Casting Process Report by Savan

Kautilya Inst. Of Tech. & Engg.
Jaipur
A Training Report
(Submitted for the partial fulfillment of
Bachelor of Technology in MECHANICAL ENGG.
Rajasthan Tech. Univ.-Kota)
Submitted By
GHADIYA SUGNESHKUMAR (B.Tech. VIIth semester)
Submitted To: Head of the Department:

Mr. Mukul Sharma Mr. K.K Khatri
Training Co-ordinator
2010-2011
Department of Mechanical Engineering
KAUTILYA INSTITUTE OF TECHNOLOGY AND ENGINEERING
Sitapura, Jaipur
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KAUTILYA INSTITUTE OF TECHNOLOGY AND ENGINEERING,

JAIPUR
A
REPORT ON
PRACTICAL TRAINING
TAKEN
AT
Shining Engineers & Founders Pvt. Ltd.

(In partial fulfillment of Award of Bachelor of Technology in
MECHANICAL ENGG. Rajasthan Tech. Univ.-Kota)
SUBMITTED TO: SUBMITTED BY:

Mr. Mukul Sharma Ghadiya Sugnesh G.
TRAINING CO-ORDINATOR, MECHANICAL ENGG.
(MECH. ENGG. DEPT.)
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To whom so ever It May Concern
This is certifying that the Practical Training Seminar Report entitled

“SHINING ENGINEERS & FOUNDERS PVT. LTD. RAJKOT,
GUJARAT” being submitted by Mr.Ghadiya Sugneshkumar G. (IVyr
B. Tech., VII Sem.) for the partial fulfilment of the requirement of the
Degree of Bachelor of Technology in Mechanical Engineering of
Kautilya Institute of Technology & Engineering & School of
Management, Jaipur is a record of the practical training taken by him.
(Internal Examiner) H.O.D (Mech.)

Mr. Mukul Sharma Mr. K.K Khatri
(External examiner)
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AKNOWLEDGEMENT
I express my deep sense of gratitude to Mr. SANJAY BHAI
(H.O.D, SHINING ENGINEERS & FOUNDERS PVT. LTD )
for giving me a golden opportunity to pursue
My industrial training at SHINING, Rajkot ( Gujarat )
I owe my heartiest thanks to my training guide Mr. Brijesh sir for
giving me the opportunity to learn & understand the
practical implementation of academic studies. He is always there in the
hours of need. Here I express my sincere thanks to all other Colleagues of
Engineering department who extend their help in the
Understanding of the duties and responsibilities of the Dept.
Here I express my sincere gratitude to Mr. Nittin Goyal sir (Training and
Placement Officer of K.I.T.E. jaipur ) for his active cooperation and sincere
Advice in choosing the right company to pursue my training. He is not only
my guide but also my mentor.
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CONTENTS
Page No.
1. Introduction of Company 1
1.1. Company Profile 1

1.2. History of Company 1
1.3. Organization Chart
2. Introduction about Casting 2
2.1. Definition 2
2.2. Type of Casting 3
2.2.1 Sand Casting
2.2.2 Die casting
2.2.3 Investment Casting
2.2.4 Centrifugal casting
2.2.5 Plaster-mould casting
2.2.6 Permanent-mold casting
2.2.7 Squeeze casting
2.3 Advantages & Disadvantages
3. Casting Terminology 13
3.1 Pattern 13
3.1.1 Pattern Material

3.1.2 Type of Pattern
3.1.2.1 Solid or single piece pattern.
3.1.2.2 Split pattern or two-piece pattern
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3.1.2.3 Cope and Drag Pattern

3.1.2.4 Match plate pattern
3.1.2.5 Gated Pattern
3.1.2.6 Skeleton Pattern
3.1.2.7 Pattern with Loose – Pieces
3.1.3 Pattern Allowances
3.1.3.1 Shrinkage allowance

3.1.3.2 Draft allowances
3.1.3.3 Machining allowance
3.1.3.4 Distortion allowance
3.1.3.5 Rapping Allowance
3.2 Core
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3.2.1 Types of Core
3.2.1.1 Green sand core

3.2.1.2 Dry sand core
3.2.2 Core Print

3.2.3 Core Box
3.3 Mould
3.3.1 Type of Mould
3.3.1.1 Permanent mould

3.3.1.2 Temporary mould
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3.3.2 Moulding Sand
3.3.2.1 Properties of Moulding Sand

3.3.2.2 Sand Testing
4. Melting Equipment
4.1 Cupola Furnace

4.2 Electric Furnace
5. Melting & Pouring
5.1 Gating System
5.1.1 Runner & Sprue

5.1.2 Riser
6. Cleaning & Finishing.
7. Casting Defects
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1.1 INTRODUCTION OF THE COMPANY:
M/s Shining Engineers & Founders Pvt. Ltd. are capable and equipped with all
kind of manufacturing facilities to produce high quality of products under one roof. The
production unit consist melting furnace with controlled environment, conventional &
non-conventional to be assured about the good quality of products.
Spanned across 34,000 square meter area and environment friendly foundry
setup along with the full fledge testing facilities like instance lab, chemical lab,
standard room for inspection is the infrastructure that we have for high-quality product
manufacturing as well as quality assurance.
This is the core of quality and process improvement as well as the

infrastructure that can stand in the most demanding situations. This is what have gained
us strong client base.
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 COMPANY PROFILE
1. Name of the company:

Shining Engineers & Founders Pvt. Ltd
2. Address:
Shining Engineers & Founders Pvt. Ltd.
At : - Shaper (Veraval),
Shaper GIDC,
Dist :- Rajkot
State :- Gujarat
3. Year of Establishment:
1968
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1.2 History and Development of Company
Founded in the year 1968, M/s Shining Engineers & Founders Pvt. Ltd. has its
strong hold on the Electric Motor Body and Cast Iron Castings. From its inception
company set its focus on producing high-quality cast iron casting parts.
Started with the production capacity of 100 MT/Month, company keeps capturing
the niche market while maintaining its strong focus on quality and process improvement.
With the efforts of the company promoters and their global team, company entered into
the global market in the year 1996 with its products in Electric Motor Components.
Today company is prominent supplier of electric motor housing and end-shield with a
range of 10 kg to 600 kg withthe1200MT/Month capacity.
Today company has shining share in export market of Electric Motor Housing and
End-Shield. Company started supply to leading OEM motor manufacturers like Siemens,
Demag Crains & Components.
With more responsible and committed approach towards quality and environment,
company validated, confirmed and certified the ISO 9001-2000 standards by RWTUV
Germany in the year 2003
To answer the ever growing requirements of customers, M/s Shining Engineers &
Founders Pvt. Ltd has tied up its activities with M/s D. N. Engineers, India, an ISO 9001-
2000 company. M/s D. N. Engineers aim to manufacture Motor Components and
Automobile parts. It supplies electric motor housing and its parts to OEM like ABB,
Bharat Bijlee, Siemens, Crompton Greaves and Eicher Motors Ltd.
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1.3 Organization Chart:
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2. Introduction about Casting
Casting is basically melting a solid material, heating to a special temperature, and

pouring the molten material into a cavity or mould, which is in proper shape. Casting has been
known by human being since the 4th century B.C.
Today it is nearly impossible to design anything that cannot be cast by means of one or
more of the available casting processes. However, as with other manufacturing processes, best
results and economy can be achieved if the designer understands the various casting processes
and adapts his designs so as to use the process most efficient.
2.1 Definition
In casting involves pouring a liquid metal into a mold, which contains a hollow cavity
of the desired shape, and then is allowed to 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
2.2 Type of Casting

2.2.1 Sand casting
2.2.2 Die casting
2.2.3 Investment casting
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2.2.1 Sand casting
Sand casting is a flexible, inexpensive

process. Sand is used as the mold material. The
sand grains, mixed with small amounts of other
materials to improve the mold ability and
cohesive strength, are packed around a pattern
that has the shape of the desired casting. Products
covering a wide range of sizes and detail can be
made by this method. A new mold must be made
for each casting, and gravity usually is employed
to cause the metal to flow into the mold. As
shown below in figure steps of sand casing
The process of sand casting is very old going back to the Bronze Age; the technique has
changed very little since. It involves making a suitable void in compacted sand which is then
filled with molten metal. This process is best suited to large casting where surface finish is not
important or which will be machined later. Thin sections are not really suitable as the molten
material starts to cool before the mould is completely filled, forming “cold shuts”.
The first stage in sand casting is to make a pattern in wood or metal of the shape to be cast. This
pattern is made slightly larger to allow for shrinkage of the hot metal as it cools down after
casting. Any part that requires machining after casting would have a machining allowance
incorporated in the pattern. The pattern maker is a very skilled craftsman because as well as
making the pattern he must have a complete understanding of the actual process of casting. In
making the pattern he decides the way the item will be cast. Depending on the shape of the item
the pattern could be in one or several pieces. If the pattern is split the separate parts are located
together with metal pins or dowels. In deciding which way to cast a particular item the pattern
maker would consider several factors such as, which way up to cast it. Molten metal is very
heavy and most of the impurities in the metal float. When the metal is cast the impurities get
carried around the mould with the metal as they have a tendency to float they are likely to be
deposited in one place, either trapped by a narrowing in the shape or floating to the top of the
casting.
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2.2.2 Die casting
Die castings are among the highest volume, mass-produced items manufactured by the
metalworking industry. They can be found in thousands of consumer, commercial and
industrial products. Die cast parts are important components of products ranging from
automotive to toys. Parts can be as simple as a trowel handle or a complex engine block.
A versatile process for producing engineered metal parts,

die casting calls for forcing molten metal under high
pressure into reusable steel moulds. These moulds, called
dies, can be designed to produce complex shapes with a
high degree of accuracy and repeatability. Parts can be
sharply defined, with smooth or textured surfaces, and are
suitable for a wide variety of attractive and serviceable
finishes.
Refinements are continuing in both the alloys used in die casting and the process itself,
expanding die casting applications into almost every known market. Today’s die casters can
produce castings in a variety of sizes, shapes and wall thicknesses that are lightweight, strong,
durable and dimensionally precise. The process has been well researched and systematically
quantified in terms of thermodynamics, heat transfer and fluid flow. A new range of machine
casting technologies such as squeeze casting and semi-solid metal casting (SSM) are able to
combine the near-net-shape benefits of traditional die casting with innovative approaches to
producing highly dense, heat-treatable parts.
The basic die casting process consists of injecting molten metal under high pressure into a steel
mould called a die. Die casting machines are typically rated in clamping tons equal to the
amount of pressure hey can exert on the die. Machine sizes range from 200 tons to 5,000 tons.
Regardless of their size, the only fundamental difference in die casting machines is the method
used to inject molten metal into a die.
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2.2.2 Investment Casting
Investment casting (known as lost-wax casting in art) is a process that has been
practiced for thousands of years, with the lost-wax process being one of the oldest known
metal forming techniques. From 5000 years ago, when beeswax formed the pattern, to
today’s high technology waxes, refractory materials and specialist alloys, the castings ensure
high-quality components are produced with the key benefits of accuracy, repeatability,
versatility and integrity.
Investment casting derives its name from the fact that the pattern is invested, or
surrounded, with a refractory material. The wax patterns require extreme care for they are not
strong enough to withstand forces encountered during the mold making. One advantage of
investment casting is that the wax can be reused.
The process is suitable for repeatable production of net shape components from a
variety of different metals and high performance alloys. Although generally used for small
castings, this process has been used to produce complete aircraft door frames, with steel
castings of up to 300 kg and aluminum castings of up to 30 kg. Compared to other casting
processes such as die casting or sand casting, it can be an expensive process, however the
components that can be produced using investment casting can incorporate intricate contours,
and in most cases the components are cast near net shape, so requiring little or no rework
once cast.
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Centrifugal casting consists of having sand, metal, or ceramic mold that is rotated at
high speeds. When the molten metal is poured into the mold it is thrown against the mold
wall, where it remains until it cools and solidifies. The process is being increasingly used for
such products as cast-iron pipes, cylinder liners, gun barrels, pressure vessels, brake drums
gears, and flywheels. The metals used include almost all castable alloys.
Because of the relatively fast cooling time, centrifugal castings have a fine gram size.
There is a tendency for the lighter non-metallic inclusions slag particles, and dross to
segregate toward the inner radius of the casting where it can be easily removed by machining.
Due to the high purity of the outer skin, centrifugally cast pipes have a high resistance to
atmospheric corrosion.
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Plaster-mold casting is somewhat similar to sand casting in that only one casting is
made and then the mold is destroyed, in this case the mold is made out of a specially
formulated plaster. 70 to 80% gypsum and 20 to 30% fibrous strengtheners. Water is added to
make a creamy s1urry. This process is limited to non-ferrous metals, because ferrous metals
react with sulphur in gypsum. The core boxes are usually made form brass, plastics, or
aluminium.
The process utilizes a metal casting die in conjunction with metal or sand cores.
Molten metal is introduced at the top of the mold that has two or more parts, using only the
force of gravity. After solidification, the mold is opened and the casting ejected. The mold is
re-assembled and the cyc1e is repeated. The molds are either metal or graphite and,
consequently, most permanent-mold castings are restricted to lower melting point nonferrous
metals and alloys.
Squeeze casting, also known as liquid-metal forging, is a process by which molten

metal solidifies under pressure within c1osed dies positioned between the plates of a
hydraulic press. Squeeze casting consists of metering liquid metal into a preheated, lubricated
die and forging the metal while it so1idifies. The load is applied shortly after the metal begins
to freeze and is maintained until the entire casting has solidified. Casting ejection and
handling are done in much the same way as in closed die forging.
The applied pressure and the instant contact of the molten metal with the die surface
produce a rapid heat transfer condition that yields a pore-free fine-grain casting with
mechanical properties approaching those of a wrought product.
The squeeze casting process is easily automated to produce near-net to net shape
high-quality components.
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2.3 Advantages & Disadvantages
2.3.1 Advantages
1 Complex shapes can be produced.

2 Minimal directional properties are obtained
3 Hollow sections can be produced
4 Very large part can be produced.
5 Metals that are very difficult to machine can be used to produce an object.
6 Cheapest method of fabrication
7 Casting with wide range of properties can be produce by adding various alloys
elements.
8 Almost all the metals and alloys and some plastics can be casted.
9 The number Of casting can be vary from very few to several thousands.
2.3.2 Disadvantages
1 Time required for the process of making casting is quite long.

2 Metal casting involving melting of metal which is high energy consuming process.
3 The working condition in foundries are quite bad due to heat, dust,fumes, slags etc.
Compare to other process.
4 Metal casting is still high labour-intensive compare to other process.
5 Productivity is less than the other automatic process. E.g. Rolling.
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3. Casting Terminology
3.1 Pattern
The pattern is the principal tool during the casting process. It is the replica of
the object to be made by the casting process, with some modifications. The main
modifications are the addition of pattern allowances, and the provision of core prints. If the
casting is to be hollow, additional patterns called cores are used to create these cavities in the
finished product. The quality of the casting produced depends upon the material of the
pattern, its design, and construction.
3.1.1 Pattern Material
There are many types of pattern material used in industries as:
1) Wooden 2) Metal
3) Plastic 4) Quick setting material.
3.1.1 Type of Pattern

3.1.2.2 Split pattern or two-piece pattern
3.1.2.3 Cope and Drag Pattern
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A single piece pattern is the simplest of all

forms. As the name indicates they are made of a single piece
as shown in fig. This type of pattern is used only in cases
where the product is very simple and can be easily withdrawn
from the mould. This pattern is contained entirely in the drag.
One of the surfaces is usually flat which is used as the parting
plane.
3.1.2.2 Split pattern or two-piece pattern.
This is the most common type of pattern for intricate castings. When the
contour of the casting makes its withdrawal from the mould difficult or when the depth of the
casting is too high, then the pattern is split into two parts. One part is contained in the drag
and the other in the cope. The split surface of the pattern is same as the parting plane of the
mould. The two halves of the pattern should
be aligned properly by making use of dowel
pins which are fitted to the top half.
3.1.2.3 Cope and Drag Pattern.
When very large castings are to be made the complete pattern becomes too
heavy to be handled by a single operator. Such a pattern is made in two parts which are
separately moulded in different moulding boxes. After
completion of the moulds, the two boxes are assembled
to form the complete cavity. One part is contained by the
drag and the other by the cope. Thus it is different from
split pattern in which both pieces are moulded separately
instead of being moulded in the assembled position.
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These patterns are made in two pieces. One piece

is mounted on one side and the other on the other side of a plate
called match plate. Gates and runners are also attached to the
plate along with the pattern. After moulding when the match
plate is removed a complete mould with gating is obtained by
joining the cope and drag together. The complete pattern with
match plate is entirely made of metal, usually aluminium for its light weight and
machinability. These are generally used for mass production of small castings with higher
dimensional accuracy. These patterns are mainly employed for machine moulding. Their
construction cost is high but the same is easily compensated by a high rate of production and
greater dimensional accuracy.
They are used for mass production of

small castings. For such castings multi-cavity moulds are
prepared, i.e. a single sand mould carriers a number of
cavities as shown in fig. Pattern for these castings are
connected to each other by means of gate formers. They
provide suitable channels or gates in sand for feeding the
molten metal to these cavities. A single runner can be
used for feeding all the cavities. This enables a considerable saving in moulding time and a
uniform feeding of molten metal.
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When the size of the casting is very large, but easy to shape and only a few
numbers are to be made, it is not economical to make a large solid pattern of that size. In such
cases a pattern consisting of wooden frame and strips is made called skeleton pattern. It is
filled with moulding sand and rammed properly. The surplus sand is removed by means of a
strickle. A skeleton pattern for a pipe is shown in figure.
Certain single piece patterns are made to

have loose pieces in order to enable their easy
withdrawal from the mould. These pieces from an
integral part of the pattern during moulding. After the
mould is complete the pattern is withdrawn leaving the
pieces in the sand. These pieces are later withdrawn
separately through the cavity formed by the pattern as
shown in figure. Moulding with loose piece is a highly
skilled job and is generally expensive.
3.1.3 Pattern Allowances
3.1.3.1 Shrinkage allowance
The pattern needs to incorporate suitable allowances for shrinkage; these are
called contraction allowances, and their exact values depend on the alloy being cast and the
exact sand casting method being used. Some alloys will have overall linear shrinkage of up to
2.5%, whereas other alloys may actually experience no shrinkage or a slight "positive"
shrinkage or increase in size in the casting process (notably type metal and certain cast irons).
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The shrinkage amount is also dependent on the sand casting process employed, for example
clay-bonded sand, chemical bonded sands, or other bonding materials used within the sand.
3.1.3.2 Draft allowances
The pattern needs to incorporate suitable allowances for draft, which means
that its sides are tapered so that when it is pulled from the sand, it will tend not to drag sand
out of place along with it. This is also known as taper which is normally between 1 and 3
degrees.
3.1.3.3 Machining allowance
The finish and accuracy achieved in sand casting are generally poor and
therefore when the casting is functionally required to be of good surface finish or
dimensionally accurate, it is generally achieved by subsequent machining. Machining or
finish allowances are therefore added in the pattern dimension. The amount of machining
allowance to be provided for is affected by the method of moulding and casting used viz.
hand moulding or machine moulding, sand casting or metal mould casting. The amount of
machining allowance is also affected by the size and shape of the casting; the casting
orientation; the metal; and the degree of accuracy and finish required.
3.1.3.4 Distortion allowance
Sometimes castings get distorted, during solidification, due to their typical

shape. For example, if the casting has the form of the letter U, V, T, or L etc. it will tend to
contract at the closed end causing the vertical legs to look slightly inclined. This can be
prevented by making the legs of the U, V, T, or L shaped pattern converge slightly (inward)
so that the casting after distortion will have its sides vertical.
The distortion in casting may occur due to internal stresses. These internal
stresses are caused on account of unequal cooling of different section of the casting and
hindered contraction. Measure taken to prevent the distortion in casting include:
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3.1.3.5 Rapping Allowance
Before the withdrawal from the sand mold, the pattern is rapped all around the
vertical faces to enlarge the mold cavity slightly, which facilitate its removal. Since it
enlarges the final casting made, it is desirable that the original pattern dimension should be
reduced to account for this increase. There is no sure way of quantifying this allowance, since
it is highly dependent on the foundry personnel practice involved. It is a negative allowance
and is to be applied only to those dimensions that are parallel to the parting plane.
3.2 Core
A core is a device used in casting and moulding processes to produce internal

cavities and re-entrant angles. 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, but are also used in
injection moulding.
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3.2.1 Types of Core
3.2.1.1 Green-sand core
Green-sand cores are not a typical type of core in

that it is part of the cope and drag, but still form an internal
feature. Their major disadvantage is their lack of strength, which
makes casting long narrow features difficult or impossible. Even
for long features that can be cast it still leave much material to
be machined. A typical application is a through hole in a casting.
3.2.1.2 Dry-sand cores
Dry-sand cores overcome some of the disadvantages of the green-sand cores.

They are formed independently of the mold and then inserted into the core prints in the mold,
which hold the core in position. They are made by mixing sand with a binder in a wooden or
metal core box, which contains a cavity in the shape of the desired core.
3.2.2 Core Print
Castings are often required to have holes, recesses, etc. of various sizes and
shapes. These impressions can be obtained by using cores. So where coring is required,
provision should be made to support the core inside the mold cavity. Core prints are used to
serve this purpose. The core print is an added projection on the pattern and it forms a seat in
the mold on which the sand core rests during pouring of the mold. The core print must be of
adequate size and shape so that it can support the weight of the core during the casting
operation. Depending upon the requirement a core can be placed horizontal, vertical and can
be hanged inside the mold cavity.
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3.2.3 Core Box

The most simple way to make dry-sand cores is in a dump core box, in which sand is
packed into the box and scraped level with the top. A wood or metal plate is then placed over
the box, and then the two are flipped over and the core segment falls out of the core box. The
core segment is then baked or hardened. Multiple core segments are then hot glued together
or attached by some other means.
There are many types of core box use in industries as :
 half core box

 dump core box
 split core box
 left and right core box
 gang core box
 strickle core box
 loose piece core box
3.3 Mould
In sand casting, the primary piece of
equipment is the mold, which contains several
components. The mold is divided into two halves -
the cope (upper half) and the drag (bottom half),
which meet along a parting line. Both mold halves
are contained inside a box, called a flask, which
itself is divided along this parting line. The mold
cavity is formed by packing sand around the
pattern in each half of the flask. The sand can be
packed by hand, but machines that use pressure or impact ensure even packing of the sand
and require far less time, thus increasing the production rate. After the sand has been packed
and the pattern is removed, a cavity will remain that forms the external shape of the casting.
Some internal surfaces of the casting may be formed by cores.
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3.3.1 Type of Mould
3.3.1.1 Permanent mould casting
Permanent mold casting is metal casting process that employs reusable molds
("permanent molds"), usually made from metal. The most common process uses gravity to
fill the mold, however gas pressure or a vacuum are also used. A variation on the typical
gravity casting process, called slush casting, produces hollow castings. Common casting
metals are aluminum, magnesium, and copper alloys. Other materials include tin, zinc, and
lead alloys and iron and steel are also cast in graphite molds. Permanent molds, while lasting
more than one casting still have a limited life before wearing out.
3.3.1.2 Temporary Mould casting
This mould are destroyed at the time of removing casting from them.
There are many type of temporary mould which are mentioned below.
 Type of Temporary Mould
 Greensand mold –
Greensand molds use a mixture of sand, water, and a clay or binder. Typical
composition of the mixture is 90% sand, 3% water, and 7% clay or binder. Greensand molds
are the least expensive and most widely used.
 Skin-dried mold –
A skin-dried mold begins like a greensand mold, but additional bonding materials are
added and the cavity surface is dried by a torch or heating lamp to increase mold strength.
Doing so also improves the dimensional accuracy and surface finish, but will lower the
collapsibility. Dry skin molds are more expensive and require more time, thus lowering the
production rate.
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 Dry sand mold –
In a dry sand mold, sometimes called a cold box mold, the sand is mixed only with an
organic binder. The mold is strengthened by baking it in an oven. The resulting mold has high
dimensional accuracy, but is expensive and results in a lower production rate.
 No-bake mold –
The sand in a no-bake mold is mixed with a liquid resin and hardens at room
temperature.
3.3.2 Moulding Sand
Molding sand is more than just sand. Typically it is a fine grade of sand (mine is 110
grit sand blasting sand), clay binder and something to moisten it. There are two types of
molding sand namely natural sand and synthesis sand.
3.3.2.1 Properties of Moulding Sand
A large variety of molding materials is used in foundries for manufacturing molds and
cores. They include molding sand, system sand or backing sand, facing sand, parting sand,
and core sand. The choice of molding materials is based on their processing properties. The
properties that are generally required in molding materials are:
 Refractoriness
It is the ability of the molding material to resist the temperature of the liquid metal to
be poured so that it does not get fused with the metal. The refractoriness of the silica sand is
highest.
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 Permeability
During pouring and subsequent solidification of a casting, a large amount of gases and
steam is generated. These gases are those that have been absorbed by the metal during
melting, air absorbed from the atmosphere and the steam generated by the molding and core
sand. If these gases are not allowed to escape from the mold, they would be entrapped inside
the casting and cause casting defects. To overcome this problem the molding material must
be porous. Proper venting of the mold also helps in escaping the gases that are generated
inside the mold cavity.
 Green Strength
The molding sand that contains moisture is termed as green sand. The green sand
particles must have the ability to cling to each other to impart sufficient strength to the mold.
The green sand must have enough strength so that the constructed mold retains its shape.
 Dry Strength
When the molten metal is poured in the mold, the sand around the mold cavity is
quickly converted into dry sand as the moisture in the sand evaporates due to the heat of the
molten metal. At this stage the molding sand must posses the sufficient strength to retain the
exact shape of the mold cavity and at the same time it must be able to withstand the
metallostatic pressure of the liquid material.
 Hot Strength
As soon as the moisture is eliminated, the sand would reach at a high temperature
when the metal in the mold is still in liquid state. The strength of the sand that is required to
hold the shape of the cavity is called hot strength.
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 Collapsibility
The molding sand should also have collapsibility so that during the contraction of the
solidified casting it does not provide any resistance, which may result in cracks in the
castings.Besides these specific properties the molding material should be cheap, reusable and
should have good thermal conductivity.
 Thermal stability
Heat from the casting causes rapid expansion of the sand surface at the mould-metal
interface. The mould surface may crack, buckle, or flake off (scab ) unless the moulding sand
is relatively stable dimensionally under rapid heating.
3.3.1.2 Sand Testing
 Moisture Content test
Moisture is an important element of the moulding sand as it affects many properties.

To test the moisture of moulding sand a carefully weighed sand test sample of 50g is dried at
a temperature of 1050 C to 1100 C for 2 hours by which time all the moisture in the sand
would have been evaporated. The sample is then weighed. The weight difference in grams
when multiplied by two would give the percentage of moisture contained in the moulding
sand. Alternatively a moisture teller can also be used for measuring the moisture content. In
this sand is dried by suspending the sample on a fine metallic screen and allowing hot air to
flow through the sample. This method of drying completes the removal of moisture in a
matter of minutes compared to 2 hours as in the earlier method. \
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 Permeability test
The permeability number, which has no units, is determined by the rate of flow of air,
under standard pressure, through a 2 x 2-in. rammed AFS cylindrical specimen.
The grain size, shape and distribution of the foundry sand, the type and quantity of
bonding materials, the density to which the sand is rammed and the percentage of moisture
used for tempering the sand are important factors in regulating the degree of permeability. An
increase in permeability usually indicates a more open structure in the rammed sand, and if
the increase continues, it will lead to penetration-type defects and rough castings. A decrease
in permeability indicates tighter packing and could lead to blows and pinholes.
 Clay Content Test
A known amount of dried molding sand mixed with a pyrophosphate solution is

stirred with a high-speed mixer for 5 min. Water is added to the top level line, and the
mixture is allowed to settle for 5 min. before the top 5 in. of the water is siphoned off. The
procedure is repeated until the water above the sample is clear. The sand then is dried, and
the weight loss is recorded as Clay.
Clay may contain active clay, dead clay, silt, seacoal, cellulose, cereal, ash, fines and
all materials that float in water. Only the active clay gives active bonding capacity to the
system.
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4. Melting Equipment
4.1 Cupola Furnace
A Cupola or Cupola furnace is a melting device used in foundries that can be

used to melt cast iron, ni-resist iron and some bronzes. The cupola can be made almost any
practical size. The size of a cupola is expressed in diameters and can range from 1.5 to 13 feet
(0.5 to 4.0 m). The overall shape is cylindrical and the equipment is arranged vertically,
usually supported by four legs. The overall look is similar to a large smokestack.
The bottom of the cylinder is fitted

with doors which swing down and out to 'drop
bottom'. The top where gases escape can be open or
fitted with a cap to prevent rain from entering the
cupola. To control emissions a cupola may be fitted
with a cap that is designed to pull the gases into a
device to cool the gasses and remove particulate
matter.
The shell of the cupola, being

usually made of steel, has refractory brick and refractory patching material lining it. The
bottom is lined in a similar manner but often a clay and sand mixture ("bod") may be used, as
this lining is temporary. Finely divided coal ("sea coal") can be mixed with the clay lining so
when heated the coal decomposes and the bod becomes slightly friable, easing the opening up
of the tap holes. The bottom lining is compressed or 'rammed' against the bottom doors. Some
cupolas are fitted with cooling jackets to keep the sides cool and with oxygen injection to
make the coke fire burn hotter.
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 Operation
To begin a production run, called a 'cupola campaign', the furnace is filled

with layers of coke and ignited with torches. Some smaller cupolas may be ignited with wood
to start the coke burning. When the coke is ignited, air is introduced to the coke bed through
ports in the sides called tuyeres.
When the coke is very hot, solid pieces of metal are charged into the furnace
through an opening in the top. The metal is alternated with additional layers of fresh coke.
Limestone is added to act as a flux. As the heat rises within the stack the metal is melted. It
drips down through the coke bed to collect in a pool at the bottom, just above the bottom
doors. A thermodynamic reaction takes place. The carbon in the coke combines with the
oxygen in the air to form carbon monoxide. The carbon monoxide further burns to form
carbon dioxide. Some of the carbon is picked up by the falling droplets of molten steel and
iron which raises the carbon content of the iron. Silicon carbide and ferromanganese briquets
may also be added to the charge materials. The silicon carbide dissociates and carbon and
silicon enters into the molten metal. Likewise the ferromanganese melts and is combined into
the pool of liquid iron in the 'well' at the bottom of the cupola.
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The operator of the cupola, the 'cupola tender', observes the amount of iron
rising in the well of the cupola. When the metal level is sufficiently high, the cupola tender
opens the taphole to let the metal flow into a ladle or other container to hold the molten
metal. When enough metal is drawn off the taphole is plugged with a refractory plug made of
clay.
The cupola tender observes the iron through the sight glass for signs of slag
formation, which is normal. Most slags will rise to the top of the pool of iron being formed. A
slag tap hole, located higher up on the cylinder, and usually to the rear or side of the iron
taphole, is opened to let the slag flow out. The viscosity is low (with proper fluxing) and the
red hot molten slag will flow easily. Sometimes the slag which runs out the slaghole is
collected in a small cup shaped tool, allowed to cool and harden. It is fractured and visually
examined. With acid refractory lined cuploas a greenish colored slag means the fluxing is
proper and adequate.
After the cupola has produced enough metal to supply the foundry with its
needs, the bottom is opened, or 'dropped' and the remaining materials fall to the floor between
the legs. This material is allowed to cool and subsequently removed. The cupola can be used
over and over. A 'campaign' may last a few hours, a day, weeks or even months.
5 Electric Furnace
Electric furnace is used for heating purpose in various industrial production

processes. Electric furnaces are used where more accurate temperature control is required.
There are three types of electrical furnaces namely: (1) Induction Heating Furnace (2)
Resistance Heating Furnace and (3) Arc furnace depending upon the method of heat
generation.
Induction heating furnaces and arc furnaces are beyond the scope of this project
profile. The scope of this project profile is confined to the resistance heating furnace only. In
resistance heating furnaces, the resistance heating
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The heating elements used are Nichrome wire, Kanthal wire or Graphite rods depending
upon the temperature requirements. The unit proposed in this project profile envisages
manufacturing furnaces to a maximum
O
temperature of 1000 C and only up to 50 kW
power rating. In this case, Kanthal wire is used.
The temperature is controlled using thermostats
and the temperature is monitored by
thermocouples. The heating chamber is
constructed by M. S. Sheets and channels and for
thermal Insulation, fire clay bricks and refractory
bricks are used
 Operation
Scrap metal is delivered to a scrap bay, located next to the melt shop. Scrap generally
comes in two main grades: shred (white goods, cars and other objects made of similar light-
gauge steel) and heavy melt (large slabs and beams), along with some direct reduced iron
(DRI) or pig iron for chemical balance. Some furnaces melt almost 100% DRI.
The scrap is loaded into large buckets called baskets, with 'clamshell' doors for a base.
Care is taken to layer the scrap in the basket to ensure good furnace operation; heavy melt is
placed on top of a light layer of protective shred, on top of which is placed more shred. These
layers should be present in the furnace after charging. After loading, the basket may pass to a
scrap pre-heater, which uses hot furnace off-gases to heat the scrap and recover energy,
increasing plant efficiency.
The scrap basket is then taken to the melt shop, the roof is swung off the furnace, and
the furnace is charged with scrap from the basket. Charging is one of the more dangerous
operations for the EAF operators. There is a lot of energy generated by multiple tonnes of
falling metal; any liquid metal in the furnace is often displaced upwards and outwards by the
solid scrap, and the grease and dust on the scrap is ignited if the furnace is hot, resulting in a
fireball erupting. In some twin-shell furnaces, the scrap is charged into the second shell while
the first is being melted down, and pre-heated with off-gas from the active shell. Other
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operations are continuous charging - pre-heating scrap on a conveyor belt, which then
discharges the scrap into the furnace proper, or charging the scrap from a shaft set above the
furnace, with off-gases directed through the shaft. Other furnaces can be charged with hot
(molten) metal from other operations.
After charging, the roof is swung back over the furnace and meltdown commences.
The electrodes are lowered onto the scrap, an arc is struck and the electrodes are then set to
bore into the layer of shred at the top of the furnace. Lower voltages are selected for this first
part of the operation to protect the roof and walls from excessive heat and damage from the
arcs. Once the electrodes have reached the heavy melt at the base of the furnace and the arcs
are shielded by the scrap, the voltage can be increased and the electrodes raised slightly,
lengthening the arcs and increasing power to the melt. This enables a molten pool to form
more rapidly, reducing tap-to-tap times. Oxygen is also supersonically blown into the scrap,
combusting or cutting the steel, and extra chemical heat is provided by wall-mounted oxygen-
fuel burners. Both processes accelerate scrap meltdown.
5. Melting & Pouring
Many foundries, particularly ferrous foundries, use a high proportion of scrap

metal to make up a charge. As such, foundries play an important role in the metal recycling
industry. Internally generated scrap from runners and risers, as well as reject product, is also
recycled. The charge is weighed and introduced to the furnace. Alloys and other materials are
added to the charge to produce the desired melt. In some operations the charge may be
preheated, often using waste heat.
In traditional processes metal is

superheated in the furnace. Molten metal is
transferred from the furnace to a ladle and held
until it reaches the desired pouring temperature.
The molten metal is poured into the mould and
allowed to solidify.
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5.1 Gating System
The gating system serves many purposes, the most important being conveying the
liquid material to the mold, but also controlling shrinkage, the speed of the liquid, turbulence,
and trapping dross. The gates are usually attached to the thickest part of the casting to assist
in controlling shrinkage. In especially large castings multiple gates or runners may be
required to introduce metal to more than one point in the mold cavity. The speed of the
material is important because if the material is traveling too slow it can cool before
completely filling, leading to mis-runs and cold shuts. If the material is moving too fast then
the liquid material can erode the mold and contaminate the final casting. The shape and
length of the gating system can also control how quickly the material cools; short round or
square channels minimize heat loss.
The gating system may be designed to minimize turbulence, depending on the

material being cast. For example, steel, cast iron, and most copper alloys are turbulent
insensitive, but aluminum and magnesium alloys are turbulent sensitive. The turbulent
insensitive materials usually have a short and open gating system to fill the mold as quickly
as possible. However, for turbulent sensitive materials short sprues are used to minimize the
distance the material must fall when entering the mold. Rectangular pouring cups and tapered
sprues are used to prevent the formation of a vortex as the material flows into the mold; these
vortices tend to suck gas and oxides into the mold. A large sprue well is used to dissipate the
kinetic energy of the liquid material as it falls down the sprue, decreasing turbulence. The
choke, which is the smallest cross-sectional area in the gating system used to control flow,
can be placed near the sprue well to slow down and smooth out the flow.
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5.1.1 Runner & Sprue
The molten material is poured in the pouring cup, which is part of the gating
system that supplies the molten material to the mold cavity. The vertical part of the gating
system connected to the pouring cup is the sprue, and the horizontal portion is called the
runners and finally to the multiple points where it is introduced to the mold cavity called the
gates. Additionally there are extensions to the gating system called vents that provide the path
for the built up gases and the displaced air to vent to the atmosphere.
The cavity is usually made oversize to allow for the metal contraction as it
cools down to room temperature. This is achieved by making the pattern oversize. To account
for shrinking, the pattern must be made oversize by these factors, on the average. These are
linear factors and apply in each direction. These shrinkage allowance are only approximate,
because the exact allowance is determined the shape and size of the casting. In addition,
different parts of the casting might require a different shrinkage allowance. See the casting
allowance table for the approximate shrinkage allowance expressed as the Pattern Oversize
Factor.
5.1.2 Riser
A riser, also known as a feeder, is a reservoir built into a metal casting mold to
prevent cavities due to shrinkage. Most metals are less dense as a liquid than as a solid so
castings shrink upon cooling, which can leave a void at the last point to solidify. Risers
prevent this by providing molten metal to the casting as it solidifies, so that the cavity forms
in the riser and not the casting. Risers are not effective on materials that have a large freezing
range, because directional solidification is not possible. They are also not needed for casting
processes that utilized pressure to fill the mold cavity. A feeder operated by a treadle is called
an under feeder.
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6 Cleaning & Finishing.
 Cleaning
After degating, sand or other moulding media may adhere to the casting. To
remove this the surface is cleaned using a blasting process. This means a granular media will
be propelled against the surface of the casting to mechanically knock away the adhering sand.
The media may be blown with compressed air, or may be hurled using a shot wheel. The
media strikes the casting surface at high velocity to dislodge the molding media (for example,
sand, slag) from the casting surface. Numerous materials may be used as media, including
steel, iron, other metal alloys, aluminum oxides, glass beads, walnut shells, baking powder
among others. The blasting media is selected to develop the color and reflectance of the cast
surface. Terms used to describe this process include cleaning, blasting, shot blasting and sand
blasting.
 Finishing
The final step in the process usually

involves grinding, sanding, or machining the
component in order to achieve the desired
dimensional accuracies, physical shape and surface
finish.
Removing the remaining gate

material, called a gate stub, is usually done using a
grinder or sanding. These processes are used
because their material removal rates are slow enough to control the amount of material. These
steps are done prior to any final machining.
After grinding, any surfaces that require tight dimensional control are
machined. Many castings are machined in CNC milling centers. The reason for this is that
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these processes have better dimensional capability and repeatability than many casting
processes. However, it is not uncommon today for many components to be used without
machining.
A few foundries provide other services before shipping components to their

customers. Painting components to prevent corrosion and improve visual appeal is common.
Some foundries will assemble their castings into complete machines or sub-assemblies. Other
foundries weld multiple castings or wrought metals together to form a finished product.
More and more the process of finishing a casting is being achieved using
robotic machines which eliminate the need for a human to physically grind or break parting
lines, gating material or feeders. The introduction of these machines has reduced injury to
workers, costs of consumables whilst also reducing the time necessary to finish a casting. It
also eliminates the problem of human error so as to increase repeatability in the quality of
grinding. With a change of tooling these machines can finish a wide variety of materials
including iron, bronze and aluminium.
7 Casting Defects
 Flash
This casting shows a very common defect, flash. This is where the mold
somehow separated enough to allow metal between the halves, along the parting line. (See
also the trivet for more flash.) You can see the inside circle here is nearly completely filled in
with flash. Fixing flash is no problem as it's usually less than 1/8" thick (unless something
really bad happened) so can be broken off with a hammer or pliers. A file will take it down to
the parting line. Causes include letting the mold dry out; the clay in the sand shrinks resulting
in a gap between the halves. In the pictured case, it was left out overnight.
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Jaipur
 Mold Shift
This is due to operator error: not aligning the mold correctly.
Most flasks have alignment pins to prevent this, but I never installed
them on my 6x6 set so I have to guess at it.
 Porosity
This is an investment casting. Different from sand casting, but defects still happen all
the same. In this case, it was either gas or slag (but the area doesn't have the right appearance
for slag). Come to think of it, it could be gas from the mould, but that's just a thought. In any
case, the area in question is on the right, where it looks rough (the area on the left appears to
be a broken section of the mould, which might've contributed to the next listed defect). There
are actually a few pinholes which you can see light clear though in the porous area.
 Slag Inclusions
During the melting process, flux is added to remove the undesirable oxides and
impurities present in the metal. At the time of tapping, the slag should be properly removed
from the ladle, before the metal is poured into the mould. Otherwise any slag entering the
mould cavity will be weakening the casting and also spoiling the surface of the casting.
 Gas pockets
Gas pockets come from gas dissolving in the melt then coming out when it
solidifies. This usually manifests itself as a rough surface on areas exposed to air or pockets
of varying size in the cross-section of the metal. Gas comes from melting too long or heating
too hot, 'stewing' the metal using an unusually oxidizing or reducing flame in the furnace,
getting water in the melt, and the alignment of the Moon with the Earth and Sun. A good
idea is to recycle scrap into ingots as a first step since the scrap might be wet, oily or painted
and will add gas to the melt. The gas comes out in the ingots, not your casting.
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 Swell :
Under the influence of metallostatic forces, the

mould wall may move back causing a swell in the
dimensions of the casting. As a result of the swell, the
feeding requirements of the casting increase which should
be taken care of by the proper choice of risering. The
main cause of this defect is improper ramming of the mould.
 Drop:
An irregularly shaped projection on the cope surface of a casting is called a drop.

This is caused by dropping of sand from the cope or other overhanging projections into the
mould. An adequate strength of the sand and the use of gaggers can help in avoiding the
drops.
 Misrun:
Many a time, the liquid metal may, due to insufficient superheat,

start freezing before reaching the farthest point of the mould cavity. This
defect is called Mis-run.
 Hot tears:
Since metal has low strength at higher temperatures, any

unwanted cooling stress may cause the rupture of the casting. The
better design of casting avoids this defect.
 Cold shut:
For a casting with gates at its two sides, the misrun may show up at the centre of the
casting due to non fusion of two streams of metal resulting in a discontinuity or weak spot in
casting.Above two defects are due to lower fluidity of the molten metal or small thickness of
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the casting. The fluidity of the metal can be increased by changing the composition of molten
metal or raising the pouring temperature. The other causes for these defects are large surface
area to volume ratio of the casting, high heat transfer rate of the mould material and back
pressure of the gases entrapped in the mould cavity due to inadequate venting.
 References
1 ) Manufacturing Technology - R. K. Rajput
44

Casting Process Report by Savan

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Kautilya Inst. Of Tech. & Engg.

Submitted To: Head of the Department:

KAUTILYA INSTITUTE OF TECHNOLOGY AND ENGINEERING,

Shining Engineers & Founders Pvt. Ltd.

SUBMITTED TO: SUBMITTED BY:

To whom so ever It May Concern

This is certifying that the Practical Training Seminar Report entitled

(Internal Examiner) H.O.D (Mech.)

I express my deep sense of gratitude to Mr. SANJAY BHAI

(H.O.D, SHINING ENGINEERS & FOUNDERS PVT. LTD )

for giving me a golden opportunity to pursue

My industrial training at SHINING, Rajkot ( Gujarat )

I owe my heartiest thanks to my training guide Mr. Brijesh sir for

giving me the opportunity to learn & understand the

practical implementation of academic studies. He is always there in the

hours of need. Here I express my sincere thanks to all other Colleagues of

Engineering department who extend their help in the

Understanding of the duties and responsibilities of the Dept.

Advice in choosing the right company to pursue my training. He is not only

my guide but also my mentor.

1.1. Company Profile 1

2. Introduction about Casting 2

2.3 Advantages & Disadvantages

3.1.1 Pattern Material

3.1.2.3 Cope and Drag Pattern

3.1.3 Pattern Allowances

3.1.3.1 Shrinkage allowance

3.2.1.1 Green sand core

3.2.2 Core Print

3.3.1 Type of Mould

3.3.1.1 Permanent mould

3.3.2 Moulding Sand

3.3.2.1 Properties of Moulding Sand

4.1 Cupola Furnace

5. Melting & Pouring

5.1 Gating System

5.1.1 Runner & Sprue

6. Cleaning & Finishing.

1.1 INTRODUCTION OF THE COMPANY:

This is the core of quality and process improvement as well as the

1. Name of the company:

Shining Engineers & Founders Pvt. Ltd.

1.2 History and Development of Company

1.3 Organization Chart:

2. Introduction about Casting

Casting is basically melting a solid material, heating to a special temperature, and

2.2 Type of Casting

2.2.1 Sand casting

Sand casting is a flexible, inexpensive

2.2.2 Die casting

A versatile process for producing engineered metal parts,

2.2.2 Investment Casting

2.2.4 Centrifugal casting

2.2.5 Plaster-mould casting

2.2.6 Permanent-mold casting

2.2.7 Squeeze casting

Squeeze casting, also known as liquid-metal forging, is a process by which molten

2.3 Advantages & Disadvantages

1 Complex shapes can be produced.

1 Time required for the process of making casting is quite long.

3.1.1 Pattern Material

There are many types of pattern material used in industries as:

3.1.1 Type of Pattern