Report

On
Industrial visit.
Submitted To
MSBTE
In Partial Fulfillments of Requirement of Diploma In
Mechanical Engineering
Under I Scheme
Submitted By

Name of the students Roll No

Jericho Almeida 18

Under I Scheme

Under the Guidance of

Mr. M.T.PATIL

FOR ACADEMIC YEAR 2020-2021

YASHWANTRAO BHONSALE POLYTECHNIC, SAWANTWADI.

 MAHARASHTRA STATE BOARD OF TECHNICAL
EDUCATION

CERTIFICATE
This is to certify that:-

Sr.No Name Enrollment No. Roll No.

.
1 Jericho Almeida 1917420197 18

Of Fifth semester of diploma in MACHANICAL ENGINEERING Of

institute Yashwantrao Bhonsale Polytechnic, Sawantwadi (1742) has
completed the Industrial visit satisfactorily in for the academic year 2020
to 2021 as prescribed in the curriculum.

Course Teacher HOD Principal

1: INTRODUCTION: New Supreme Castings.

New Supreme Castings is one of the companies of Supreme Group having

Foundry Division. It was established in the year of 2004 as the name of M/s J.R.
Engineers under the aegis of Mr. Ravi J. Waradkar and Mr. Pramod J.
Waradkar. After Dec 2009 it was named as M/s New Supreme Castings. The
company manufactures various type Castings in Graded Gray Cast Iron, S. G
Iron for various Automobile component & Agricultural Industries product in the
range of 0.20 Kg to 20 Kg., with well equipped & skilled employees, to provide
better quality and service. Company also provides Machining Facility to various
automobile components using latest technologies. Company has special
business interest in development of patterns with latest technologies.

Melting Capacity of the unit is around 150 Tons per Month, and also interested
in extend their capacity with development of bigger castings weight up to 50-75
kg/piece. Our sister concern unit M/s J. R. Tools is also one of the company of
Supreme Group. It was established in year of 1998. This unit provides
machining facility to Cast Iron components using latest Machines like CNC,
VMC for various Automobile & Agricultural Industries. Company is equipped
with skilled employees, so they provide better quality and better service.
Presently our machining unit have equipped with Three VMC Machines &
Conventional Machines for Machining of Component. For inspection a Trimos
(Electronic Make) is present & also various types inspection facility.

COMPANY DETAILS

Company Name: - NEW SUPREME CASTINGS

Company Address: - Plot No. J-9, MIDC, Gokul Shirgaon, Kolhapur-41623,
Maharashtra
Country: - India
Phone No. [Office]:- +91-231-2671644
Contact Details.: - Mr. Ravindranath J. Waradkar [CEO] +91-9822240362
Mr. Mahendra P. Waradkar [MR] +91-7722016633
E-mail I.D.: - newsupreme.casting@gmail.com
2: Processes observed in the industry:

1.Pattern making: Patterns are a model for the object to be cast. A

pattern makes an impression on the mould, liquid metal is poured into
the mould, and the metal solidifies in the shape of the original pattern.
Patternmaking isn’t as simple as the definition suggests. In addition to
shaping the mould cavity, a pattern must provide accurate dimensions,
have means of exiting the mould cavity without breaking it,
compensate for solidification shrinkage and distortion, and include a
feeding system of gates and risers to deliver liquid metal into the
mould. Any flaw can result in a failed casting.
Getting all those factors right requires precision and more than a few
calculations. Each pattern is carefully designed and constructed.
2.Sand preparation: Sand casting, also known as sand moulded
casting, is a metal casting process characterized by using sand as the
mould material. The term "sand casting" can also refer to an object
produced via the sand-casting process. Sand castings are produced in
specialized factories called foundries. Over 60% of all metal castings
are produced via sand casting process.
Moulds made of sand are relatively cheap, and sufficiently refractory
even for steel foundry use. In addition to the sand, a suitable bonding
agent (usually clay) is mixed or occurs with the sand. The mixture is
moistened, typically with water, but sometimes with other substances,
to develop the strength and plasticity of the clay and to make the
aggregate suitable for moulding.
3.Mould making:The mould flask is used as container for holding
the mould. The mould flask is designed and separated into two halves
to help in the process of mould making. The sand moulds made are
actually temporary moulding. This results in the process of making
new moulds to carry out each individual casting of mould. The sand
mould is divided into two halves, which has the architecture and
functionality as follows. The moulding board holds the drag, which is
nothing but the bottom, half of the mould. Since the moulds are
poured with greater force the cores must be of higher strength to
handle the same. The precision to be handled in the process must also
be higher and so proper steps for handling higher accurate precision
must be taken. This is because the surfaces which are interior are
much difficult to machine. If proper steps are not taken for handling
precisions of higher accuracy errors might crop inside.
4.Core setting process: A core is a sand or metal insert used to shape
any part of a casting that cannot be shaped by the primary removable
pattern. Cores are created to allow more complexity in the design.
Automotive engine moulds might have up to five cores in them to
create the chambers necessary for the working of a combustion
engine. Cores can also help create angles that would be impossible
with a pattern. Any overhang above an empty space would make it
impossible to withdraw the pattern without breaking the overhang. In
these instances, a core can be used.

5.Melting process:
The preparation of molten metal for casting is referred to as melting. It is
usually done in a specifically designated area of the foundry, and the molten
metal is transferred to the pouring area where the moulds are filled. Melting
may be done by gas or electricity.
6.Pouring process: The process of pouring is not just another procedure to
be followed in the holistic process of casting. Poring today has become an art of
modern technology. It has to done in a certain manner to ensure minimal energy
consumption along with efficiency and convenience.

7.Cooling process: The cooling rate of a casting decreases during the cooling
process due to changing thermal gradients. This is particularly important for
very large castings with a cooling time of up to several weeks in order to reach
the desired shakeout temperature.
8.Cleaning of job with shot blasting process: Shot Blasting is an
effective process on C.I. casting to make the surface sand free, to make the
surface rust free & to create uniformity on the surface. It imparts uniform
surface roughness or anchor profile that leads to increased surface area for
better bonding strength with paint or any other coat.

9.Finishing processes and Trimming: Casting finishing is the process of

taking cooled, moulded cast assemblies and preparing them for use. Depending
on the process used, (nobake, green sand, investment, etc.) the castings will
require various levels of finishing. The type of metal cast also plays a part in the
finishing process.
10.Quality inspection: Finished product inspections are carried out
after the castings have all been completed to make sure that the
product meets the requirements specified by the customer. Defective
castings may be salvaged or completely rejected to be re-melted for
their material content depending upon the nature and extent of defect.

11.packing and export: Once an order is completed and all its parts
and products have passed quality control standards, the next stage is
of packaging the products and their shipment. All the products are
carefully packaged to prevent any possible damage and deterioration
during the shipping process. Packaging and shipping equipment are
an integral part of the infrastructure of every foundry. These products
and equipment are used for packaging and delivery of finished goods
to their desired destinations.