Dawood College Of Engineering

and Technology, Karachi

Industrial Visit Report

Submitted By:
 Muhammad Ehsan (08-Dcet-314)
 Muhammad Idrees (08-Dcet-338)

 S. Shariq Hussain (08-Dcet-319)

 Fiaz Ahmad (08-Dcet-331)

 Rahmat Ali (08-Dcet-339)

Dept: Industrial Engineering & Management

Manufacturing Process
4th semester 2nd Year

Submitted To:
Sir. Ghulam Sarwar

Date: 28-10-2009
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 Visit to Bolan Casting
Main products which is prepared in the Bolan Casting, is various parts of tractor engine, car
engines, and some other things which a firm demands.

Various processes used to prepare these products are:

 Analyzing data
 Preparing product
 Finalizing the product (finishing of the product )
 Supplying the product

Analyzing data:
In the Bolan Casting, when they are demanded for a product. They goes through the various
steps in analyzing the data.

First they have to think about the quantity of the products. If they get high demand of a
product, then they prepare pattern of the product to work faster and get improve quality and
efficiency but if they gets a demand for less product, then they goes through the conventional
method of preparing the product.

Preparing product:
In preparing the product they go through long chain processes, which are checked at regular
basis to meet the high standards, quality, and reliability.

Pattern Making:
In pattern making they use modern technology of CAD/CAM. The use of these technologies
enable them to check there product even before preparing, by using various 3D technologies
of CAD/CAM and other simulation software’s, which is used permanently in the Bolan
Casting.

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The prepared pattern had runner, spurge, pins, risers, and in-gates. During casting all these
are very beneficial.

Hydraulic Chamber:
In this the conveyer was taking the pattern to the machine. The machine through sand on it,
after applying suitable coatings and layers of oils and other fluids. Then the pressure is
applied on it until sands gets the shape of the Pattern.

Sand Used:
The sand which is mostly used is as green sand and is the mixture of the following.

Green Sand = Silica + clay + Bentonite

Capula Furnace:
In the capula furnace molten metal is prepared (which is used for casting) by adding coal,
graphite iron, scrap iron, and carried to moulding box by means of portable furnace. After
castings, then it is cooled at room temperature.

Vibrating Chamber:
As the metal in the mould is cooled, then the mould is removed in the vibrating chamber,
where the solid metal comes out on the conveyer belt and the sand is felt down, which is
recycled again.

Finalizing the product (finishing of the product ):

The product is finalized through the following processes.

1. Product is cleaned by hitting steel balls.

2. Finished by grindings.

3. Painting of the product (if required).

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 Supplying the Product:
Finished product is supplied as per demanded.

Various testing facilities available in the Bolan Casting:

In Bolan Casting various tests are made for checking the product quality.

Some of the tests are following:

1. Permeability test

2. Hardness test

3. Effectiveness test

4. Chemical tests

5. Moisture test for Sand

6. And some other essential tests

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 Visit to Balochistan Wheels
Introduction:
This is the only rim making company in Pakistan. It prepares rims for various automobiles
companies.

Like: Hino Pak, Toyota, Suzuki, etc

The rim making process is categorized in two steps.

1. One is disk making process

2. Other is the rim making process

Disk Making Process:

The steps involved in the disk making process are:

1. The regular pieces of the metal are first cut into the required shape.

2. Then it is pressed in the hydraulic forming dies by applying pressure of few tons.

3. Then it is processed in the shearing dies, where the nut holes and other holes are
produced.

Rim Making Process:

1. Flat sheet of uniform thickness is cut in the required size with respect to the required
radius/diameter.

2. Then this flat piece of metal sheet is put in the rolling machine, which gives it circular
shape of the required radius by rolling it in the rollers.

3. The free ends are joined by means of electric welding.

4. The rough surface of the weld is grinded by the grinder to get finished surface.

5. Now the whole rim gets the circular shape, which is put in the rolling machine to gets
certain changes in the radius as per required.

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6. Then the disk is pushed in the rim by applying pressure.

7. Then the disk and rim is welded by means of arc welding.

8. The radius and roundness is checked by using certain gauges, and other sensing
machines.

9. Now there is an inspection of the rim, which consists of rim fatigue test, disk fatigue test,
hardness tests, and some other essential tests as required.

10. Then it is taken into the painting shop.

11. After painting the product is kept in the atmosphere at room temperature to settle down.

12. Then the product is taken into the packing area for packing.

13. The packed product is then supply into the market or other industry as per requirement.