Digital Assignment-1

MEE2014

Faculty In-charge: Dr. Rijesh. M

Sherin Thomas Sipri

16BME0751

Slot: F2

V R Foundries
Location:-

 Situated in Peelamedu, Coimbatore, Tamil Nadu.

 The climate present in Coimbatore is of dry one, which makes for an ideal location when it comes to
situating foundries. This ensures production of castings of very high quality.
 Due to the strategic location of Coimbatore, trade by ships to other countries can be achieved.
 With discovery of new locations in Tamil Nadu for potential iron ore mining like in Panchapalayam,
Vellakoil and Gowthimalai and Vediappanmalai hills in Thiruvannamalai, foundries present in
Coimbatore will flourish and expand in the upcoming years.
 Availability of a highly skilled labour workforce.

History :-

 Established in 1974.
 VRF was set up as a partnership firm by Mr V Rajendran and his family members.
 The company started with the manufacture pump components and now it has extended its reach in to
manufacture of castings, catering the needs of machinery giants like Caterpillar.
 Primarily involved in grey steel and ductile steel castings since its beginning.
 It got its first DNV Business Management certificate for manufacture of grey steel castings in 2005,
whose quality standards are in accordance with ISO 14001:2004.
Process:-
The manufacturing process in VR foundries includes the main processes of moulding, melting,
fettling, lab testing and quality assurance.
MOULDING
 The moulds in to which the molten steel is poured in, are made in DISA vertical green sand
moulding machine having a capacity of producing 315 moulds per hour.
 The sand for the moulding is prepared in EIRICH sand plant having a capacity of preparing 50
tones of green sand, adding in the adequate amount of bitumen, charcoal and bentonite in to
the moulding sand.
 Once the metal has been poured in to the mould, the cooling of the casting is done in DISA
cooling drum, which used a water evaporative cooling system.
 The DISA core shooter is involved in the making of the mould when it comes to cold core
making process.
MELTING

 The molten steel is melted in the INDUCTOTHERM furnace and the molten metal is poured using the
auto-pour systems utilizing VISIPOUR technology (Predictive Pour Performance) which keeps in pace
the pouring of the molten steel with the automated flasks and flask less molding machines.
 This technology helps in preventing metal wasting over pours and under pours.

FETTLING

 Fettling of the castings, are done by KOYAMA fettling machine and by online shot blasting.

LAB

 This section of the foundries is dedicated to the testing of metals and the confirmation of sand
composition and quality.
 Metal testing is done by spectroscopy and various machineries like the universal strength testing
machine for compressive and shear strength of the sand are present.

QUALITY ASSURANCE

 CMMs are used to measure the precision of the castings dimensions.

 Magma simulation software is used for the simulation of the castings.
PRODUCTS

 Involved in production of components for general engineering, pumping, textile, tractorsetc.

 Few of the products that are casted in VR foundries include:-
Heat exchanger head Mill Cutter Engine Valve Gear Box

Pump Parts Castings Automobile Castings

By-Products

By products produced in VR foundry mainly include wastes like baghouse dusts, packing
materials with remains of toxic materials, grinding dust from the machining, burnt sand.

Efforts are being made to reduce the waste production by sending wastes like burnt sand for
making construction materials.