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 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 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 CORE SHOOTING & MANUFACTURING PROCESS

1.2.1 CORE (MANUFACTURING)

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

1.2.2 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

1.3 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 -180degree Celsius 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
Figure.3 of heat.
typical setup Shell
of cold boxcore
sandiscore
sandwich between machine
manufacturing cope andwith
dragitand molten
components
metal A. Enclosed
is poured inside in heating
the sandchamber and during
cake box pneumatic
me systems, B. Sand in
casting process hopper C.
melting
Electronic panel D. Sand shooting valve E. Sand Exhaust F, Vibration motor G. Air
section. Limitation
flow system of shellstructure
H. Machine core andI. its
Boxbenefits varies
clamping because
cylinder of its
J Sand shootshape, strength,
chamber.
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 trapping 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.01 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
(ex. Guntur, amba, glass, local names)

1.3.1 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,
Fig.4 INORGANIC BINDER SYSTEM
whereas the wall thickness is decreasing and core concentration and the requirements
on the core binder systems employed, are 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.
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
neighbors, 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
utilize 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.

Figure 5 Diagram Comparing Inorganic Method and Cold Box Process

 1.3.2 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. Figure 6 Formula For phenol-formaldehyde (amine liquid)
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).
2. CATALYSTS
The gases necessary for curing are members of the tertiary amine family. The
vaporisation 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
1.3.3 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.

Figure 7 Amine Gas Core shooting Process

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

happen, the core shooter, who has a 200 kilograms supply of molding sand, would only
be able to use it for around three hours. If the outside temperature exceeds 30 degrees
Celsius, storing the molding sand for three hours may cause issues with core
manufacturing.
 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 pr

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 8 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, 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.
1. FLOW CHART FOR OBTAINING OBJECTIVE: -

UNDERSTAND AMINE PROCESS IN

COLD BOX CORE SHOOTING MACHINE

PROBLEM OCCURS IN CURRNT

AMINE GASSING PROCESS

NEW PROPOSED DESIGN FOR

AMINE SHOOTING VALVE SYSTEM

PIPE HEAT FLOW AND STREAM LINE

ANALYSIS FOR AMINE GASSINGSYSTEMS
FLOW IN ANSYS

EFFECT ANALYSIS AND RESULT

STUDY FOR MODIFIED DESIGN
SYSTEM
5. ACTIVITY CHART:

Aug2018

Nov2018

Mar2019
Dec2018

Apr2019
Sep2018

Feb2019
Oct2018

Jan2019
Sr.
No Activity / Month

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

3
Prepare the list of problem in existing

4
Prepare list of modification item

5
Define methodology

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

8
Conclusion with experimental setup
Chapter 3.0
3.1 introduction of existing cold box core shooting process with actual photos and
layout and focus on modification area
In existing setup at various core shop different machine manufacture supply their
machine as per core weight, core box types, method of ejection, method of clamping,
method of sand shooting, method of amine dosing. It varies according to core
requirement.
All machines require amine dosing systems, sand shooting chamber with air tank. Is the
essential unit is mandatory but operating may be manual or auto depend upon core box
core ejection strategy.
For 1 to 10 kg core production system, following heating chamber has been defined.

1. PROBLEM OCCURS IN CURRENT PROCESS OF AMINE GAS SHOOTING

SYSTEM

1.1 LAYOUT OF OLD PROCESS

2. OBJECTIVE: -
Design and analysis of amine gas shooting valve with 5 bar pressure hot dry air
controlling amine discharge and eliminating the spread of unprocessed amine gas
around cold box core shooting machine.

INFORMATIN ABOUT CHEMICAL DETAILS FOR COLD BOX CORE SHOOTER

SYSTEMS

POLYURETHANE COLD BOX SYSTEM

The Polyurethane Coldbox binder is a 3-component system comprising a liquid PF resin

(part1), a liquid polyisocyanate (part2) and a liquid catalyst (part3). The liquid amine
catalyst is vaporized and used to crosslink a sand mix containing part1 and part2. In
recent times the Coldbox system has grown into becoming one of the most preferred
systems for the foundries worldwide making automotive components. It offers various
benefits like:

 Very high productivity

 High tensile strengths
 Excellent dimensional accuracy
 Superior release
 Good humidity resistance
 Extended Bench life up to 60 mins
 Fast curing speeds
 Quick curing products for Core Centers

SAND MIXING
The PUNB system can be mixed in batch mixers only and the mixed sand can be stored
up to 1 hr (bench life) depending on temperature & rel. humidity without a significant
drop in performance. The mixed sand must be transferred and used in a core shooter
within this period. The catalyst (part3) must be vaporized and passed through the core
box to cure the sand mix.

 REFRACTORY COATINGS
Both alcohol and water based coatings can be used. In case of alcohol-based coatings
ignition immediately after application is suggested. For water-based coatings drying
must be done in an air-circulating oven to remove moisture out of the system.

 SAFETY PRECAUTIONS, STORAGE & HANDLING

Use of protective clothing, chemical resistant gloves & facemasks are to worn while
using and handling this binder system. For more information please refer to MSDS.
Store in shade away from direct sunlight & any flames / hot surfaces Shelf life: 6
months at 30°C from date of manufacturing The polyisocyanate (part2) reacts violently
 with water or alcohol and releases CO2. Hence care must be taken for them to not come
in contact with each other.

2.1 WORKING OF AMINE GAS SHOOTING VALVE OF PREVIOUS

DESIGN

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.

2.2 PROBLEM OCCURS IN THE PREVIOUS AMINE GAS SHOOTING

VALVE
i. AMINE gas effect on respiratory systems. :-
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.
Effect: -  Amine is irritating and corrosive. Exposure to high concentrations of Amine in air
causes immediate burning of the nose, throat, and respiratory tract. This can cause bronchiolar
and alveolar edema, and airway destruction resulting in respiratory distress or failure. Inhalation
of lower concentrations can cause coughing, and nose and throat irritation. Amine's odor
provides adequate early warning of its presence, but Amine also causes olfactory fatigue or
adaptation, reducing awareness of one's prolonged exposure at low concentrations. Children
exposed to the same concentrations of Amine vapor as adults may receive a larger dose because
they have greater lung surface area-to-body weight ratios and increased minute volumes-to-
weight ratios. In addition, they may be exposed to higher concentrations than adults in the same
location because of their shorter height and the higher concentrations of Amine vapor initially
found near the ground.
Skin or eye contact: Exposure to low concentrations of Amine in air or solution may
produce rapid skin or eye irritation. Higher concentrations of Amine may cause severe
injury and burns. Contact with concentrated Amine solutions such as industrial cleaners
may cause corrosive injury including skin burns, permanent eye damage, or blindness.
The full extent of eye injury may not be apparent for up to a week after the exposure.
Contact with liquefied Amine can also cause frostbite injury.

Ingestion: Exposure to high concentrations of Amine from swallowing Amine solution

results in corrosive damage to the mouth, throat, and stomach. Ingestion of Amine does
not normally result in systemic poisoning.

ii. DE-STABILIZED OF THE AMINE LIQUID

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.

Effect: - Destabilized of the Amine liquid and elevated levels of nitrogen dioxide
can cause damage to the human respiratory tract and increase a person's
vulnerability to, and the severity of, respiratory infections and asthma. Long-term
exposure to high levels of nitrogen dioxide can cause chronic lung disease. It may
also affect the senses, for example, by reducing a person's ability to smell an odor.

High levels of nitrogen dioxide are also harmful to vegetation—damaging foliage,

decreasing growth or reducing crop yields. Nitrogen dioxide can fade and discolor
furnishings and fabrics, reduce 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
 3. NEW PEOPOSED DESIGN SHOOTING VALVE FOR AMINE

3.1 PROPOSED DESIGN

3.2 CONSTRUCTION AND WORKING PRINCIPLE OF

APPARATUS

3.2.1 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

SET UP FOR AMINE GASING SYSTEMS

PRINCIPLE AND WORKING OF THE EACH APPARATUS

AMINE LIQUID STORAGE TANK

 A. AMINE LEVEL INDICATOR

Level Gauge is used for fluid level measurement in

several industries. The Float which is of course the
most important element of the instrument. In fact, its
structural design, volume displacement, weight, and
buoyancy force are all taken into careful consideration
when a float is specified for a particular application.
Often A typical Float & Board type Level Gauge is consist of a Float, dust proof Pulley
Housing, Pointer cradle with nylon and 150 mm width screen printed Aluminum Scale.
This instrument is an absolutely reliable and accurate system for liquid level
measurement in tall overhead tanks.

WORKING PRINCIPLE

This type of Float & Board type Level Gauge basically works on the principle of
buoyancy. The float is well connected to the counter weight along with a pointer
through flexible wire ropes. The pointer slides along the guide against a graduated scale
to indicate corresponding levels inside the tank.

APPLICATION
Most often, the Float & Board type Level Gauge finds its application in underground
and over head storage tanks. They are also used in storage tanks of petroleum products,
like furnace oil, diesel, and lube oil and so on. Also, it is used in storage of vegetable
oils, molasses, silicates, glucose and so on. In short, the Float & Board type Level
Indicator is most widely used in all non hazardous and non pressurized tanks. For Tank
height more than 10 meter we provide Anchor Plated with Anchor Housing for
Installing the Anchor Rope.
“KABIR” also offers Vapor Seal Type Float & Board type Level Gauge which is
generally used for tanks having corrosive fumes / vapors OR N2 [Nitrogen] Purging
tanks. In this level gauge the float is connected to a magnetized counter weight moving
in a sealed S.S. OR PVC pipe & which drives a follower magnetized bi - color capsule
inside a glass tube to indicate liquid level. Float Inside the tank raises and dials with the
level of fluid this makes the pointer mobe one the scale indicating level inside the tank.
In this level gauge, when tank is full the pointer is at bottom position on board and
when tank is empty, the pointer will be at top position. Float & Board Type Level
Indicator. A large self centered float follows the liquid level in this gauge. A rope fitted
with a float moves over a pair of dust free pulleys. Level is indicated by a pointer which
moves on a 150 mm width aluminums powder coated scale mainly used for storage
tanks of Oil, Fire / DM water Alkalis, Acids furnace Oils, Lube Oil, Vegetable Oil,
Molasses, Glucose etc. Vapors seals (Magnetic) for special applications like HCl,N2
purged tank, diluted alkalis, dilute HNO3,NH3 Methanol, Banzene, Toluene, IPA etc.
In vapor seal there is no sealing liquids so we get absolute vapor tightness.

HIGH AND LOW PRESSURE COMPRESSED AIR SYSTEMS

 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.

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.[1]
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.

AMINE LIQUID FEEDING SYSTEMS VOLUMETRIC BASED WITH PNUMATIC

SOLENOID VALVE

HEATING CHAMBER WITH TEMPERATURE CONTROLLER

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.

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. 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.
Typical applications in the nuclear industry are feed water control systems, dump lines,
make-up water, miscellaneous process systems, N2 systems, and monitoring and
sampling systems. In aircraft and aerospace, check valves are used where high
vibration, large temperature extremes, and corrosive fluids are present. For example,
spacecraft and launch vehicle propulsion propellant control for reaction control systems
(RCS) and Attitude Control Systems (ACS) and aircraft hydraulic systems.

The injectors in a fuel injection system are check valves with a high opening pressure
(5–8 bar). Check valves are also often used when multiple gases are mixed into one gas
stream. A check valve is installed on each of the individual gas streams to prevent
mixing of the gases in the original source. For example, if a fuel and an oxidizer are to
be mixed, then check valves will normally be used on both the fuel and oxidizer sources
to ensure that the original gas cylinders remain pure and therefore nonflammable.

In 2010, NASA's Jet Propulsion Laboratory slightly modified a simple check valve
design with the intention to store liquid samples indicative to life on Mars in
separate reservoirs of the device without fear of cross contamination.
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.
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.
 The solenoid valve has an enclosed chamber inside and ventilated holes in different
positions. Every hole is connected with different oil pipes. The chamber has a piston in
the middle. The two sides are two pieces of electromagnets. The electrifying magnetic
coil will attract the valve body to its side, so that different oil outlets will be opened or
closed through controlling the movement of the valve body. However, the oil inlet is
constantly open. The hydraulic oil will enter into different draw-off pipes. The oil
pressure will be used to drive the piston of the oil cylinder, which will drive the piston
rod and then the mechanical device. In this way, through controlling the current of the
solenoid valve, the mechanical movement will be controlled. Furthermore, let's briefly
learn about the working principle of two main types of solenoid valve.

1. Direct-acting solenoid valve

 Principle of Working

When the power is on, the solenoid

coil generates the electromagnetic
force to lift the closure member from
the valve seat to open the valve.
When the power is cut off, the
electromagnetic force disappears and
the spring presses the closure
member on the valve seat to close the
valve.

Characteristics

it can work normally in the vacuum, negative pressure and zero pressure. However, the
diameter normally doesn’t exceed 25mm.

2. Pilot-operated solenoid valve

 Principle of Working

When the power is on, the electromagnetic force opens the pilot hole and the pressure
of the upper chamber decreases rapidly, forming a pressure difference which is low in
the upside and high in the bottom around the closure element. The fluid pressure
promotes the closure element to move upwards to open the valve. When the power is
off, the spring force closes the pilot hole. The pressure through the bypass port rapidly
forms a pressure difference which is high in the upside and low in the bottom around
the closure element. The fluid pressure drives the closure element to move downwards
and close the valve.
Characteristics
the fluid pressure scope has a relatively high upper limit. It can be installed randomly,
with the fluid pressure difference condition being satisfied.

HEATING COIL FIN TYPES

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.
 4.4 SPECIFICATION

Sr. PART NAME SPECIFICATION

No.

1. PNUMATIC SOLENOID VALVE

2. HEATING COIL FIN TYPE 750Watt. 3Coil

3. NON RETURN VALVE

GRAVITY TYPE HORIZONTAL,
VERTICAL
SPRING TYPE

4. AMINE LEVEL INDICATOR

GLASS TUBE

5. FLOW REGULATOR VALVE

FOR HIGH AND LOW PRESSURE

4. BENEFITS OF NEWLY DESIGN SYSTEM

REDUCE AMINE GAS SPREADING IN ATMOSPHERE :-Pleasant of Amine is totally

Decrease due to addition of the new Pneumatic solenoid valve to provide the exact amount of
the Amine to the mixing chamber

INCREASE STABILITY OF THE AMINE IN STORAGE CHAMBER:In new system we add

a new air relief valve so that’s affected the excess air is removed from the storage chamber and
that effect stability of Amine

MULTI PRESSURES SYSTEM :In new system there are two Pressure systems available such
as High Pressure Line i.e. 5Bar to 6 bar and Low Pressure Line i.e.2 to 5 Bar. With the help of
this two system we can manage the core shooting process with linear manner for reduce the
unfilled problem.

BALANCED AND CONTROLED HEATING TEMPRATURE

In new system there is Heater provided with 3 series coil which can help to balance the
temperature of heating of the Air and that’s affect increase the quality of the core.

3.2 Design analysis and fabrication of machine structure

Table no. xx machine frame structure details
Structure with c channel 100mm x 50mm Structure with rectangular M.S. pipe
M.S. material 5 mm taper thickness 3.5 mm thick x 50mm x 100mm

weight
length

3.3 design of heating chamber with illustrating diagram

Chapter 4
4.1 design of heating chamber, input parameters
4.2 analysis and update factor of core box for efficiency production.
CFX Analysis of Stream Line Flow of Core Introduction to CFX Analysis

Study of fluid flow has been around for millennium, dating back to ancient Greece, but
their understanding did not go beyond what they needed to know to run aqueducts and
other water works. Da Vinci further pursued the topic during the renaissance observing
waves and free jets. Even Newton studied fluids. The topic did not mature until people
like Bernaulli and Euler investigated it and developed equations that were named after
them. The Eulerequations were further modified by Claude Marie Henery Navier and
George Gabriel Stokes to create Navier-Stokes equation. These men laid the
groundwork that would be the foundation of computational fluid dynamics.
Computational fluid dynamics is a term used to describe a way of modeling fluids using
alogorithms and numerical methods. Currently they are solved utilizing computers but
early methods were completed manually without the aid of computers. Computational
fluid dynamics are a powerful tool to model fluids ,but even with the most state of art
supercomputers and technological advances they are only an approximation of what
would occur in reality.
It is unclear exactly when computational fluid dynamics came into being. Lewis
FryRichardson attempted to predict the weather by creating a grid in physical space and
usingBjerkne’ “primitive differential equation”. His method involved a stadium of
64,000 people
Each using a mechanical calculator to solve part of the flow equation. It ended in
failure.In 1933 A. Thom was able to numerically compute flow past a cylinder. Another
mechanicalsolution was made by K. Kawaguti which took 20 hours a week over 18
months. NASA’stheoretical division also made contributions during 1960, but it wasn’t
until the 1980s whencommercial methods for computational fluid dynamics became
available.Fluid flow is classified as external and internal , depending on whether the
fluid is forced toflow over a surface or, in a conduit. Fluid flow in circular and non-
circular pipes iscommonly encountered in practice. The hot and cold water that we use
in our homes ispumped through pipe. Water in a city is distributed by extensive piping
network. Oil andnatural gas are transported hundreds of miles by large pipelines. Blood
is carried throught ourbodies by arteries and veins. The cooling water in an engine is
transported by hoses to thepipes in radiator where it is cooled as it flows.
Thermal energy in a hydronic space heating system is transferred to the circulating
water inthe boiler and then it is transported to the desired location through pipes.So, it
can be seen that many of the industrial processes have to deal with flow through pipe.
Ifanalysis and simulation of flow through pipe is done well than many of the industrial
problems can be understood and solved using the results obtained.

COMPUTATIONAL FLUID DYNAMICS AND FLUENT:

Computational fluid dynamics essentially mean computational transport phenomenon
which involves fluid dynamics, heat and mass transfer or any phenomenon involving
transportphenomenon.CFX is about “numerical simulation of governing equations for
sometransportPhenomenon. Computational fluid is applied in many fields of science
likeaerospace,biomedical,automobile, chemical industry,electronics,marine
engineering,materialprocessing,micro fluids, turbo machines etc.Fluent is a CFX code
used for flow modeling applications. Fluent needs some input data and domain drawn
from various software like GAMBIT, CATIA, PRO-E and other design software. Now
fluent can analyse the givendomain with boundary conditions and solve the governing
equations for the flow giving the
different flow parameters. Steps for analysis in the fluent are:
A) Pre-processing: It involves building a model or importing one from a CAD
package, applying.
B) Calculation: Once the numerical model is prepared fluent performs the necessary
calculations and produces the desire results.
C) Post-processing: it involves organization and interpolation of the data and images.
It can handle:
 Transient and steady flow
 Laminar and turbulent flow
 Newtonian and non-Newtonian fluid
 Single and multiphase flow
 Chemical reactions including combustion
 Flows through porous media
 Heat transfer
 Flow induced vibration
 Heating chamber ANALYSIS FOR AMONIA FLOW IN ANSYS

o MODELLING OF HEATING CHAMBER FOR AIR FLOW

5.2 PRESUURE ANALYSIS

5.2 STREAM VELOCUTY ANALYSIS

 5.3 COUNTOR PRESSURE ANALYSIS

5.2 Design & Analysis Of Amine Flow In Core Box

In MIDC Kolhapur, Kaneri Industry, During the Core Shooting Process Lots of
Problem occurs in the Break Drum Core before amine Gas system change. After
change the process we analysis the Break Drum Core amine gas flow in Ansys
CFX.

In the Above Fig we can see that the different layer of core and actual Break Drum
which can Design in Siemens NX9 Modeling.

Break Drum
Model

Core Box
Halfs
In this Design there is Model of Break Drum and two halves of the core box shown
these two halves’ are used to make core in NX9 are show in bellow

5.3 ANALYSIS OF CORE IN ANSYS

After complete the model import in Ansys and open in design modular and prepare
the volumetric model for analysis of pressure and velocity flow through it.

Fig. xx Wire Frame Design of Core in cad software (eg. Ugnx)

Fig. xx Volumetric Model of Core in Ansys CFX

After the volumetric model extract next step is meshing the model in Mesh section. The
meshing is shown in bellow.

After Complete meshing apply boundary condition to the overall the model
Fig. xx Meshing Core Model in Ansys CFX

5.4 RESULT ANALYSIS

After apply all the boundary conditions we start the solution

Fig. xx Boundary Condition of Core Ansys

Fig. xx Solution Analysis in Ansys CFX

Run the solution for 20 iteration and graph of iteration show in bellow.

After the complete solution the velocity counter plot as shown in below

Fig. xx iterational analysis after run solution in Ansys

Fig. xxCFX Post analysis of Velocity Counter of amine gas

4.3 design and development of amine dosing systems

Chapter 5
Result of parameters
5.1 machine structure result and comparison
5.2 heating chamber result and comparison

chapter 6
Conclusion
Define criteria for machine parameter according core category.
Elimination of hazards factor control method and elimination of its source.
Achieve core production rate with core hardness and surface finish
Cost cutting method for development of cold box core making process

Chapter 7
A. References

[1] Prof. Amarjeet R. et al. “A Review on Issues Related to Manual Core Making Process in
Foundry Industry” 2016, International Journal for Scientific Research & Development,
Vol. 3, Issue 11,and ISSN (online): 2321-0613, Pages 355-357.
[2] J. Danko et al. “Assessment of core sands suitability for filling the core box and for
compaction –by blowing methods” 2009, Archives of Foundry Engineering, ISSN (1897-
3310), Volume 9, Issue 1/2009, Pages 37-40.
[3] A. Fedoryszyn et al. “Characteristic of Core Manufacturing Process with Use of Sand,
Bonded by Ecological Friendly Nonorganic Binders” 2013, Archives of Foundry
Engineering,ISSN (2299-2944), Volume 13, Issue 3/2013 Pages 19 – 24.
[4] M. Asłanowicz et al. “Conceptual Design of a Core Making System” 2013, Archives of
Foundry Engineering, ISSN (1897-3310), Volume 13, Special Issue 1/2013, Pages 13–
16.
[5] Mosim Attar et al. “Design, Development & Testing of Core Shooter analysis” March
2015, International Journal of Advance Foundation And Research In Science &
Engineering Volume 1, Impact Factor: 1.036, Science Central Value: 26.54.
[6] R. Dańko et al. “Core Blowing Process - Assessment of Core Sands Properties and
Preliminary Model Testing” 2014, Archives of Foundry Engineering, ISSN (1897-3310),
 Volume 14, Issue 1/2014, and Pages 25 – 28.
[7] J. Dańko et al. “Effective cross-section area of a shooting valve in core shooting
machines” 2010,Archives of Foundry Engineering, ISSN (1897-3310) ,Volume 10 ,Issue
Special1/2010 ,Pages243-246 .
[8] A. Fedoryszyn, et al. “Examinations of Parameters influencing the outflow of two-phase
air-sand stream from machine chamber and core box filling in shooting process” 2013,
Archives of metallurgy and materials, Volume 58, Issue 3, and DOI: 10.2478/amm-
2013-0097.
[9] R. Danko, et al. “Parameters of the Two-Phase Sand-Air Stream Blowing
process”2012,Archives of Foundry Engineering, ISSN (2299-2944), Volume 12,
Issue4/2012, Pages25 – 30.
[10] M. Schneider et al. “Simulation of the entire core production process” 2012,American
Foundry Society.
[11] Danko, J. Zych, et al. “Diagnostic Methods of Technological Properties and Casting
cores quality”2009,Archives of Metallurgy and Materials, Volume 54, Issue2.