Ferrous Alloys (B-9) [E-Ic] ............................. 350 Foundry Furnaces z Cupola Practice ................Vol.......................... 350 z Energy Management and Audit in Foundries ........................ 350 z Some Aspects of Foundry Practice ............................................................ 550 z Grey Cast Iron Technology ..............................................................................I ................................................... to p... 350 Energy and Pollution Management z Air Pollution Measurement and Control in Foundries ........ 350 Foundry Metallurgy z Basic Metallurgy of Steel Castings ................... 350 Contd...... 550 z Ductile Iron Technology Defects Analysis and In-mould and Stream Treatment .. 350 z Moulding Practices for Grey Iron Castings ................. 350 z Moulding Sands and Processes for Steel Castings ............. 350 z Methoding Principle for Ferrous Casting – Major Pattern Making Technique & Methods ................................. 350 z Laboratory and Shop-floor Testing for Ferrous Foundry ................................................................. 950 Price (including Postage) Conventional Methoding............................................... 450 Introduction to Materials (A-6) . 400 z Foundry Management (B-5) ................. DI) .................. Simulation ` and Solid Modelling ................................................. 500 z Foundry Mechanisation Automation (B-10) [E-IIc] .............. 350 Methoding z Casting Simulation Case Studies.............................. 350 z Methoding/Solidification Related Defects and Their Remedies for Iron and Steel Castings ............................ 350 Cast Iron / Ductile Iron z Alloy Cast Iron ............................. 350 Steel z Steel Foundry Technology ................ 350 z Foundry Raw Materials ............ 400 z Special Casting Processes ............................. 800 z Ductile Iron Foundry Practice .................................. 11 zNovember 2015 ................................... 350 z z z z z z z ` Fuels............. 350 Handbook z Cast Iron ..........................................Causes & Remedies (CI................................................. 350 z Analysis of Casting Defects ................................................ Furnaces & Refractories (B-4) .............................................................. 350 z Mould and Core Making (B-2) .......Causes & Remedies (Steel) ..................... 200 z Non-Destructive Testing ................................II ..................... 350 z Induction Furnace and Electric Arc Furnace (Operation Optimisation of Melting.. 550 z Ductile Iron Production .................. 400 z Energy Efficiency & Pollution Control (B-7) ...... 350 z CET GUIDE NOTES FOR MODULAR EXAMINATION Module-IV ` z Advances in Casting Technology (B-8) ......... 450 Steel Foundry Technology (B-9b) ................................ 350 z Engineering Drawing I & II (Module IV) (A-10) ............ 350 z Machining Technology for Cast Iron Castings .............................................. Refractory Lining and Maintenance) ............. 350 z Inspection and Quality Control .....139 Indian Foundry Journal 137 Vol 61 zNo....... 200 z Moulding Processes and Sand System ....................... 450 z Metallurgy for Foundrymen ............................................ 350 Foundry Practice z Advances in Casting Technology .................. 350 z Engineering Methoding Practice in a Foundry ......................II ............... 450 Testing z Heat Treatment of Quality Ferrous Castings ................................................................... 350 z CO2 ..

Pouring & Cooling line. Capacity: 1000 MT/ Month Total Area: 16000 SQ. Stress Relieving Furnace and Primering. Thermal and Mechanical Reclamation Fettling: Shot Blasting Machine. Temperature Measurement. Moulding and Core Shop : IMF-make Continuous Sand Mixer 60 MT cap/ 10 MT cap. We will exceed customer expectations through reliable product. Mission : We will recognise our responsibilities as corporate citizens to faster progress. Infrared Oven / Gas Oven. Laboratory Spectrometer. Closing Station with Mould Handler. Sand Testing. on-time delivery. Other Information ^. Carbon Silicon Analyser. create an environment to our staff to grow and advance to prosperity and thus promote a sense of belongingness. to promote general welfare of the society.SG Iron: 500 kg to 3000 kg Infrastructure Melting : 4 MT Dual-track. Medium Frequency Induction Furnace. Moulding Line with Rollover. MTR No. Mould Pusher & Shake-out.Ace Designers Limited Foundry Division (Established : 2013) Vision : Large-Scale Producer of World-class Casting and Machine Tools. Mechanical Testing. cost-effective solution with an added assurance of prompt service. of Employees: 125 Weight Range: Grey Iron: 300 kg to 6000 kg .

562132. Grinding beds.% %?4 .?%[ <G! Typical Parts Lathe beds. Columns. Agriculture.. Customer Sectors Machine Tools.co. Ace Designers Ltd.560058. General Manager. 7&8. Printing. Karnataka 138 Vol 61 zNo. Bangalore . E-mail: ramesh_a@acedesigners. General Engineering. Karnataka Peenya Industrial Area Bangalore . E-mail: erb@acedesigners. 53/4 to 53/8. – Foundry Division Plot No. Earthmoving.co. M: +919845102870. 11 zNovember 2015 Indian Foundry Journal .in C  Works: Ace Designers Ltd. Contact Persons: Mr. Foundry. No. Deputy General Manager. Phase-II Sy. Ramesh A. Minnapura Village Thyamagondu Road. M: +91 9845995165. E. NelamangalaTq. Energy. Badreesh. etc. Pumps. R.in Mr.

................................................. 350 z Electrical Technology and Electronic Devices (A-7) ... Kolkata . 100 z Pattern Construction (P-7) ........................... The Institute of Indian Foundrymen.... 335......................... 400 z z Principles of Methoding & Casting Design (B-8) [E-III] – Vol.................................. 350 z Workshop Technology for Foundrymen (A-7) .................................. Fax : 033 2442 4491......................................................................................................I ............. P...org Indian Foundry Journal 139 Vol 61 zNo............................ Phone : 033 2442 4489 / 7385.. 100 z Engg..................................... 450 z Special Casting Processes (B-4) ........ 350 z Engineering Drawing .....I (A-5)......................... 11 zNovember 2015 ................................700 107............... 100 50% Discount on CET Guide Notes for Students registered in IIF Courses All payments should be made by at Par Cheque or Demand Draft favouring “The Institute of Indian Foundrymen CET” payable at Kolkata..... Please Contact : Centre for Education and Training (CET)............. 350 z Heat Treatment of Castings & Related Equipments (B-5) ............ Rajdanga Main Road. E-mail : cet@indianfoundry.... 100 z Melting Technology (P-9) [A] ................... 100 z Cupola Melting Emission Control (P-9) [B] . 100 z Chemistry (P-3)................................... 350 z Technology of Cast Iron ............. IIF Center.............. Drawing (P-5) ... 100 z English (P-1) ..........CET GUIDE NOTES FOR MODULAR EXAMINATION (contd........................ East Kolkata Township........ 350 z Pollution Control and Occupational Health in Foundry Industry (B-8) (E-II) .......... 350 z Industrial Management (B-7) .... 700 Module : II z Basic Mechanical Engineering (A-9) ........................... 350 z Melting & Casting Technology (B-3) ... 100 z z Workshop Technology (P-6) .......... 100 z Mathematics (P-4)..............................................) Testing of Metals and Alloys (B-3) ........ 350 z Mould and Core Making (B-2) ................... 400 Theory of Foundry Processes (B-1) ..... 350 z Testing and Inspection in Foundry (B-6)................... 100 z Moulding Technology (P-8).......................O.... 400 z Introduction to Engineering Materials (A-8) . 100 z Physics (P-2) ......... 350 z Casting Technology (B-1) . 400 Module : I z Cast Metal Technology (P-10)...............

Spectrometer and a complete in-house Testing facility ¾ Complete in-house Machine Shop with CNC Turning and Vertical Machining Centres ¾ Strong Technical team on-board. capable of manufacturing export quality castings across sectors ¾ Currently supplying to Automotive. For more information. Toyota amongst other global buyers ¾ Equipped with Induction Furnace. Bosch.   . Railways.000 tonnes/annum ¾ High EBITDA Margin potential of 30% ¾ Concession of 50% Central Sales Tax ¾ Capable of producing 1-400 kg single-piece castings ¾ Strong Customer Base with supplies to Delhi Metro. experienced Foundryman is now available to reduce your Energy Bills. Eicher plants ¾ Cheaper and abundant power availability.com Foundrymen! Reduce Your Energy Bills Improve Efficiency of Your Plant Services of a resourceful.Investment Opportunity in Metro Railways Approved Foundry in NCR Region (Just 65 Km from New Delhi Airport) ¾ Looking for Joint Venture / Collaboration Opportunities for a world-class Foundry. Honda Car & Bike. Moulding & Automatic Sand Plant. ¾ Strategically located. Hero. Hydraulics industry etc.000 tonnes/annum Grey and Ductile Iron castings ¾ Provision to expand the capacity to 9. please contact: M: +91 99584 30257 Email: foundryjv@gmail. within close proximity of Suzuki. with 100% captive power source. with an installed capacity of 3.

Ahmedabad. Braruch-392 001.. Water Lines. D. Mobile: 09377761888 E-mail: gajendra. If interested. ¾ Review of Furnace Operational and Energy Consumption Parameters. ¾ Reduction in Maximum Demand by Improving Power Factor. Ramvatika. ¾ Annual Maintenance Contract for the entire foundry.. (ii) Worked with Bhagwati Spherocast Pvt. Furnace Transformers. Hydraulic Equipment in a Foundry. please contact: G.raval123@gmail. ¾ Liaisoning with Government Electrical Inspectors to get approvals of Electrical Installations. Raval Apple Engineering 4 Niravkunj. initially as Works Manager. (iii) Worked till 2013 for almost 30 years with Vishal Malleables Ltd. ¾ Installations of Foundry Equipment. Halol. Ankleshwar.     ¾ Energy Bill Scrutiny to avoid payment of unnecessary items. and also to identify process operations needing improvement. wherever applicable. Background of the Foundryman: (i) Started Foundry career in 1972 as a Trainee in SLM Maneklal Foundry in Ahmedabad. and later as Director. worked as Technical Advisor to Indsur Global. 11 zNovember 2015 Indian Foundry Journal . Opp. Ltd. ¾ Improvement in Thermal Processes to save Fuels like LPG/CNG and others. (iv) After 2013. and getting Electricity Duty Exemption.com 140 Vol 61 zNo. ¾ Implementation of Energy Audit in units having more than 300 KVA Power Demand.

11 zNovember 2015 . Kolkata . Rajdanga Main Road.DVDs) CET/DVD/NO-BAKE-1 Price : (Inclusive of Postage) : ` 1..150/Technology of Ductile Iron & Defect Analysis of SG Iron Castings (2.DVDs) CET/DVD/DI-1 Price : (Inclusive of Postage) : ` 1.550/Austempered Ductile Iron (ADI) and Compacted Graphite Iron (CGI) CET/DVD/DI-2 Price : (Inclusive of Postage) : ` 850/Subjective Moulding Process for Improvement in Methoding CET/DVD/ METHOD-1 & Metallurgical Aspects of Methoding for Steel & Ductile Iron Castings Price : (2 DVDs) (Inclusive of Postage) : ` 1150/Casting Defects and Remedies (Ductile Iron. Please Contact : Centre for Education and Training (CET) The Institute of Indian Foundrymen IIF Center.org Indian Foundry Journal 141 Vol 61 zNo. Fax : 033 2442 4491 E-mail : cet@indianfoundry.700 107 Phone : 033 2442 4489 / 7385.O.DVDs on Workshops/Trainings Conducted Recently by Renowned Faculty Prepared by Centre for Education & Training of IIF z z z z z z z z Elementary Metallurgy for Foundrymen (1-DVD ) CET/DVD/MET-1 Price : (Inclusive of Postage) : ` 850/Operating Aspects on the Use of Resin Binders & No-Bake Equipment (2. East Kolkata Township P. Grey Iron & Steel Castings) (2 DVDs) (CET/DVD/ CAST-DEFECT-1) Price : (Inclusive of Postage) : ` 1150/Metallurgy Made Easy for Foundrymen (1 DVD) Price : (Inclusive of Postage) : ` 850/- z Sand-Related Defects and Their Remedies in Producing Quality Casting (1 DVD) Price : (Inclusive of Postage) : ` 850/- z Safety Operation and Maintenance in Induction Melting System (2 DVDs) Price : (Inclusive of Postage) : ` 1150/- z Selection Installation and Maintenance of Refractory Lining in Coreless Induction Furnaces (1 DVD) Price : (Inclusive of Postage) : ` 850/- z Practical Pathway to Rejection Control in Grey and Ductile Iron Casting Production (1 DVD) Price : (Inclusive of Postage) : ` 850/- z Foundry Process of Core and Mould Making Relevant to Ductile and Grey Iron Castings (1 DVD) Price : (Inclusive of Postage) : ` 850/- z Using Casting Simulation to Increase the Yield and Reduce Rejections in Castings – Arun Pandion (1 DVD) Price : (Inclusive of Postage) : ` 850/- z Analysis of Casting Defects in Foundry by CAE – Tapan Roy (1 DVD) Price : (Inclusive of Postage) : ` 850/- All payments should be made by at Par Cheque or Demand Draft favouring “The Institute of Indian Foundrymen CET” payable at Kolkata. 335.

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11  November 2015 .Indian Foundry Journal 143 Vol 61  No.

144 Vol 61  No. 11  November 2015 Indian Foundry Journal .

11  November 2015 .Indian Foundry Journal 145 Vol 61  No.

146 Vol 61  No. 11  November 2015 Indian Foundry Journal .