INTERNSHIP AT GLOBAL EXPORTECH LLP

AN INTERNSHIP REPORT

Submitted by

BHOI HARDIKKUMAR N.
Enrolment no – 210640119516

in partial fulfilment for the award of the degree of

BACHELOR OF ENGINEERING
in

MECHANICAL ENGINEERING

K J Institute of Engineering & Technology, Savli -Vadodara

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 ACKNOWLEDGMENT

This is the place to admit that while there appears only author on the cover, this work just as
any other, is a product of the interaction with and support during our thesis work, among them,
first I express my graduate to my guides Mr. Bhavin Pandya & Mr. Prakash Patel for their
affection throughout guidance, advice and encouragement. Thanks to all my family members
for their affection, care and encouragement. Special thanks to my college for giving me
invaluable knowledge. Above all I am thankful to almighty God for everything.

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ABSTRACT
Industrial training plays a vital role in the development of future engineers. It bridges the gap
between the theoretical and practical aspects of the study. I was fortunate enough to get an
opportunity to get industrial training at GLOBAL EXPORTECH LLP., RANIA, Vadodara. The
experience that I gained here was very fascinating and I believe it would be very useful in my
coming life as an engineer. I was very excited and interested to visit the sand casting process.
And I have learned the casting process. Sand casting is a Mold based net shape manufacturing
process in which metal parts are melded by pouring molten metal into a cavity. The Mold cavity
is created by withdrawing a pattern from sand that has been packed around it.

During my training I realized to be a successful mechanical engineer, one needs to have sound
theoretical knowledge as well as should possess sound practical knowledge to apply the
theoretical knowledge. Thus, I hope by doing this Industrial training, it would serve as a
stepping stone for me in future and would help me get myself ready for this field.

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CONTENTS
Chapter 1: About Company ………………………………………………………… 1

Chapter 2: Foundry …………………………………………………………………. 5

Chapter 3: Surface Finishing Process ………………………………………………. 13

Chapter 4: Inspection Area …………………………………………………………. 16

Chapter 5: Work done by me during an internship …………………………………. 20

Chapter 6: Conclusion ……………………………………………………………… 21

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LIST OF FIGURES

Figure 1: Global Exportech LLP ………………………………………………………... 1

Figure 2: Sand plant …………………………………………………………………….. 2
Figure 3: Pattern shop …………………………………………………………………… 3
Figure 4: Core making area ……………………………………………………………... 4
Figure 5: Furnace ………………………………………………………………………... 5
Figure 6: Single plant pattern …………………………………………………………… 7
Figure 7: Two piece pattern …………………………………………………………….. 8
Figure 8: Gated pattern …………………………………………………………………. 8
Figure 9: Cope and drag pattern ……………………………………………………….. 9
Figure 10: Modeling …………………………………………………………………… 10
Figure 11: Pouring ………………………………………………………………………11
Figure 12: Shakeout ……………………………………………………………………. 12
Figure 13: Accumulator …………………………………………………………………12
Figure 14: Shot blasting machine ……………………………………………………….13
Figure 15: Drilling machine ……………………………………………………………. 13
Figure 16: Welding machine …………………………………………………………… 14
Figure 17: Vernier machine ……………………………………………………………. 14
Figure 18: CNC machine ………………………………………………………………. 15
Figure 19: Micrometre …………………………………………………………………. 17
Figure 20: Height gauge ……………………………………………………………….. 18

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CHAPTER – 1
ABOUT COMPANY

1. INTRODUCTION
 Fig 1. Global Exportech LLP

GLOBAL EXPORTECH LLP is an OEM supplier engaged in manufacturing and exports of

Quality Castings The company distinguishes itself by its high-level performances in the
precision iron casting industry because of teamwork, meticulous quality control, the capacity
of production, the skills of technicians and specialized engineers and also state of the art
equipment.

The company specializes in Wheels, cover plates, bowls, volutes, horns. The company seeks to
identify, develop, and more importantly, apply new and improved technologies in order to
produce the evolving specifications of our clients in India and abroad.
It has good setup foundry facilities like fast loop and hand moulding, Induction furnace, with
capacity (1ton &1.5ton).
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• PLANTS

I. SAND PLANT
 Fig 2. sand plat
In the sand plant, sand casting is prepared using silica sand, clay, and water additives (like coal
powder). In sand, a suitable bonding agent (usually clay) is mixed or occurs with the sand. The
mixture is moistened, typically with water, but sometimes with other substances, to develop
the strength and plasticity of the clay and to make the aggregate suitable for molding. The sand
is typically contained in a system of frames or mold boxes known as a flask. The mold cavities
and gate system are created by compacting the sand around models called patterns, by carving
directly into the sand. The molding sand after it is prepared should be properly tested to see
that required properties are achieved. Tests are conducted on a sample of the standard sand.
The molding sand should be prepared exactly as it is done in the shop on the standard equipment
and then carefully enclosed in a container to safeguard its moisture content.

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II. PATTERN SHOP
A pattern is a full-size model of the part you are trying to cast; patterns can be made from
various materials such as mahogany, metal, plastic or Styrofoam. It is very important to have
suitable patterns, for the quality of the casting is influenced by the quality of the pattern. The
engineers of the pattern shop work closely with the foundry to ensure that the proper patterns
are built and maintained in order to meet their customers’ requirements …

Fig 3. Pattern shop

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III. CORE MAKING AREA :-
 Fig 4. Core making

core is a device used in casting and molding processes to produce internal cavities. The core is
normally a disposable item that is destroyed to get it out of the piece. They are most commonly
used in sand casting. Materials required to make cores are Core sand, Bentonite clay, Resin
oilA . Usually sand-molded, cores are inserted into the casting box after removal of the pattern.
Whenever possible, designs are made that avoid the use of cores, due to the additional set-up
time and thus greater cost. After casting, the cores are broken up by rods or shot and removed
from the casting.

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CHAPTER -2

• FOUNDRY
 1. INTRODUCTION

A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them
into a liquid, pouring the metal into a mold, and removing the mold material or casting after
the metal has solidified as it cools. The most common metals processed are aluminum and cast
iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used
to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.

• FURNACE:-

Fig 5. Furnace

An Induction furnace is a furnace that heats charged material by means of an electric arc.
Industrial arc furnaces range in size from small units of approximately one-ton capacity (used
in foundries for producing cast iron products) TEMPERATURE RANGE:- Induction furnaces
used in research laboratories and by dentists may have a capacity of only a few dozen grams.
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Induction furnace temperatures can be up to 1,800 °C (3,272 °F), while laboratory units can
exceed 3,000 °C (5,432 °F). Arc furnaces differ from induction furnaces in that the charge
material is directly exposed to an electric arc, and the current in the furnace terminals passes
through the charged material.

2. PROCESS
In metalworking, casting involves pouring liquid metal into a mold, which contains a hollow
cavity of the desired shape and then allowing it to cool and solidify. The solidified part is also
known as a casting, which is ejected or broken out of the mold to complete the process. Casting
is most often used for making complex shapes that would be difficult or uneconomical to make
by other methods.

I. PATTERN MAKING
In casting, a pattern is a replica of the object to be cast, used to prepare the cavity into which
molten material will be poured during the casting process. Patterns used in sand casting may
be made of wood, metal, plastics or other materials. Patterns are made to exacting standards of
construction, so that they can last for a reasonable length of time, according to the quality grade
of the pattern being built, and so that they will repeatably provide a dimensionally acceptable
casting.

Material Used:
Typically, materials used for pattern making are wood, metal or plastics. Wax and Plaster of
Paris are also used, but only for specialized applications. Mahogany is the most commonly
used material for patterns, primarily because it is soft, light, and easy to work, but also once
properly cured it is about as stable as any wood available, not subject to warping or curling.
Once the pattern is built the foundry does not want it changing shape. The downside is that it
wears out fast, and is prone to moisture attack. Metal patterns are more long-lasting and do not
succumb to moisture, but they are heavier and difficult to repair once damaged.

Design:
The patternmaker or foundry engineer decides where the sprues, gating systems, and risers are
placed with respect to the pattern. Where a hole is desired in a casting, a core may be used
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which defines a volume or location in a casting where metal will not flow into. Sometimes
chills may be placed on a pattern surface prior to molding, which is then formed into the sand
mold. Chills are heat sinks which enable localized rapid cooling. The rapid cooling may be
desired to refine the grain structure or determine the freezing sequence of the molten metal
which is poured into the mold. Because they are at a much cooler temperature, and often a
different metal than what is being poured, they do not attach to the casting when the casting
cools. The chills can then be reclaimed and reused. The design of the feeding and gating system
is usually referred to as methoding or methods design.
Types of Pattern:

i. Single Piece Pattern: -

These are inexpensive and the simplest type of pattern. As the name indicates, they are made
of a single piece. This type of pattern used in the case where the job is very simple and does
not create any withdrawal problems. It is also used for applications in very small-scale
production or in prototype development.

Fig 6. Single plat pattern

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ii. Split Pattern or Two Piece Pattern: -
This is the most widely used type of pattern for intricate castings. When the contour of casting
makes its withdrawal from the mold difficult, or when the depth of the casting is too high, then
the pattern is split into two parts so that one part is in the drag and the other in the cope.
 Fig 7.two piece pattern

iii. Gated Pattern: -

This is an improvement over the simple pattern where the gating and runner system is integral
to the pattern. This would eliminate the hand cutting off the runner and gates and help in
improving the productivity of the molder.

Fig 8. Gated pattern

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iv. Cope and Drag Pattern: -
These are similar to split patterns. In addition to splitting the pattern, the cope and drag halves
of the pattern along with the gating and risering system are attached separately to the metal or
wooden plate along with the alignment pins. They are called the cope and drag pattern. These
types of patterns are used for castings which are heavy and inconvenient for handling as also
for continuous production.
 Fig 9. Cope and drag pattern

II. MOLDING
Sand casting, also known as sand molded casting, is a metal casting process characterized by
using sand as the mold material. In addition to the sand, a suitable bonding agent (usually clay)
is mixed or occurs with the sand. The mixture is moistened, typically with water, but sometimes
with other substances, to develop strength and plasticity of the clay and to make the aggregate
suitable for molding. The sand is typically contained in a system of frames or mold boxes
known as a flask. The mold cavities and gate system are created by compacting the sand around
models, or patterns, or carved directly into the sand. Sand casting is one of the most popular
and simplest types of casting and has been used for centuries.

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 Fig 10. Molding

Sand casting allows for smaller batches than permanent mold casting and at a very reasonable
cost. Not only does this method allow manufacturers to create products at a low cost, but there
are other benefits to sand casting, such as very small-size operations. From castings that fit in
the palm of your hand to train beds (one casting can create the entire bed for one rail car), it
can all be done with sand casting. Sand casting also allows most metals to be cast depending
on the type of sand used for the molds.

Basic Process:-
There are six steps in this process:
i. Place a pattern in the sand to create a mold.
ii. Incorporate the pattern and sand in a gating system. iii. Remove the
pattern.
iv. Fill the mold cavity with molten metal
v. Allow the metal to cool.
vi. Breakaway the sand mold and remove the casting

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Mold Material:
There are four main components for making a sand casting mold: base sand, a binder, additives,
and a parting compound
i. Types of base sands
- Facing sand(silica sand)
- Back sand (reclaim sand)

III. MELTING
Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and alloying
elements are used to charge the furnace. Virgin material refers to commercially pure forms of
the primary metal used to form a particular alloy. The process includes melting the charge,
refining the melt, adjusting the melt chemistry and tapping.

• POURING

Fig 11.poring

In a foundry, molten metal is poured into molds. Pouring can be accomplished with gravity, or
it may be assisted with a vacuum or pressurized gas. Many modern foundries use robots or
automatic pouring machines to pour molten metal. Traditionally, molds were poured by hand
using ladles.
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• SHAKEOUT
The solidified metal component is then removed from its
mold. Where the mold is sand based, this can be done by
shaking or tumbling. This frees the casting from the sand,
which is still attached to the metal runners and gates which are
the channels through which the molten metal traveled to reach
the component itself.

Fig 12.shakeout

• ACCUMULATOR:-

A hydraulic accumulator is a pressure

storage reservoir in which an incompressible
hydraulic fluid is held under pressure that is
applied by an external source of mechanical
energy.

Fig 13 accumulator

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CHAPTER - 3
 • SURFACE CLEANING (MACHINING PROCESSES)

SHOT BLASTING:-

Fig 14. Shot blasting machine

A Shot blasting machine is an enclosed equipment designed for abrasive blasting for cleaning
and preparing metal, stone and other surfaces. It is a machine for shot peening, cleaning metal
parts such as forging, casting parts, steel surfaces, heavy metal structures, rusted metal parts
etc. Shot blasting machine uses blast media on the metal parts in an enclosed chamber to
remove surface rust, welding slag and descaling, making it uniform, shiny and improving
coating quality of anti rust chemicals.

• GRINDER MACHINE:-
Grinding is a unit operation that reduces solid matter into smaller particles. Grinding is a
processing method that uses abrasives to remove material. The process of removing material
with abrasives is one of the earliest production techniques used by humans.Grinding process is
a micro-processing method. Grinding uses a grinding tools and abrasive (a free abrasive) to
generate relative movement between the processed surface of the workpiece and the grinding
tool, and apply pressure to remove it from the workpiece. Tiny surface raised layer to reduce
surface roughness and improve dimensional accuracy, geometric accuracy, etc.
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Grinding process can be used in various metal and non-metal materials. The processed surface
shapes include flat surfaces, inner and outer cylindrical and conical surfaces, convex and
concave spherical surfaces, threads, tooth surfaces, and other profiles. In-mold manufacturing,
especially precision die-casting molds, plastic molds, and automobile panel molds that require
high product appearance quality are widely used.

• DRILLING PROCESSES:-
Drilling is a process of producing a cylindrical hole
using drill bit, in a solid material. It is a process in
which a drill bit is uses to cut a hole of a circular
crosssection in a solid material. The drilling is a single
purpose machine for the production of holes.
Drilling process is the best method of producing holes.
The drill bit is rotary cutting tool, a cylindrical bar with
helical flutes and radial cutting edges at one end.
Fig 15. Drilling process

• WELDING PROCESS:-

Fig 16 welding process

Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using
high heat to melt the parts together and allowing them to cool, causing fusion. Welding is
distinct from lower temperature techniques such as brazing and soldering, which do not melt
the base metal (parent metal).Many different energy sources can be used for welding, including
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a gas flame (chemical), an electric arc (electrical), a laser, an electron beam, friction, and
ultrasound.
 • CNC MACHINE

Fig 17. CNC machine

Numerical control is the automated control of machining tools by means of a computer. A CNC
machine processes a piece of material to meet specifications by following coded programmed
instructions and without a manual operator directly controlling the machining operation.

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CHAPTER - 4
QUALITY CONTROL DEPARTMENT

• INSPECTION AREA
Every step in the process of metal casting, from patternmaking to heat treating, is done carefully
to avoid problems with the soundness, surface finish, mechanical properties, and final
dimensions of the finished casting. Yet even castings made with diligence should undergo
inspection for quality control. Small problems can arise unexpectedly, and many castings have
mechanical requirements that may be undermined by a hidden defect. Castings inspection
allows foundry and clients to feel confident they have a quality casting. Casting inspection
methods are in place to ensure any hidden defects are identified during the manufacturing
process. Some common casting defects include surface defects, inclusion defects, and cooling
defects.

➔ Visual Inspection
This method uses the human eye to identify surface defects, cracks, gas evolution, slag or sand
inclusions, misruns, cold shuts, and molding flaws.

➔ Dimensional Inspection
This type of castings inspection is undertaken to ensure a part meets dimensional
requirements/tolerances. This can be done manually or with a coordinate measuring machine
(CMM) that uses probes to get very precise measurements.

➔ Ultrasonic Testing (UT)

This test finds defects by using high frequency acoustic energy transmitted into a casting, in a
technology like the ultrasounds used by medical technicians. Sound waves travel through a
casting until they hit the opposite surface or an interface or defect. Any barrier reflects the
sound waves, which bounce back and are recorded for an analyst to look at. The pattern of the
energy deflection can indicate the location and size of an internal defect. This non-destructive
test can also be used to examine wall thickness, and the nodule count of ductile iron. Extremely
small flaws can be found with UT at very large depths, allowing for a great deal of accuracy
and confidence. An experienced technician can even make estimates as to the nature of an alloy
by looking at the acoustic signature of an unknown metal.
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Ultrasonic testing requires knowledge and experience for an accurate interpretation of results.
The part must be cleaned of loose scale and paint, and must not be too irregular, small, or
thin. In most cases, a surface to be examine with ultrasound must be wet, and often water is
used: if the surface will rust, then an anti-freeze solution with rust inhibitors can be used
instead.
➔ VERNIER CALIPER
A vernier scale which is named after Pierre Vernier is
defined as a visual aid to take an accurate measurement
reading between two graduation markings on a linear
scale by using mechanical interpolation.
It is used to calculate the internal and external diameters
of hollow cylinders. It is also used for the measurement
of diameters of round objects with the help of the
measuring jaws. It is an extremely precise measuring
instrument. It is a device that is used to calculate very
accurate linear measurements. In simple words, it
measures the straight linear distance between two points.
Fig18. Vernier caliper It is a very useful tool to carry in the toolbox.A vernier caliper is also used
to measure the diameter of round and cylindrical objects, by positioning the jaws of the caliper
on either side of the circumference. Vernier caliper is a very useful tool to carry in the toolbox.

➔ MICROMETER

Fig 19. Micrometer

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Do you need a very precise measurement for any physical quantity? Well, micrometers can give
you the liberty to measure small parts and fittings. Also, you can use a micrometer symbol for
identifying the right unit.The use of micrometer measurement is very high among different
industries. It is helpful for the measurement of precise and accurate measurements. You can
avoid the potential dangers by the use of um measurement. All you need to have is a gauge.
This measurement can give you a fine output.

• HEIGHT GAUGE

Fig 20. Height gauge

A height gauge is a measuring device used for determining the height of objects, and for
marking of items to be worked on.

These measuring tools are used in metalworking or metrology to either set or measure vertical
distances; the pointer is sharpened to allow it to act as a scriber and assist in making out work
pieces. Devices similar in concept, with lower resolutions, are used in healthcare settings to
find the height of people, in which context they are called stadiometers Height gauges may also
be used to measure the height of an object by using the underside of the scriber as the datum.

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The datum may be permanently fixed or the height gauge may have provision to adjust the
scale, this is done by sliding the scale vertically along the body of the height gauge by turning
a fine feed screw at the top of the gauge; then with the scriber set to the same level as the base,
the scale can be matched to it. This adjustment allows different scribers or probes to be used,
as well as adjusting for any errors in a damaged or resharpened probe.

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 CHAPTER - 5 Work done by Me During an Internship

During my internship at GLOBAL EXPOTECH LLP, I learned how to put my knowledge and
skills into practice from designing the machine to the assembly of that machine, my knowledge
of designing softwares like solidworks & autocad was transformed into a series of practical
techniques and skills that I can now implement in real-life business scenarios.

During my internship, I learned how to communicate and build relationships with the people I
worked with. I learned how to introduce myself, talk about my interests, knowledge and skills
with entrepreneurs and business owners, as well as how to ask questions and gain a better
understanding of businesses not only in the co-working space, but also others in the market.

During my internship, I had a journal and took notes every day about new things I learned,
feedback I was given by my manager, strengths and weaknesses I noticed, and things I wanted
to research and learn more about. This helped me understand myself more and identify the
areas that I needed to improve in.

CHAPTER- 6
• CONCLUSION
As an undergraduate, I would like to say that this training program is an excellent opportunity
for me to get to the ground level and experience the things that I would have never gained
through going straight into a job. In this report, various works of the company are described.

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No. of plants, shops, and labs are there into which engineers do their research continuously to
improve the quality of the product so that the company gets benefits and ultimately is
influenced to them also. Various casting processes are described in the report like molding,
melting, pouring, shake out, fettling and machining.

These processes will give you a brief overview of how the casting product is formed, what
challenges come across during the processes and what action should be taken either to eliminate
or reduce the problem. The major problem of the foundry is the casting defects. Because casting
defects result in increased unit cost and lower morale of shop floor personnel.So defects need
to be diagnosed correctly for appropriate remedial measures. Various casting defects are also
described in this report like blowholes, porosity, cold shut, mis run, shrinkage, etc. and what
are the causes due to which these defects arise and there remedies also.Various testing is also
described in the report like hardness testing, metallurgical testing. Brinell Hardness Testing
Machine is used for the measurement of hardness of the material.

The microstructure is observed using a microscope and measurement is done by Metallurgical

Image Analysis Software. A measurement like nodularity, graphite flakes, pearlite, ferrite, etc.
Various metallurgical defects of grey and ductile cast iron are described also. This training
provides me to observe and practice how engineering is applicable in the real industry. I had a
taste of how the real atmosphere in the workplace, as well as a good relationship of mutual help
- help, and cooperation during my industrial training.

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• REFERENCE

1. https://en.wikipedia.org/wiki/Casting_defect
2. https://en.wikipedia.org/wiki/Foundry
3. http://ferro-casting-ductile.blogspot.com/2011/07/common-metallurgical-defects-
ingrey.html
4. http://www.themetalcasting.com/gating-design-analysis.html
5. https://www.reliance-foundry.com/blog/what-is-a-foundry#gref
6. https://en.wikipedia.org/wiki/Pattern_(casting)
7. https://en.wikipedia.org/wiki/Riser_(casting)
8. https://en.wikipedia.org/wiki/Visual_inspection
9. https://en.wikipedia.org/wiki/Sand_casting

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