CHAPTER 1

INTRODUCTION
In Maharashtra Industrial hub for casting Manufacturing Processes, Kolhapur,
Industrial Area is worldwide known as metal pouring and expert in manufacturing and
exporter of all type of casting. For hollow shape casting large market Automotive &
industrial demand consistently increases for manufacturing of cold box sand cores
respectively. It varies in shapes, mass, complexity, thickness, material, quality.
This project is related to cold box sand core shooter process requires of the sponsor’s
client at some advanced working condition and modification for improve production
rate with quality assurance output.
As per requirement of customer to design and manufacturing and testing of cold box
sand core shooting machine for SHIROLI MIDC client with lot of practical and
analysis report to reduce all problem generating in current available process of core
making.
CAD CAM MANTRA is a company work with CAD CAM CAE software having a
design and manufacturing center to solve foundry development and processing problem
from year 2006 and providing process tooling ex. For Wood, Aluminum, CI material
Patterns and Dies and assembly product design, pattern design, core and core box
design, machine tool design with verity type of fixture, CNC plug in tools, Automobile
and Agriculture system design and many more.
Individually I will get experience to observe The Company expertise in following
category requires complete this project.
 Design, development, analysis of product design, casting, pattern design, core and core
box design, gating systems, Manufacturing and Prototyping up to project execution
 Machine tool design for foundry processing with SPM and instruments.
 Fabrication Machineries Helps a lot in manufacturing of cold box core shooting
machine.
Without Technical and practical Experience support the comparison of cold box core
shooting process is critical and the importance of elements use for this process is
Functioning different task as per cold box core size, shape, types of raw material. In
next topic the data and the parameter with specification required to process as define.
1.1 INTRODUCTION TO CASTING

1.1.1 CASTING (METAL WORKING)

In metalworking, casting means a process, in which molten metal is poured into a
mould with an empty chamber of the required shape & left to cool & solidify to finish a
task, the solidified component, also called as a casting, is expelled or broken out of the
sand mould. Casting has been most commonly used to create complicated forms that'd
be hard or costly to create using other processes.

FIGURE 1.1 CASTING, SAND MOLDING BOX WITH CORES, MOLTEN METAL
POURING IN SAND MOLD

Casting methods have indeed been known since ancient times and been frequently
utilized for sculpting, particularly in bronze, precious metal jewelry, and ornaments &
equipment. Lost-wax casting, clay mould casting, & sand casting are examples of
traditional methods. The modern casting process is subdivided into two main
categories: expendable and non-expendable casting. The mould material, including
such sand or metal, as well as the filling process, is including such gravitation, vacuum,
or low pressure, further break that down.
1.1.2 SAND CASTING

Sand casting is one of the most common and basic forms of casting, and it has been
practiced for millennium. Sand casting provides for smaller batch sizes and lower costs
than permanent mould casting. Sand casting not only allows businesses to make goods
at a low cost, but it also has other advantages, such as being very small-size operations.
Sand casting may be used to create anything from castings that fits in the palm of the
hand to train beds. Sand casting can also cast many metals, depending on the type of
sand used in

FIGURE 1.2 PRODUCTION PROCESS FLOW OF SAND CASTING

The moulds. Sand casting has a delivery time of days, or perhaps even weeks, at high
output rates (1–20 pieces/hr-mold) and therefore is unrivalled for large-part
manufacturing. Green (wet) sand having essentially no functional component weight
restriction, but dry sand does have a functional part mass limit of 2,300–2,700 kg. The
minimal component weight is between 0.075 and 0.1 kilo gram. Clays, chemical binder,
or polymerized oils are used to hold the sand together (such as motor oil). In most
processes, sand may be reused several times & requires very little maintenance.
 1.2 INTRODUCTION CORE SHOOTING & MANUFACTURING PROCESS
1.2.1 INTRODUCTION TO CORE MACHINE STRUCTURE

The Existing Layout of the Core shooting Machine structure shown in bellow the main
element of the all system is follows
1. Sand hopper
2. Sand shooting mechanism
3. Base-frame
4. Pipeline
5. Electrical Devices

Figure.1.3 typical setup of cold box sand core manufacturing machine with it components A.
Enclosed heating chamber and pneumatic systems, B. Sand hopper C. Electronic panel D. Sand
shooting valve E. Sand Exhaust F, Vibration motor G. Air flow system H. Machine structure I.
Box clamping cylinder J Sand shoot chamber.

1. Sand hopper
The sand hopper is attached to the side of the column, that is used for storing and
transporting sand cores. It is a tetrahedral pyramid groove or a circular cone. The sand
cores will fall into the sand-shooting drum through the sand hopper's exit.
2. Sand shooting mechanism
The sand shooting mechanism is made up of a shooting head, a sand-shooting drum, a
spinning stand, a cylinder, and a sand shooting valve that is controlled by the
operational valve. When you shoot, its sand shooting valve opens, allowing compressed
air from the air storage tank to reach the sand-shooting drum. The firing head would
fire the core sand inside the drum into the core box. After firing the sand, the shooting
valve's inlet closes while its outlet opens, and the leftover gases inside the shooting
chamber are expelled by the exhaust port & muffler.
3. Base-frame
The base-frame consists of an upright column, base, clamping cylinder and core-
pushing cylinder. The upright column is connected with the rear part of the base-frame
and its upper part is connected with the sand hopper. The hollow part of the upright
column is also used as an air storage chamber. The clamping cylinder, core-pushing
cylinder and core pulling cylinder are situated in the front of the base. The back
cylinder of the base contains an outlet valve which is used to discharge the water in the
air storage chamber.
4. Pipeline
This core shooting machine is operated by a six-position manual operating valve, a
two-position four-way air operated directional valve.
5. Electrical parts
Temperature of the heating plate can be controlled automatically. Using the
thermoelectric couple, temperature indicating controller and contactor inserted in the
heating plate, the temperature of the heating core box will be kept within a certain
range. Automatic signal device for solidifying time: when the shooting-head clamping
cylinder returns to the original position (rise), the time relay and contactor with
inductive switches start counting simultaneously. When reaching the set solidifying
time, the indicator light will shine and die can be opened. The machine must be earth
connected.

1.2.2 WHY COLD BOX SAND CORE MANUFACTURING PROCESS?

Different processes are used to manufacture sand core with heat, without heat. A resign
coated sand normally used for shell core process with a metal core box is heated up to
150 -180⁰c inside in a gas heated chamber and kept out a metal core box and resign
coted sand inside in a cavity because a contact of resign sand with a heated metal
surface sand particles are binding with each other from the metal face to the sand area
the heating convection and conduction place the major role to cure the resign shell core
sand to get the desire shape of imitation of hollow geometry of internal faces of casting
body that should be produced. Then this shell core is placed in sand core box having the
cavity of Hollow imitation of pattern embossed on it. the shell core manufacturing
always require a metal core box and it is heated up to desire temperature to achieve the
strength of shell core and the shell core strength is varies from its external surface to the
center because absorption of heat. Shell core is sandwich between cope and drag and
molten metal is poured inside in the sand cakebox during me casting process in melting
section. Limitation of shell core and its benefits varies because of its shape, strength,
size surface finish of casting is always better by using shell cores but the defect of
casting processes of blow holes and air treatment is more in shell cores but large size
shell cores create more difficulties and defect during the casting of break disc or
Minimum thickness component casting with hollow area here we require different
types of core that will eliminates air trapment during casting solidification process short
fill and blowhole defects it is necessary to move a cold box core manufacturing process.
Benefits of Core box core over shell Core are as Follows
 In cold Box core manufacturing process, no need of heat the core box so it is
possible to use variety of material to manufacture i.e. Wood, aluminum, metal, silicon,
Plastic, Rubber.
 Rapid Prototyping, 3D printing process useful for cold core box.
 Catalyst A & Catalyst B with equal amount is dropped in sand mixer with raw
sand required to cold box core.

Table No.1.1 Elements of Cold Box Core sand

Sr.No. Item Amount Type
1 Catalyst A 950ml Resign
2 Catalyst B 950ml Hardener
3 Raw Sand 100kg Dust free Tested Process Mine sand
1.2.3 THE COLD BOX PROCESS – A BRIDGING TECHNOLOGY

The innovative cold box system from Hüttenes-Albertus is a bridge technology towards
inorganic core manufacturing by merging the benefits of the cold box process with the
inorganic approach. Castings production needs at foundries have increased
considerably in recent years. The components are getting increasingly complicated,
whereas the wall thickness is decreasing and core concentration, and the requirements
on the core binder systems employed, is increasing. In recent times, there has also been
an increase in the amount of mechanization as well as the development of new alloys.
The foundry environment, on the other hand, has become extremely difficult.

FIGURE 1.4 INORGANIC BINDER SYSTEMS

Environmental rules and regulations have indeed been strengthened and would be
tightened further. These procedures are being pursued not just at the national scale, and
also at the European commission. Compliance with pollution limits is getting more
challenging. Furthermore, many foundries face a lack of acceptability from surrounding
neighbours, who frequently file complaints about air and noise pollution. In addition to
being required to decrease greenhouse gas emissions and participate in the trading of
CO2 emission permits, the foundry sector is also motivated to reduce overall Emissions
of co2. As a result, the foundry sector and its suppliers have redoubled their efforts to
utilise low-carbon materials wherever possible. Working in an environment with
apparently competing interests, the foundry sector must demonstrate its worth. Modern,
reduced purpose binding agents have a significant contribution in improving the entire
issue.

Fig.1.5 DIAGRAM COMPAIRING INORGANIC METHOD AND COLD BOX

PROCESS
1.2.4 COLD BOX CORE SHOOTING PROCESS

In recent years, the cold box process has become increasingly popular in the Indian
foundry industry. Many foundries already use this core making process, or are
interested in doing so. Many questions arise in connection with the use or planning of
this process, and will be considered in the following remarks.
1. CHEMICAL CHARACTERIZATION OF COLD BOX RESINS AND
ACTIVATORS
The binder in the traditional polyurethane-based cold box method is a two-component
solution chemically consisting of a polyol and a polyisocyanate. One of the components
is a phenol-formaldehyde resin with benzyl ether properties, represented by the term
"polyol." These resins have a generic formula wherein the sum of m and n is at least
two as well as the m:n ratio is at least 1:1 (x = -H or - CH2OH).

FIG 1.6 CHEMICAL FORMULA FOR PHENOL-FORMALDEHYDE

2. CATALYSTS
The gases necessary for curing are members of the tertiary amine family. The
vaporization points of these tertiary amines differ:
• Vaporization point of DMEA: 36-38 C
• DMIA Vaporization point: 65-68 C
• TEA Vaporization Point: 87-89 C
1.2.5 CORE SHOOTERS, GASSING EQUIPMENT
These topics will only be explored to the degree that they are required. The relevant
manufacturers can provide more specific information. The core shooters must be
matched to the size of the cores that will be created with them, according to the binder
supplier. The following is an explanation for this need.

FIG .1.7 AMINE GAS CORE SHOOTING PROCESS

Shooting a 1 kilogramme core on a 25 L core shooter is not recommended. If this were to

happen, the core shooter, who has a 200 kilogramme supply of moulding sand, would
only be able to use it for around three hours. If the outside temperature exceeds 30
degrees Celsius, storing the moulding sand for three hours may cause issues with core
manufacturing (cf. Section 4).
1.2.6 CORE (MANUFACTURING) PROCESS
A core is a device that is used in the casting and molding operations to create interior
voids and reentrant angles. The core is often a throwaway component that is damaged
in order to extract it from the component. They are mostly employed in sand casting,
although they are also utilized in injection molding process.
There are seven essential aspects of core:
1. Green Strength: Sufficient resilience for handle is required in the green
condition.
2. Hardness: In the hard condition, it should be strong enough to withstand casting
pressures; hence, the average compressive strength ought to be 100 to 300 psi.
3. Permeability: should be very high in order for gasses to exit.
4. Friability: The core of the casting or mounding must be weak enough just to
break down when the material contracts as it starts to cool. Furthermore, they
must be simple to release during shakeout.
5. Because the core is frequently surrounded by hot metal during casting or
molding, excellent refractoriness is necessary.
6. A slick surface finish and Minimal gas production while metal pouring

1.2.7 DRY-SAND CORES (shell core)

The easiest technique to create dry-sand cores is really in a drop core box, where sand
is put into to the box & scrapped level with top. The box is then covered with a wood or
metal plate, as well as the two were flipped over, causing the core section to fall out of
the core box. Afterwards when, the core section is baked or hardened. Several core
parts are then hot bonded or otherwise connected together. Rough patches are filed and
sanded down. Lastly, the core is gently coated using graphite, silica, or mica to provide
a better surface finish & increased heat resistance. Since they are manufactured in a
split core box, single-piece cores do not require assembly. A split core box, as the name
implies, is constructed of two parts and includes at least one hole through which sand
can be injected. On special core-producing extruders, simple cores with consistent
cross-sections may be produced. The extrusions are then simply trimmed to length and
hardened. More complicated single-piece cores can be created in the same way those
injection moldings and die castings. Types of Core is Cold Box, Half core box, Dump
core box, Split core box, Left and Right core box, Gang core box, Stickle core box,
Loose piece core box, Loose piece core box.
 CHAPTER 2

1. LITERATURE REVIEW
[1] Prof. Amarjeet R. et al.in the “A Review on Issues Related to Manual Core Making
Process in Foundry Industry” Researcher describes the Core making is an important
branch in any foundry and the choice of core making depends on various factors. To
mention a few, they are dependent on the type of metal to be cast, the size of the
casting, the complexity of the casting process, the demand for excellence in the
finished product, the machinery used for output, as well as the energy supply. It
provides foundries with a feature which no other metallurgical technique provides: the
capacity to produce exterior and interior curves, forms, hollow, & passages in a single
operation. Foundries have to increase production and profitability. However, intense
competition & common industrial circumstances have strengthened metal casters'
drive to optimize current methods and create new technologies that enhance
productivity and reducing costs in recent years.

[2] J. Danko et al. in the “Assessment of core sands suitability for filling the core box and
for compaction –by blowing methods” in this research paper analysis by a researcher
The apparent density achieved after filling a checking core box of a complex form
was indeed the primary criterion for validating the supplied core sand as appropriate
again for blowing procedure. The graph represents the dependency of the sand
outflow ratio on core density, as measured by blasting core sand into the testing
equipment at a pressure impulsive duration of 0.2s. The effect of pressure – at which
core sand blasting was performed. It can be observed that the outcomes of the data are
essentially linear and specified by supplied equations. This implies it is possible to
arrange sand grades based on their appropriateness for the blowing process based on
establishing the sand evacuation coefficient - not having to do the crushing quality
assessment every time. Current techniques of assessing core sand compatibility for
the blowing operation can be called transitional since they are dependent on different
ways of evaluating sand fluidity, which have no relation to the blowing operation. The
purpose of the tests was to see if it was feasible to evaluate the suitability of core
sands - for core box loading and compacting by blowing techniques - by measuring
the sand evacuation induced by a single air pressure impulse in the shooting &
blowing equipment. The obtained findings allow for a positive estimation of the
usefulness of assessing the filling ability factor and the coefficient of sand evacuation
 from the blow compartment of the experimental apparatus – which is similar to the
one employed by Boenisch for core compacted quality assessment.
[3] A. Fedoryszyn et al. In the “Characteristic of Core Manufacturing Process with Use of
Sand, Bonded by Ecological Friendly Non-organic Binders” Researchers debate The
most well-known eco-friendly inorganic binder technologies. The aforementioned
technologies are mostly based on silicate liquid solutions, and the hardness process is
carried out using a thermal technique that includes preheating in the core-box and
further purging with warm air. The use of such binders in core sands improves
handling comfort; no odors or toxic chemical emissions occurred throughout core
production & pouring into moulds. The primary benefits of using blowing processes
in technology: Decrease in the emissions of steamy harmful gases (such as furfural,
volatile amines, formaldehyde, and organic solvents), decrease in odor (compared to
cold-box and hot-box operations), The scope of the work helps determine the bending
strength of the hardened samples. Heating up in the core-box and drying chamber, as
well as purged using heated air, hardened the samples. An apparatus was used to
create squares cross-section specimens of sand with sizes of 22, 36, 165 mm. This
machine is intended for the production of shaped elements and tiny cores in hot-box,
cold-box, CO2 hardening, and warm air hardening technologies. The core-blowing
device has shooting chambers with such a volume of 3 liters and a shooting tip with
three nozzles of 5, 5 and 12 mm. The shooting head is outfitted with vents. Depicts
the sample findings of the investigation. For the experiments, the appropriate molding
sand mixture was used.
[4] M. Asłanowicz et al. in the “Conceptual Design of a Core Making System” explain
the researcher The following measuring techniques and procedures are used to acquire
the characteristics of box filling and sand compaction using blowing and shooting
methods. A device for manufacturing shaped elements and tiny cores in hot-box and
cold-box processes, as well as CO2 and hot air gassing blowing machine for
determining core compaction settings, primarily in hot-box and cold-box operations, -
a mechanism for blowing/shooting outfitted with a valve with a variable releasing
stroke & bushings in the shape of cylindrical inserts holding core sand. The
equipment is used to measure the influence of air pressure as well as its distribution
inside the shooting tank just on major (sand flow rate, thrust force) as minor (sand-air
flux density, speed).
[5] Mosim Attar et al. In the “Design, Development & Testing of Core Shooter analysis”
 the researcher explains A core is a device that is used in the casting and molding
operations to create interior voids and re-entrant angles. They are most often seen in
sand casting, although they are also found in injection molding. The core shooter
machine is used to increase core manufacturing rate, quality, and cost effectiveness. A
core shooter is a machine that pushes sand from a hopper into a core box, following
which CO2 gas or heat is blasted into the core box to harden the core. There are
numerous types of core shooters available on the market today, but most of them give
either hot box / cold box core shooters, therefore we designed a core shooter that is
appropriate for both cold box & hot box and therefore does not require additional
operating problems.
[6] R. Dańko et al. in the “Core Blowing Process - Assessment of Core Sands Properties
and Preliminary Model Testing” It is difficult for researchers to analyze parameters of
the a sand-air stream throughout core manufacturing using blowing methodologies,
that aerodynamic characteristics have been determined by the a solid phase fraction in
an air stream, because either parallel measurements of flow intensities of both phases
are required or dynamic stream characteristics determined by: - solid phase outflow
intensity, - dynamic force valuation of a two-phase stream. For useful purposes, it
may be considered that the aforementioned amounts impact core sand compaction &
structure inside the core-box, and the actual time of loading the mould cavity. The
supplementary quantities, which symbolize other variables of the air-solid phase
combination stream evaluated as a pneumatic transport, are as follows: - density of
the two-phase stream or amounts specifically linked to density (concentration or a
solid phase volume or mass fraction, porosity), - estimated average motion of both
phases of the sand-air stream, - solid phase rubbing speed and consensual speed ratio
of a solid and gas phase inside the stream out flow in.
[7] J. Dańko et al .in the “Effective cross-section area of a shooting valve in core
shooting machines” research explain the working parameters of the core-box filling
and sands compaction and also concerning sands hardening by means of gaseous or
thermal factors is a very important for the optimization of the core production process
done by shooting. Those problems were the subject of the previous investigation
realized by the application of the traditional core binders (oil or linseed oil varnish,
water-glass, resins for the hot-box process). One of the effects of these studies was the
approximation of numerous measurement data, which enabled taking into account, in
empirical formulas used for the calculation of the average value of sands compaction -
 kind of core sands, initial apparent density of loosely built sands, working pressure p r

and diameter of an outlet of a shooting machine head. As the result of experimental

investigations quantitative relations between pressure, supplied to the shooting
machine from the compressed air grid, and pressure which is established in a blowing
chamber – were found. Its value depends on the following factors: - Air shooting
valve cross-section area and velocity of its operation, - Area of an outlet from a
shooting machine head, - Volume of a blowing chamber, constituting a container of
core or molding sands. The results of the average apparent density, porosity and
permeability in cores made by shooting of the determined core sand, indicate that
regardless of the kind of the core sand there is a continuation of the character obtained
from the apparent density. This justifies their joint presentation in a form of a
synthetic diagram, comprising a very wide range of the apparent sand density and
related to it permeability and porosity.
[8] A. Fedoryszyn, et al. in the “Examinations of Parameters influencing the outflow of
two-phase air-sand stream from machine chamber and core box filling in shooting
process” researcher explain Evaluation of usability of the core sand in box filling and
sand compaction by blowing methods Optimization of core production by the
shooting method involves the selection of operating parameters of the box-filling and
sand compaction processes as well as sand hardening using gases or by thermal
methods. The degree of core sand ejection from the core chamber controls the
effective volume of core achievable in the given core machine It is dependent both on
the machine construction, particularly the shooting valve and the method of air supply
to the core sand to eliminate air channels, and on physico-chemical parameters of the
core sand, which affect its flow-ability. Factors controlling the core box filling and
sand compaction processes include the intricacy of the core shape, core sand type,
shooting pressure parameters and recommended surface areas and spacing between
the shooting and venting holes. Tests were done on conventional core binders (oil or
linseed oil varnish, water glass, resins for hot-box processes). In the case of the state
of the art cold-box and warm air technologies, there is a need to modify the
parameters of the blowing process in relation to core sands used previously. This is
associated with physico-chemical properties of the applied binders (high reactivity,
low viscosity) and the sand compaction conditions, particularly through airing with
gaseous agents.
[9] R. Danko, et al. in the “Parameters of the Two-Phase Sand-Air Stream in the Blowing
Process” explain the researcher Core sand compaction distribution inside the core-box
As sands are compacted by blowing techniques, the characteristic rise in sand
apparent density is observed at the extension of the shot hole axis when compared to
zones where the sand-air stream is not immediately impacting on sand layers. The
capacity of the central core zones to evacuate gases after the mould has been poured
using liquid metal is reduced as a result of this compactness distribution. It's also bad
for sands, which are hardened by blowing gaseous hardening agents through the core
of the mould. Irregularity in compactness also is a common cause of degradation &
deformation in not completely hardened cores. In certain cases, specimens were taken
out from core-box using a probe. Weighted samples on an electronic scale allowed the
distribution of core sand compactness in the core-box to be determined.
[10 M. Schneider et al. In the “Simulation of the entire core production process” The
] intricacy of the core manufacturing method, according to the researchers, is
attributable in part to the huge number of factors that ultimately determines the
ultimate quality of a core. The total number of shoot nozzles and vents utilized in the
core shooting process, as well as the size and placement of nozzles and vents
employed, will frequently have a dramatic influence on the ultimate quality of a core.
Furthermore, process characteristics such as the amount of pressure used during
shooting, overall shot duration, and sand to binder ratio can all have an impact about
how the core box fills. After filling the core box, the binder should be cured as well as
hardened to provide the core adequate capacity. The core curing process also
incorporates a number of elements that will influence the ultimate quality of the core.
Inside the instance of phenol urethane cold box (PUCB) binder systems, the number
of vents, shape of vents, and placements of vents, as well as the volume of curing gas
&pressure profile used to deliver the curing gas, will affect whether a core is properly
cured. To make matters even more complicated, a venting situation that works well
for the core firing procedure may not be optimum for the succeeding curing process.
Other binder methods, including such inorganic & resin coated shell sand, need a
uniform tempering of a core box to provide adequate curing & core strength. It is
difficult to know where to install heating units and how long to heat in each region for
these procedures. As a consequence, putting a new core box into production might
sometimes take several weeks. The time and expenses associated with effectively
bringing a core into production are frequently not recorded and are not connected
 back into to the cost of the casting, despite the considerable influence that these
expenditures have.
[11 Danko, J. Zych, et al. in the “Diagnostic Methods of Technological Properties and
] Casting cores quality” explain the researcher Perceived density, porosity, &
permeability in shooting technique cores The various core box filling ratios and
significant scatter of compactness values as well as their distribution in a core are
obtained under similar realization conditions of the blowing process (blowing,
shooting), i.e. the same values J of a shooting hole diameter, blowing pressure,
duration of opening of a shooting valve for various kinds of core sands. This is due to
the variety in technical qualities of cores, which are reflected by their permeability,
strength, and degree of projection of a core box surface. Thus, this influences an
accuracy and smoothness of castings. These variables, which have a major impact on
the effectiveness & quality of produced castings, compel laboratories to use simple,
quick, and accurate quality evaluation procedures, enabling them to identify the ideal
operation parameters of a blowing machine for the given core sand.

2. FINDING FROM LITERATURE REVIEW

A. Reducing the rejection factor of cold box core production, reduce cycle time and
optimize process time achieve better quality, strength, hardness for low weight, low
volume high surface area complex shape sand core.
B. Analyze sand grain particle flow simulation to obtain behavior of particle
desertion and pressure drop at various area of cold box core cavity to produce perfect
shape of cold box manufacturing factors.
C. Optimize the human error resulting accident by rearranging parts on
manufacturing machine unit and design prototype of frame for operator safety.
D. Find out the standard time for curing sand core with changing volume of sand,
sand type, binding agent process time, amine gas shooting time.

3. LITERATURE GAP
Because of commercial aspect lot of Technological foundry tricks keep secretes
because of Market competition and industrial race of country regions. From number of
papers the observation is no typical practice analysis process has been shared in all
paper and different types and technology with different domain available to study.
All theory contains the conceptual illustration with discussion, but lot of difference in
actual experimental setup and theory description. Various brought out element and
component with different make having multiple specification and capacities have to
recognize and utilize in core shooting process.

4. PROBLEM DEFINATION
Each and every Foundry facing the problem to produce hollow shapes casting. For
hollow shape casting requires sand core with high density and strength. In
manufacturing of core cold box sand core machine require to use with ammonia gas,
compressed air pressure, sand with perfect require binding chemical at correct
composition within a certain time limit. Core curing time, compressed air pressure with
temperature, binding element is varying according to environment condition.

FIGURE 2.1 KANERI INDUSTRIES, SHIROLI MIDC, KOLHAPUR, AND CORE

PRODUCTION LINE

Core complex shapes, crack in core, low strength because of moisture, short filing,
surface finish, rejection of core during loading unloading ejecting from machine
Ammonia gas with high pressure air is dangers when leak and spread in environment at
atmospheric pressure cause dangers effect on human skin, breathing, temporary eye
blind. Always reduce rejection rate because rejected sand not able to recycle because of
high rate of recycling cost. Quick maintaining of machine is required because within 30
min sand will hard and not useful because of its binding agent. Machine structure
material optimization required and advanced air shut off valve design required. Each
 and every core box CFD CFX sand air flow simulation required to avoid core rejection
rate.
5. OBJECTIVE
A. Design and fabrication of cold box sand core shooting machine structure

fabrication and its structural analysis in ANSYS CAE software.

B. To improve cold box sand core density with testing equipment, strength, remove

short fill, crack, low production cycle, reduce rejection factor, good surface finish, low

operate effort, auto machine cycle & double production rate by single machine.

C. Design and analysis of shooting valve for amine with hot dry air shooting with

7.5bar pressure controlling ammonia discharge and eliminating ammonia entry around

machine and 3D modeling in Siemens NX software.

D. CFD CFX analysis in Ansys software with stream line flow of core sand with

compressed air in shooting chamber

6. METHODOLOGY

Phase I – Data collection: all data collection of existing problem in foundry during
production of cold box sand core on core shooting machine. Investigation of causes for
sand core rejection factor, worker working comfort, worker safety environment, loading
and unloading a raw material for cold box sand core machine, machine sand core
production cycle time. Ejection of core from cold box. Find out international papers and
research paper from internet, college library, E-library, text book, industrial
publications data. Find out industrial material standards, working process standards,
quality control reports, parameter effecting on sand core production. Free hand sketch
generation of existing verity of machine available in cold box sand core production
industries, collect al data related to core shapes, core raw material for different casting
types, core vents, and core design terminology.

Phase II – Implementation of all data with the help of computer software, CAD
software, CAE software, generating data sheets, and Generate cold box sand core
machine structural drawing using CAD software. And structural analysis of machine
structure with natural frequency and modal analysis. Prepare all models for air sand
flow simulation velocity analysis in CFD software.
Calculate material standards, boundary conditions, named selection, formulation, input
output pressure, (details for simulation)Finding meshing types, elements, nodes, for
CFD analysis post processing solutions. Changing strategy for CASE studies and its
assumption. AUTOCAD, UGNX, ANSYS

Phase III – Design and analysis of air shutoff valve for hot compressed air at 7.5 bar
pressure within two different case studies. Generate CAD model, assembly simulation
for functional working with CAD software UGNX. Structural, natural frequency, and
modal analysis of air shutoff valve.

HOT air flow simulation CFD CFX stream line analysis of shutoff valve. Compare
model in case one and case two. Generate analysis report for all type of analysis.
Generate manufacturing drawing, process drawing, assembly drawing, BOM for cold
box sand core shooting machine building.

Phase IV – Comparison of Result

Comparison of result velocity and pressure of air and sand in shutoff valve work on
machine with all analysis repost generated in CAD CAE software, (EX. AUTOCAD,
UGNX, and ANSYS) Compare experimental result with software result report. Review
of cold box sand core shooting machine.
Phase V – Interpenetration and Modification.
Check all data, result and improve up to client requirements. And rework if any
problem observed.

7. FLOW CHART FOR OBTAINING OBJECTIVE: -

UNDERSTAND AMINE PROCESS IN COLD

BOX CORE SHOOTING MACHINE
 PROBLEM OCCURS IN CURRNT AMINE
GASSING PROCESS

C-FRAME TYPE FRAME AMINE LEAKAGE

BUCKLE AFTER AMINE GAS SHOOTING PROBLEM
CONTINUOUS USE SYSTEM

DESIGN OF NEW AMINE DESIGN OF SHOOTING

DESIGN NEW FRAME FOR
GAS SHOOTING VALVE FOR AMINE
SUSTAIN BUCKLING
COPY
LOAD METHOD

DESIGN IN NX & MANUFACTURING NEW ANALYSIS IN THE

ANALYSIS IN ANSYS LAYOUT ANSYS

Analysis in IMPROVE IN Analysis in

Ansys PERFORMANCE Ansys

MANUFACTURING ALL
THE COMPONENT

ANALYSIS STREAM LINE

FLOW OF CORE SAND

GENRATE REPORT

8. ACTIVITY CHART:
Sr. Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr-
No Activity / Month 2018 2018 2018 2018 2018 2019 2019 2019 2019

1
Literature review
Understanding the
Automotive
Quality Control
2
Core Tools for
Developing part
and production

3 Prepare the list of

problem in existing
Prepare list of
4
modification item

5 Define
methodology
Design and
6
analysis phase
Comparing the
result and redefine
7
parameters for
efficiency

8 Conclusion with
experimental setup

CHAPTER 3

1. AMINE GAS DOSING SYSTEM

1.1 CURRENT LAYOUT OF AMINE SHOOTING METHOD

FIG.3.1 CURRENT LAYOUT OF AMINE GAS SHOOTING SYSTEM

1.2 WORKING OF CURRENT AMINE GAS SHOOTING METHOD

i. Amine Liquid is store in the closed tank and the Amine Pump is used for pump
the Amine liquid from tank and proceeds to the amine gas chamber to Mixing with hot
dry air.
ii. Dry air is passing through the pressure line and heating with the Heating coil
which heat the air collected from compressor at atmospheric air temperature.

iii. Mixing chamber is mixed the Amine Liquid and the heated air and passing
toward the cold box core entry Shooting area where already core box filled with the
processed core sand.

1.3 PROBLEM OCCURS IN THE CURRENT AMINE GAS SHOOTING

METHOD
i. AMINE GAS EFFECT ON RESPIRATORY SYSTEMS :-
A. REASON: - if the amine gas not process with hot dry air, improper mixing of
amine liquid and dry hot air temperature variation. Density variation of amine gas in
because of high hot air.

B. EFFECT: - Amine is an irritant and a corrosive substance. When exposed to

high quantities of Amine in the air, the nose, throat, & respiratory tract burn
immediately. It can result in bronchiolar & alveolar edoema, as well as airway damage,
which can lead to lung distress or collapse. Lower amounts might induce coughing &
nose and throat discomfort if inhaled. The odour of amine offers an appropriate early
warning of its existence, yet amine also produces olfactory weariness or adaptation,
which reduces consciousness of one's extended exposure at low concentrations.
Children exposed to same quantities of Amine vapour as adults may get a higher
dosage due to higher lung surface area-to-body weight ratios and minute volume-to-
weight ratios. Furthermore, due to their lower height as well as the higher quantities of
Amine vapor first detected close to the ground, kids may be exposed to larger amounts
than adults in the same place. Contact with the skin or eyes: Exposure to low amounts
of Amine in the air or solution might cause immediate skin or eye discomfort. Amine at
higher quantities can cause severe damage and burns. Contact with concentrated Amine
solutions, such as those used in industrial cleaners, can result in corrosive injuries such
as skin burns, severe eye damage, or blindness. It is possible that the entire amount of
eye damage will not be visible for up to a week after the exposure. Contact with liquid
Amine can potentially result in frostbite. Ingestion: High quantities of Amine in the
mouth, throat, and stomach cause corrosive damage. Ingestion of Amine does not
normally result in systemic poisoning.

ii. DE-STABILIZED OF THE AMINE LIQUID

A. REASON: - there is no provision for the remove excess of air from the Amine
storage tank that for Amine Liquid will react with oxygen gas to yield nitrogen
monoxide and water vapor.
B. EFFECT: - The destabilization of the Amine liquid, as well as higher amounts
of nitrogen dioxide can harm the human respiratory tract and enhance a person's
susceptibility to, and severity of, respiratory infections and asthma. Chronic lung
disease can be caused by long-term exposure to high amounts of nitrogen dioxide. It
may also have an effect on the senses, such as impairing a person's ability to detect an
odor. High amounts of nitrogen dioxide are also detrimental to vegetation, causing
damage to the leaves, slowing growth, and lowering agricultural yields. Nitrogen
dioxide has the ability to fade and discolor furniture and textiles, as well as impair
visibility and react with surfaces.

iii. UNEVEN HEATING OF THE AIR FROM THE COIL

Reason: - The Heating Coil is Hollow spiral type when the air is passing through the
coil that’s affected to the Heating temperature of the air which is variable temperature.

Effect: - The Air is heating unevenly so that’s affect with air mixed with the Amine
liquid and that reason the quality of the core is decrease

Fig.3.2 UNEVEN HEATING COIL OF CURRENT SYSTEM

2. NEW PEOPOSED DESIGN AMINE SHOOTING METHOD

2.1 NEW PROPOSED DESIGN

FIG.3.3 NEW PROPOSED LAYOUT OF SHOOTING VALVE OF AMONIA

FIG.3.4 NEW PROPOSED LAYOUT OF SHOOTING VALVE OF AMONIA

2.2 CONSTRUCTION AND WORKING PRINCIPLE OF APPARATUS

2.2.1 LIST OF APPARATUS

A. AMINE LIQUID STORAGE TANK WITH LEVEL INDICATOR

B. HIGH- AND LOW-PRESSURE COMPRESSED AIR SYSTEMS.
C. FLOW REGULATOR VALVE
D. AMINE LIQUID FEEDING SYSTEMS VOLUMETRIC BASED WITH
PNUMATIC SOLENOID VALVE
E. HEATING COIL WITH TEMPERATURE CONTROLLER
F. NON-RETURN VALVES
G. PNEUMATIC Y TYPE ANGLE SOLENOID VALVE
H. FINS TYPE HEATING COIL
2.2.2 PRINCIPLE AND WORKING OF THE EACH APPARATUS

A. AMINE LIQUID STORAGE TANK WITH LEVEL INDICATOR

I. INTRODUCTION
Level Gauge is used for fluid level measurement in several industries. The Float is of
course the most important element of the instrument. When a float is required for a
specific purpose, its structural design, volume displacement, weight, and buoyancy
force are all carefully considered. Often A standard Float & Board type Level Gauge is
made up of a float, a dust resistant Pulley Housing, a pointer cradle made of nylon, and
a screen printed Aluminum Scale with a width of 150 mm. This device is a completely
dependable and precise method for measuring liquid levels in large overhead tanks.

STORAGE
TANK

AMINE LEVEL
INDICATOR

FIG.3.5 AMINE LIQUID STORAGE TANK WITH INDICATOR

II. WORKING PRINCIPLE

This sort of Float & Board type Level Gauge operates primarily on the basis of
buoyancy. The float is well linked to the counterweight and an indicator through
flexible wire ropes. The pointer moves along the guide against a graded scale to show
equivalent levels within the tank.

III. APPLICATION
This sort of Float & Board type Level Gauge operates primarily on the basis of
buoyancy. The float is well linked to the counterweight and an indicator through
flexible wire ropes. The pointer moves along the guide against a graded scale to show
equivalent levels within the tank. Vapor Seal Type is also available from "KABIR."
Level gauges of the float and board variety are commonly employed in tanks containing
corrosive gases or vapors, or in N2 [Nitrogen] purging tanks. The float in this level
gauge is coupled to a magnetic counter weight that moves in a sealed stainless steel or
PVC pipe and drives a follower magnetized bi-color capsule within a glass tube to
show liquid level. The float in the tank rises & dials in proportion to the volume of
fluid, causing the pointer to move up and down the scale, indicating the level inside the
tank. The pointer on this level gauge is at the bottom of the board when the tank is full,
and it is at the top when the tank is empty. Float & Board Level Indicator A massive
self-centered float records the liquid level in this gauge. A rope with floats passes over
a pair of dust-free pulleys. A pointer travels on a 150 mm wide aluminum powder
covered scale to indicate the level, which is usually can use for storage tanks of Oil,
Fire / DM water Alkalis, Acids furnace Oils, Lube Oil, Vegetable Oil, Molasses,
Glucose, as well as other chemicals. Magnetic vapor seals for HCl, N2 purged tanks,
diluted alkalis; dilute HNO3, NH3 Methanol, Banzene, Toluene, IPA, and other
specialized applications. We accomplish complete vapour tightness since there are no
sealing chemicals in a vapor seal.

B. HIGH- AND LOW-PRESSURE COMPRESSED AIR SYSTEMS

 FIG.3.6 HIGH & LOW PRESSURE COMPRESSED AIR

C. FLOW REGULATOR VALVE

A flow control valve regulates the flow or pressure of a fluid. Control valves normally

respond to signals generated by independent devices such as flow
meters or temperature gauges. Control valves are normally fitted with actuators and
petitioners. Pneumatically-actuated globe valves and diaphragm valves are widely used
for control purposes in many industries, although quarter-turn types such as
(modified) ball and butterfly valves are also used. Control valves can also work with
hydraulic actuators (also known as hydraulic pilots). These types of valves are also
known as automatic control valves. The hydraulic actuators respond to changes of
pressure or flow and will open/close the valve. Automatic control valves do not require
an external power source, meaning that the fluid pressure is enough to open and close
them. Automatic control valves include pressure reducing valves, flow control
valves, back-pressure sustaining valves, altitude valves, and relief valves.
 FIG: 3.7 FLOW REGULATOR VALVE

Process plants consist of hundreds, or even thousands, of control loops all networked
together to produce a product to be offered for sale. Each of these control loops is
designed to keep some important process variable, such as pressure, flow, level, or
temperature, within a required operating range to ensure the quality of the end product.
Each loop receives and internally creates disturbances that detrimentally affect the
process variable, and interaction from other loops in the network provides disturbances
that influence the process variable. To reduce the effect of these load disturbances,
sensors and transmitters collect information about the process variable and its
relationship to some desired set point. A controller then processes this information and
decides what must be done to get the process variable back to where it should be after a
load disturbance occurs. When all the measuring, comparing, and calculating are done,
some type of final control element must implement the strategy selected by the
controller. The most common final control element in the process control industries is
the control valve. The control valve manipulates a flowing fluid, such as gas, steam,
water, or chemical compounds, to compensate for the load disturbance and keep the
regulated process variable as close as possible to the desired set point.

D. AMINE LIQUID FEEDING SYSTEMS VOLUMETRIC BASED WITH

PNUMATIC SOLENOID VALVE
 FIG.3.8 AMINE FEEDING SYSTEM

E. HEATING CHAMBER WITH TEMPERATURE CONTROLLER

FIG.3.9 HEATING CHAMBER

Electric heating is a process in which electrical energy is converted to heat energy.

Common applications include space heating, cooking, water heating and industrial
processes. An electric heater is an electrical device that converts an electric current into
heat. The heating element inside every electric heater is an electrical resistor, and works
on the principle of Joule heating: an electric current passing through a resistor will
convert that electrical energy into heat energy. Most modern electric heating devices
use nichrome  wire as the active element; the heating element, depicted on the right,
uses nichrome wire supported by ceramic insulators. Alternatively, a heat pump uses
an electric motor to drive a refrigeration cycle that draws heat energy from a source
such as the ground or outside air and directs that heat into the space to be warmed.
Some systems can be reversed so that the interior space is cooled and the warm air is
discharged outside or into the ground.

F. NON-RETURN VALVE

(GRAVITY BASED HORIZONAL AND VERTICAL, SPRING TYPE)A check

valve, clack valve, non-return valve, reflux valve, retention valve or one-way valve is
a valve that normally allows fluid (liquid or gas) to flow through it in only one
direction. Check valves are two-port valves, meaning they have two openings in the
body, one for fluid to enter and the other for fluid to leave. There are various types of
check valves used in a wide variety of applications. Check valves are often part of
common household items.

FIG.3.10 NON RETURN VALVE

Although they are available in a wide range of sizes and costs, check valves generally
are very small, simple, or inexpensive. Check valves work automatically and most are
not controlled by a person or any external control; accordingly, most do not have any
valve handle or stem. The bodies (external shells) of most check valves are made of
plastic or metal. An important concept in check valves is the cracking pressure which is
the minimum differential upstream pressure between inlet and outlet at which the valve
will operate. Typically, the check valve is designed for and can therefore be specified
for a specific cracking pressure. Heart is essentially inlet and outlet check valves for
the heart ventricles, since the ventricles act as pumps. Check valves are used in many
fluid systems such as those in chemical and power plants, and in many other industrial
processes.

G. PNEUMATIC SOLENOID Y TYPE ANGLE VALVE WITH COIL

The solenoid valve is industrial equipment controlled by electromagnetism. It is an

automatic basic element to control the fluid. It belongs to the actuator, but not limits to
the hydraulic pressure and pneumatic control. In the industrial control system, the
solenoid valve is used to regulate the direction, flow rate, speed and other parameters of
the medium. The solenoid valve can coordinate with different circuits to realize the
anticipated control, with both control precision and flexibility being guaranteed.

FIG.3.11 PNEUMATIC SOLENOID Y TYPE ANGLE VALVE

The solenoid valve is constituted by the solenoid coil and magnetic core. It is the valve
body containing one or several holes. When the coil is get through or cut off with
power, the operation of the magnetic core will result in that the fluid passes through the
valve body and is cut off, so as to reach the goal of changing the fluid direction. The
electromagnetic component of the solenoid valve is constituted by the fixed iron core,
movable iron core, coil and so on. The valve body is constituted by the slide valve core,
slide valve harness and spring base. The solenoid coil is installed on the valve body
directly while the valve body is enclosed in the seal pipe, so as to constitute a simple
and compact combination.
H. HEATING COIL FIN TYPES

FIG.3.12 FIN TYPE HEATING COIL

Understand the basics of finned tube coils and maximize coil capacity and efficiency.
Finned-tube coils are found in many process heating systems and many times are the
first major component to show symptoms of improper upstream filtration. In a dirty
atmosphere, they can actually cause many systematic problems, including pump,
compressor and fan failures. Finned-tube coils (sometimes known as heat transfer coils)
have two important parts that convey heat transfer. The first is the tubes, which also are
called the "primary surface." The second is the finned surface, which also is known as
the "secondary surface. “Both are ultra-important to creating the designed heat transfer
with balanced air- and water-side resistance. The tubes do a lot of the work via a
transfer of energy between what is going through the tubes and what is on the outside.
(As we all know, there is no such thing as "cold" - only the absence of heat - but for
purposes of clarity, I'll use the word cold to describe the lower temperature stream.) In
heat transfer coils, the transfer goes from the hottest to coldest of the two streams.

3. ANALYSIS OF CURRENT BASE FRAME

4. DESIGN OF NEW BASE FRAME
5.