KLS Gogte Institute of Technology, Belagavi

Department of Mechanical Engineering

Metal Casting and Welding Process 18ME45A
Open Book Assignment 1
Date of Visit:20/07/2022 Time of Visit:1.30pm

Name USN Roll No Signature

Ganesh Shivalli 2GI21ME417 318
Harish Kammar 2GI21ME422 323
Prajakt Patil 2GI21ME400 353
Abhishek Ambewadi 2GI21ME452 301

Industry Abhishek Alloys Pvt.Ltd.

Name
Industry Started in the year of 1993
Started year
CEO/MD Mr. M.N. Acharya and Mr. Mayur Acharya
name

Customers VOITS, BOSCH, MAN, Atlas copco, Polyhydro, Veljan.

Casting
materials
(SG,CI etc
with grade)
Department Pattern shop
Allotted
Supervisor
name
No. of People working in the Department: 32 No. of Shifts: 02
Raw materials used in that department: cast iron, Spheroidal Gray iron

Safety Precautions: Following are few safety precautions:

 Wear eye protection, gloves, spats (covering top of feet), and thick clothing 
 Sand Floor in pouring area shall be clear of all objects not involved in pouring.
 Metal added to heat must be free of moisture and impurities.
 Move Slowly while removing crucible from furnace and moving to mold.
 Do not look into exhaust during operation.
Productivity (No.of castings/cores/molten metal melted in a shift):22 Tones per day
and 13000 tones per year
 a)

Photo b)

List of
Equipment’s/  Generators
Machines  Compressors
  Annealing Furnaces
 Universal Testing machine of 40-ton cap.
 Microscopic testing equipment
 Hardness Testers.
 Tri Track Medium Frequency Furnace with 3-500kgs/pot.
 Core shooters.
 Shell shooting Machines.
 Resin Coating Sand Mixers.
 Shot blasting and Tumblasting machines.

Process Steps Involved in Casting Process:

There are five steps involved in the casting process:
 Pattern Forming
 Core Forming
 Mold Making
 Pouring Process and
 Solidification Process

Pattern Forming:
The First step of this process is to select the shape that we have to
cast. Then we have to make the dummy material of that equipment
that we have selected to cast. The dummy material is also called the
pattern. The dummy material can be made of wax, wood, metal,
plastic, etc.

Core Forming:
After making the pattern then comes the core making. The core is
made when the casting requires some internal features like a hole.
The core is made from the sand of higher purity. Now after making
the core comes the mold making.

Mold Making:
To make the mold we take a wooden box, and then place the pattern
in the wooden box. After that, we will put the drag above the wooden
box and fill the drag with the sand. We will fill the sand tightly in the
drag. After the sand sets, we will reserve the drag as the pattern
pointing upward. Now we will remove the pattern. As we remove the
pattern we can see the mold cavity has formed. Now we can create a
runner and a gate that regulate the flow of molten metal to the cavity

Pouring Process:
The first step of this method is to select the type of metal to be used
for the casting purpose. Then the selected metal is melted to remove
all the impurities and gases. While melting the treatment of the metal
is done like degassing, fluxing, etc.

Solidification Process:
This process depends upon the gating system and the temperature
gradients after pouring molten metal. Efforts always made to raise
the raiser or use the chills to get suitable temperature gradients.
 Casting should be designed in such a way so, that directional
solidification (from one end to another end) takes place to avoid
defects. Chills & Padding are useful for directional solidification.

Equipment name Specification

Hyjack hydraulic Model:HPPR-4510/REV 05
core making Capacity: 60 tones
machine Oil tank capacity: 200 lit
Max. working pressure should not exceed:200kg/cm.sq.
Motor:7.5KP/ 5.5KW
HCN- 5000- Mazak Maximum workpiece diameter 800 mm
corporation Maximum workpiece height 1,000 mm
X-axis travel (column right and left) 730 mm
Y-axis travel (spindle up and down) 730 mm
Z-axis travel (table back and forth) 800 mm
Spindle speed maximum 18,000 min-¹
Main motor (30 minute rating) 35.0 kW
Width 2,444 mm
Length 4,943 mm
Shell shooting Material Mild Steel
machine Air Flow Rate 15-20 Cfm
Frequency 50-60Hz
Power SourceElectric
Voltage 380 V
Usage Industrial
Universal Testing Material : Mild Steel
machine of 40-ton Model Name/Number: ELSHADDAI
cap Usage/Application : Laboratory
Type Of Testing Machines Powder: Dynamometer
Display Type : Digital
Load Capacity : 400 TONN

Concluding Remarks: