WORK INSTRUCTION FOR ESTIMATION OF LIQUID METAL

REQUIREMENT FOR POURING OF STEEL CASTINGS

1. Calculate the following:
a) Metal required for the component with requisite machining allowance and grinding
allowances on as cast surfaces.
b) Metal required for Riser, pad and gating system.
c) Metal required for pattern/core box draft and anticrack ribs, additional fillet/radii
provided in technology.
d) Metal required for some special provisions, e.g., Tie bar, ribs to prevent deformation,
etc.

Add all the above requirements to estimate the requirement of liquid metal for pouring
the casting.

2. Calculate excess metal requirement:

a) For the castings like cylinder, flange, guide vanes, stay vanes, where weight
calculation is simple and accurate add only 5% for the first piece.
b) In case of 1st casting of complicated shapes or in cases where methoding and
pattern has undergone major revision/rectification add 10% extra over the figure
calculated as per point no. 1.

3. Get the metal requirement of pouring of the moulds as envisaged in point no. 2 from
shop QC, where load cell facility is available. Otherwise get the weighment slip of the
knocked out casting from shop planning.

4. For small and medium size castings (upto 10T despatch weight), add 2% extra over the
value obtained from point no. 3.
For large size castings (despatch weight between 10-20T), extra addition will be 5%.
For extra large size castings (despatch weight above 20T), extra addition will be 7%
only.

5. Revise the Technology drawing incorporating liquid metal requirement value based on
shop feedback (casting SL. No. Weight) to continue further pouring of the casting.

6. Revise the process sheet in accordance with point no. 5