INTERNSHIP REPORT ON

FOUNDRY TECHNOLOGY AT LAMINA FOUNDRIES,NITTE.

SUBMITTED BY

AKSHAY SHENOY T

(1NT16ME141)

Under the guidance of

Internal guide External guide

Dr. Madhusudhan Mrs. Tara Hegde
Professor HR Manager
Deptartment of Mechanical Engineering, Lamina Foundries
NMIT , Bangalore Karkala, Nitte

Submitted in partial fulfillment of B.E course to

Nitte Meenakshi Institute of Technology

(an autonomous institute under VTU,Belagavi)

 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany the successful completion of any task
would be incomplete without the mention of people who made it possible,whose constant
guidance and encouragement crowned the efforts with success.

I would like to express my heartfelt gratitude to The Principal Dr. H.C Nagraj for his
encouragement that motivates us for the successful completion of the internship work.

The completion of this project would not be possible without the support and guidance of
the management at Lamina Foundries whose help and guidance made this report possible.

I am indebted to HR Manager, Administrative Department, Lamina Foundries for her

valuable support and constant guidance. Her knowledge and experience have been a great
motivating factor for me.

I take this opportunity to thank the faculty members of this college for their
encouragement and support throughout the internship.

I am grateful to all the departments of this foundry industry with whom I have spent so
much time in the mentioned 4 weeks.

I would like to thank almighty, my friends, parents and the people who supported me to
complete this internship work.

Akshay Shenoy T

(1NT16ME141)
 TABLE OF CONTENTS

Chapter no. Particulars

1 INTRODUCTION
*Locations
*Machining needs
*Products
*Product details
*Clientele
2 DEPARTMENTS
*Melting section
*Production line
*Core shop
*Shot blast
*Machine shop
*Maintenance
*Development
*Quality control
*Printing and packing

3 LEARNING EXPERIENCE AND CONCLUSION

*Learning experience
*Conclusion
 INTRODUCTION

Lamina Foundries Limited is a public limited company belonging to Lamina Group of

Companies,commissioned in the year 1983.

Initially the company was producing cast iron castings such as motor bodies,
flywheels, valve bodies etc. To cater to the needs of domestic customers. The
company has entered into the export market since 1990 by exporting machined brake
drums to Germany.

Lamina Foundries have won the Regional Export Award shield for the period 1992-93
and Govt of Karnataka State award for export performance for the period 1996-2000.

LOCATIONS

The company’s production unit is situated on a land of 16 acres and spread in

a built up area of 65,000 sq.ft at Nitte village 60kms away from Mangalore city of
Karnataka State in India on Mangalore-Kudremukh Highway which is a
industrially notified backward area.

The unit is well connected to sea, the nearest port being New Mangalore port
trust. We are also easily accessible by air from Mumbai and Bangalore.

The purchase and accounts departments are operating from the office at
Baikampady, New Mangalore.

DEPT OF MECHANICAL ENGINEERING1

MACHINING NEEDS

The company possesses in-house machining facility both at Nitte and New
Mangalore including CNC machining . Machining requirements are also met
through sub-contractors at Baikampady(New Mangalore), Nitte, Bangalore and
Coimbatore.

Painting and packing of export castings are carried out in our Nitte works/
Export shed in Baikampady. All the other departments are working at the main
workshop in Nitte.

PRODUTCS

Grades of cast iron produced

The items have been produced in the appropriate grades conforming to

Internationals standards such as DIN,BS,JIS,ASTM,NF-A and Indian standards(IS).

Grey cast iron: Grey iron is produced in the grades FG150,FG200,FG250,FG300

conforming to standards IS210 and equivalent grades in International standards.

SpheriodalGraphite( SG ) iron: SG iron is produced in the grades SG 400/12,

SG450/10 &SG500/7 conforming to standard IS 1865 and equivalent grades in
International standards.

DEPT OF MECHANICAL ENGINEERING2

PRODUCT DETAILS AND DEVELOPMENT

From the time of inspection of the foundry a large number of items of the
following categories have been developed and have been well accepted in the
market. Given below are details of ites developed in the past 10-12 years and
items among developed include items made by no bake process as per the
customer requirements.

Sl PRODUCT RANGE/TYPES NO OF ITEMS

No. DEVELOPED

01 Brake drums 450 types (4-100kgs)

02 Brake drums 30 types (4-38kgs)

03 Motor bodies/housings 150 types

(7-85kgs)

04 Other items such as end shields of motor 200 types

pumps, flywheels etc,.
(1-180 kgs)

DEPT OF MECHANICAL ENGINEERING3

CLIENTELE

Customer profile

The company enjoys good reputation among the reputed customers from
domestic and international markets for supply of machined and raw industrial castings.
Following are some major customers of Lamina Foundries Ltd.

*INTERNATIONAL CUSTOMERS:

1] Reputed Customer in Germany

-For automobile brake and discs.

2] M/s Gardener Denver Elmo Technology & Bad Neustadt,Germany.

-For parts of vacuum pumps and compressor parts.

3] M/s Gardener Denver Nash DeustchlandNurenberg, Germany.

-For parts of vacuum pumps and compressorparts.

4] M/s KometalSp.z.o.o., Koszlin,poland.

-For automobile brake drums.

5] M/s STTP Brake drum and disc factory,Netherlands

-For automobile brake drums

6] M/s Ameriparts Inc, Cleveland, Ohio United States of America.

-For Idler Hubs, brake drums.

7] M/s Modec vehicles Ltd., Coventry, UK.

-For automobile brake drums and discs.

DEPT OF MECHANICAL ENGINEERING4

 *DOMESTIC CUSTOMERS

1] Ashok Leyland Ltd., unit I & II 175, Hosur Ind. Complex 77, Hosur, TN
state

- For automobile brake drums,flywheelhousings,hubs.

2] M/s Caterpillar India pvt. Ltd

- For brake drums of x ray grade quality

3] Crompton Greaves limited, Machine divn-I, Maharashtra

- For electric motor bodies and casting accessories.

4] Bharath Bijlee Limited,Kalwae-Thane Dist

-For electric motor bodies

5] Kirloskar Electric company ltd.,Tumkur,Karnataka.

-For export items of electric motor bodies and end shields.

DEPT OF MECHANICAL ENGINEERING5

 DEPARTMENTS

*MELTING SECTION

The basic raw material melting is done in divided blast cupolas and duplexed in
induction furnaces.

There are 3 cupolas for melting process. A 2.5T,3T, and 4T of varied capacities.
These have an actual production rate of 2.5tons/hr, 3tons/hr and 4tons/hr respectively.
The raw materials used for melting are pig iron,cast iron scrap and also mild steel
scraps. The tapping temperature of the melting zone is maintained between 1460-1500
degreeCelcius. The materials melted in the induction furnace are duplexed metals
from cupola,cast iron scraps,castironboringsnd mild steel scraps. The melting rate for
an inductotherm-type furnace is 1T/hr and for an asea brown baveri type furnace is
0.5T/hr

DEPT OF MECHANICAL ENGINEERING6

*MATERIAL HANDELING:

There are 2 pouring ladles of 3 quantities one of which is electrically controlled and
the other is manual type gear controlled one, each weighing 500kgs.

3 overhead cranes weighing 10T,5T and 5T respectively for efficient transport of

vessels carrying molten metal.

Finally,2 transfer trolley’s for molten metal transfer weighing 500kgs each.

*POWER GENERATION:

There are two generators used for power transmission. Their specifications are as
follows:

250KVA,415V AC,3 PHASE and frequency 50Hz.

DEPT OF MECHANICAL ENGINEERING7

*PRODUCTION LINE (MOULDING LINE)

Three mechanised moulding lines and hand moulding facilities with sand plant,
moulding and mulling machines are installed.

DEPT OF MECHANICAL ENGINEERING8

 MOULDING LINE 1:

Sl no Equipment Maker Quantity Specifications

01 APM SM3 moulding Pioneer 2 900kgs(jolted)

machinees

02 Moulding boxes Wesman 1 750*750*350mm cope

750*750*250

mm drag

03 Sand muller wesman 1 7500kgs/hr,

750kgs/batch

04 Intensive sand mixer VME 1 7500Kgs/hr,

250kgs/batch

05 Sand drier Promac 1 1T/hr

06 Sand aerator Promac 1 20T/hr

DEPT OF MECHANICAL ENGINEERING9

MOULDING LINE 2:

Sl no Equipment Maker Quantity Specifications

01 SMFA 300 Sarvamangala 2 each 300kg

moulding
(jolted)
machine
450kg
SMFA 450
(jolted)
moulding
machine

02 Moulding TS foundry 50sets 520*500*220mm

boxes equipments
Cope

520*500*220mm

drag

03 Moulding TS foundry 50sets 520*400*175mm

boxes equipments
Cope

520*400*157mm

Drag

04 Moulding F care 80 sets 650*650*250mm

boxes
Cope

650*650*200mm

drag

05 Intensive sand UK equipment 2 6250khs/hr

mixer

06 Weight range ------------- ------------ 2-20kgs/20-55kgs

of casting/box

DEPT OF MECHANICAL ENGINEERING10

MOULDING LINE 3:

Sl no Equipment Maker Quantity Specifications

01 ARPA 450 DISA 2 450kg jolted

moulding
machines

02 Moulding TS foundry 60sets 650*630*300mm

boxes equipment
Cope

650*630*200mm

drag

03 Sand mixer Wesman 2 13000kgs/hr;

650kgs/batch

04 Weight range ------------- ------------- 25-60kgs

of casting/bbox

DEPT OF MECHANICAL ENGINEERING11

Theory:

Moulding is the process of manufacturing by shaping liquid or pliable raw

materialusing a rigid frame called a mould or matrix. This in itself maybe made using
a pattern or model of the final object.

A mold or mould is a hollowed-out block that is filled with a liquid or pliable material
such as plastic, glass, metal, or ceramic raw material.The liquid hardens or sets inside
the mold, adopting its shape. A mold is the counterpart to a cast. The very common
bi-valve molding process uses two molds, one for each half of the object. Articulated
moulds have multiple pieces that come together to form the complete mold, and then
disassemble to release the finished casting; they are expensive, but necessary when
the casting shape has complex overhangs.Piece-molding uses a number of different
molds, each creating a section of a complicated object. This is generally only used for
larger and more valuable objects.

A manufacturer who makes molds is called a mold maker. A release agent is typically
used to make removal of the hardened/set substance from the mold easily. Typical
uses for molded plastics include molded furniture, molded household goods,
molded cases, and structural materials.

DEPT OF MECHANICAL ENGINEERING12

*CORE SHOP

A core is a device used in casting and mouldingprocesses to produce internal cavities

and reentrant angles (an interior angle that is greater than 180°). The core is normally
a disposable item that is destroyed to get it out of the piece.

Materials required to make cores:

*Core sand

*Bentonite clay

*Pulverized coal

*Resin oil

DEPT OF MECHANICAL ENGINEERING13

Types of core:

 Cold Box
 half core box
 dump core box
 split core box
 left and right core box
 gang core box
 strickle core box
 loose piece core box

DEPT OF MECHANICAL ENGINEERING14

*SHOTBLAST

Shotblasting is a method used to clean, strengthen (peen) or polish metal. Shot

blasting is used in almost every industry that uses metal, including aerospace,
automotive, construction, foundry, shipbuilding, rail, and many others. There are two
technologies used: wheelblasting or airblasting.

Wheel Blasting is an airless blast operation that uses a wheel with centrifugal force to
propel the abrasive against the parts. Because the wheel spins at 3600 RPM, it is a
high velocity, high efficiency blasting operation with typically quick time cycles. Due
to its high velocity this type of blast utilizes metallic abrasives such as steel shot, steel
grit, stainless steel shot and grit and cut-wire which are available in different
hardness’s.

The advantage of wheel blasting over air blasting is its speed of cleaning and the
ability to efficiently blast large components. Also, it does not require compressed air
to operate like air blast equipment. This can be very expensive, especially when
blasting a large component which would require multiple air blast guns. However, the
high velocity is also its nemesis because it can damage parts that can’t withstand this
pressure and you are also limited to the type of abrasive that you can use.

Typical wheel blast machines are tumble blast, table blast, spinner hanger and feed
thru structural steel machines. The size of the wheel blast machine and number of
wheels necessary will depend on the parts to be blasted as well as production rates.

DEPT OF MECHANICAL ENGINEERING15

*MACHINE SHOP

A machine shop is a room, building, or company where machining is done. In a

machine shop, machinists use machine tools and cutting tools to make parts, usually
of metal or plastic (but sometimes of other materials such as glass or wood). A
machine shop can be a small business (such as a job shop) or a portion of a factory,
whether a toolroom or a production area for manufacturing. The parts produced can
be the end product of the factory, to be sold to customers in the machine industry,
the car industry, the aircraft industry, or others. In other cases, companies in those
fields have their own machine shops.

The production can consist of cutting, shaping, drilling, finishing, and other processes.
The machine tools typically include metal lathes, milling machines, machining centers,
multitasking machines, drill presses, or grinding machines, many controlled
with computer numerical control (CNC). Other processes, such as heat
treating, electroplating, or painting of the parts before or after machining, are often
done in a separate facility. A machine shop can contain some raw materials (such
as bar stock for machining) and an inventory of finished parts. These items are often
stored in a warehouse.

DEPT OF MECHANICAL ENGINEERING16

A machine shop can be a capital intensive business, because the purchase of
equipment can require large investments. A machine shop can also
be labour-intensive, especially if it is specialized in repairing machinery on a job
production basis, but production machining (both batch production and mass
production) is much more automated than it was before the development of
CNC, programmable logic control (PLC), microcomputers, and robotics. It no longer
requires masses of workers, although the jobs that remain tend to require
high talent and skill. Training and experience in a machine shop can both be scarce
and valuable.

Machine shop topics

Machines:

A machine is a tool containing one or more parts that uses energy to perform an
intended action. Machines are usually powered by mechanical, chemical, thermal, or
electrical means, and are often motorized. Historically, a power tool also required
moving parts to classify as a machine. However, the advent of electronics has led to
the development of power tools without moving parts that are considered machines.

Machining:

Machining is any of various processes in which a piece of raw material is cut into a
desired final shape and size by a controlled material-removal process. The many
processes that have this common theme, controlled material removal, are today
collectively known as subtractive manufacturing, in distinction from processes of
controlled material addition, which are known as additive manufacturing. Exactly
what the "controlled" part of the definition implies can vary, but it almost always
implies the use of machine tools (in addition to just power tools and hand tools).

DEPT OF MECHANICAL ENGINEERING17

Machine tools:

A machine tool is a machine for shaping or machining metal or other rigid materials,
usually by cutting, boring, grinding, shearing, or other forms of deformation. Machine
tools employ some sort of tool that does the cutting or shaping. All machine tools
have some means of constraining the workpiece and provide a guided movement of
the parts of the machine. Thus the relative movement between the workpiece and
the cutting tool is controlled or constrained by the machine to at least some extent,
rather than being entirely "offhand" or "freehand".

DEPT OF MECHANICAL ENGINEERING18

*MAINTAINENCE

Maintenance is an area of management in foundry which contributes towards

effective energy management. This area is otherwise called as preventive maintenance
and benefits achieved by this contributes lot. However there are many areas in which
issues would get created if maintenance is not done or concentrated properly.

To name few are equipments getting breakdown because of not proper maintenance
would cause production to be lost and there add cost of production.The cost of
production in this aspect gets added because of penalties laid by customers because of
result of delay in final delivery, labor cost getting higher because one has to make
overtime to compensate the production lost, addition in overhead costs, cost of energy
spent additionally.

If one takes measure to review and spot the cost associated with the various
components mentioned above for per hour period of time they could clearly realize
that the cost is on the higher margin.

It is thus very essential that proper steps and process must be set to prevent these costs
and have proper maintenance plans set which otherwise would lead to issues in
maintenance. Such defective and preventive measures if planned and carried out
consistently at regular intervals of time helps in cutting the down time and improves
the overall operations of the organization thereby contributing towards overall energy
consumption in a foundry.

DEPT OF MECHANICAL ENGINEERING19

Thus an efficient energy conservation program should necessarily include process for
preventive maintenance set in it. Though there are some cost involved with
installation of preventive maintenance it is easily taken back in shorter period by the
benefits achieved by operational cost and energy consumption. Proper steps to be laid
towards effective maintenance are very essential which if not done would increase
maintenance costs and decrease in product quality.

Also since workforce is involved in foundry risk management is taken care only by
efficient maintenance management program. The foundry equipment is all avoided of
issues if proper maintenance is carried out for these equipments at regular intervals.
To avoid the issues involved from maintenance proper steps to be taken is much
essential. There are various steps that could be taken in this aspect.

To name few service contracts with reputed companies can be made for maintenance
which take care of the proper maintenance at regular intervals consistently, for
maintenance that cannot be performed by the foundry technician proper contact
details maintenance would help to contact required workforce at needed times
correctly to carry out the process of production without delay and there by helps in
cost saving.

Proper maintenance programs also helps in identification of foundry equipment

purchases at essential times. These steps towards improved process for maintenance
help in reducing risks and issues and there by helps in achieving an effective efficient
system in an organization.

Proper care must be taken to include each steps and process while preparing the
preventive measures. One such thing is to include the hand tool that is, tool driven by
compressed air. These steps helps in improving the total lifetime of the equipment and
contributes a lot towards compressed air and there by helps in achieving efficiency
energy management.

DEPT OF MECHANICAL ENGINEERING20

*DEVELOPMENT DEPARTMENT (PATTERN SHOP)

Everything in the foundry has to start with a “pattern”. A pattern or tooling 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.

DEPT OF MECHANICAL ENGINEERING21

*QUALITY CONTROL

Quality control is a process through which a business seeks to ensure that product
quality is maintained or improved and manufacturing errors are reduced or eliminated.
Quality control requires the business to create an environment in which both
management and employees strive for perfection. This is done by training personnel,
creating benchmarks for product quality, and testing products to check for statistically
significantvariations.

A major aspect of quality control is the establishment of well-defined controls. These

controls help standardize both production and reactions to quality issues. Limiting
room for error by specifying which production activities are to be completed by which
personnel reduces the chance that employees will be involved in tasks for which they
do not have adequate training.

DEPT OF MECHANICAL ENGINEERING22

 LEARNING EXPERIENCE AND CONCLUSION

*LEARNING EXPERIENCE:

The project is related to the internship program at Lamina Foundries,Nitte,

for the fulfillment of the B.E course which ran through a period of 4 weeks. The
internship was carried out in all departments,such as moulding, melting, pattern
etc. In the initial stages there was a difficulty to carry out the work given, without
being familiar with work carried out there but the workers and engineers were
very friendly in nature and also they were ready to help me in the gaining
adequate knowledge. There was an opportunity to closely observe and study the
process involved ,type of materials required and various other mechanisms
involved in proper manufacturing and designing of a mould as required and
various other mechanisms involved in proper manufacturing and design of a
mould as required by the customer. The culture of the organization is such that
every intern is made to feel like as if they are working in their own company .
And another thing which was noticed was they never make the customers and
officials wait. They greet everyone with a smile which impressed a lot.

The following work were given during my internship period:

1] To notify the engineer, how many sand casting boxes were filled by the molten
metal by the trolley per minute.

2] Along with it,notify the supervisor when there is improper mixing of bentonite
and pure sand,which will interrupt in proper mixing of raw materials in the hopper.

3] At the end of day’s works, I was asked to help the supervisor in gathering the
production data,also how many materials were rejected and if any corrections needed
to be done and report the same to the production head.

DEPT OF MECHANICAL ENGINEERING23

CONCLUSION:

This study concludes that the industry is providing very good services to the customer
involved. The industry is providing importance to the automobile sector by
considering the various financial needs of the companies. The industry is also
providing adequate support to primary domestic customers. The company produces
flywheels ,brake drums and other motor body castings as per requirement . They
export products to Germany, Abu Dhabi, South Africa in the international sector and
Tamil Nadu ,Rajasthan , Hosur being primary domestic customers. This internship has
given me a good exposure to the work field, which I acknowledge.

DEPT OF MECHANICAL ENGINEERING24