Department of Production Engineering, K.I.T's COE, Kolhapur

Industrial Training at Chougule Industries 1
A
REPORT ON INDUSTRIAL TRAINING
AT
CHOUGULE INDUSTRIES
SUBMITTED TO
THE SHIVAJI UNIVERSITY, KOLHAPUR
IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR
THE DEGREE OF
BACHELOR OF PRODUCTION ENGINEERING
SUBMITTED BY
Mr. PARTH RAJENDRA KAVADE
UNDER THE GUIDANCE OF

ASST.PROF. Mr. S. SHAH.
Department of Production Engineering, K.I.T’s COE, Kolhapur

CERTIFICATE
This is to certify that Mr. KAVDE PARTH RAJEDNDRA of B.E. (Production Engineering)
has successfully completed his Industrial Training at Chougule Industries, Shiroli M.I.D.C,
Kolhapur and submitted a report towards the partial fulfillment of the award of Bachelor of
Engineering (Production) degree as laid by the Shivaji University Kolhapur, during the academic
year 2019-2020.
Guide Head
Prof. S J Shaha PROF . S. M . Kadane
Dept. of Production Engineering Dept. of Production Engineering

INTRODUCTION:
Chougule Industries, Shiroli M.I.D.C. Kolhapur an ISO 9001:2000 certified unit producing
Grey Iron and Ductile / S.G. Iron finished components for automobiles, agriculture, and
construction. This unit is focused in the manufacturing and supplying of quality components at
competitive price and delivers it on time. Chougule Industries consists of their own foundry and
machining shops are spread over 60,000 sq. ft of land with covered 30,000 sq.ft of built up and
30,000 is uncoverd area. The foundry is well equipped with induction furnace, sand plant,
moulding machines. They are consists of 500kg and 1000kg induction furnaces. At Chougule
Industries machine shop is well advanced which facilates machines like CNC, VMC, HMC and
VTL with supported by conventional machines lathe and also special purpose machines etc.
Achievements of Chougule industries are as:
CII Clusters for Competitiveness from CII Mahindra & Mahindra (FES) Vendor Cluster
during December 2009 to June 2011.
Self Certified Supplier - from Tractors and Farm Equipments Limited.
Best Supplier Award for Outstanding support in Capacity Augmentation from Tractors and
Farm Equipments Limited.

FOUNDRY LAYOUT:

CASTING PROCESS:
First up all moulding sand is passed to the sand plant through belt conveyor.
Sand is prepared with proper mixture of coal powder and bento nite with the required strength.
This sand is used for preparation of moulds as per the pattern shape.
In this process cope and drag is prepared and the assemble it together with locating pins.
Then it is passed for further operation of pouring molten metal through down sprue and runner
bar to the mould cavity with the help of laddle.
After pouring it is kept as it is for 30-45 min. for cooling and again process is repeated.
At last knock out operation is performed in which cast product is knocked out on vibrator which
is separated from mould.
Water content in the mixture of 1.5% to 8%, activates the clay in the sand, causes the
aggregate to develop plasticity and mold strength. Without water addition, no strength would be
achieved, as the sand and clay would be just two different dry materials Too little water fails to
develop adequate strength and plasticity where sands and clays grains are combined together
apart thus the permeability is very poor. The clay adsorbs the water up to a limiting amount.
Only the water rigidly held (adsorb) by the clay appears to be effective in developing strength
and permeability. The development of bond strength between the grains depends upon on the
hydration of clay. The green strength and permeability of a moulding mixture increases with
water content up to an optimum value determined by the proportion of clay.
SOP for MOISTURE TESTING:
Take 140 gm mould sand in weight pan.
Take mixture of mould sand in rapid moisture tester and clamp properly.
After clamping ram the sand for 3 times.
After ramming the sand take reading of moisture % on tester dial.
Required % of moisture is 3.0-4.0 %.
Permeability is the physical property of molded sand, which allows the gases to pass through
it. It is determined by measuring the rate of flow of air (2000 cm3) through the metric standard
rammed specimen (Ø50 mm×50 mm in height) under a standard pressure (10 g/cm2). The
amount of clay and moisture content has a significant role in improving the strength and
permeability of green sand mould and it should be controlled to get defect free castings. For

example, green sand properties for a mould prepared by using a jolt /squeeze machine are water
(3-4%), live clay (5.5%) and permeability (80-110) while for the mould prepared by using a high
pressure are water (2.5- 3.2%), live clay (6-10%) and permeability (80-100) .
SOP for PERMEABILITY CHECKING:
Take 140 gm moulding sand.
Fill the specimen tube with sand.
Compact the sand with three blows of sand rammer.
Place the rammed sand sample and tube in test position permeability.\
Take reading on pressure manometer and compare with conversion table.
Required permeability is 102-140.
Clay (Bentonite) act as a binder, mixes with water to bind the sand particles and can be
maintained in the range 5-7% to produce mould with better refractoriness and higher
permeability If the clay content is higher in the sand mixture, the permeability is lowered due to
fine clay particles occupied in the available spaces between the sand grains.
SOP for STRENGTH TESTING:
Fill the specimen tube.
After compact the sand with three blows of sand rammer.
Remove sample mould sand from tube.
Load sample mould on strength testing machine.
Rotate handle of strength testing machine upto sample mould not to brake.
Check indicating arrow point position at mould brake time and check strength by using
measuring scale.
Required strength is 900-1200.

SOP for COMPATIBILITY CHECKING:
Fill the specimen tube.
Remove excess sand from tube.
Compact the sand with three blows of sand rammer.
Compatibility measuring scale is used for checking rammed sand deep.
Required compatibility is 36-46.
MOULDING PROCESS PARAMETERS:
Parameters Specifications Checking Method Checking Time

Mould Hardness 80-95 Mould hardness tester 5 box/hr.
Mould No loose sand, Manually Per box.
damage
M/C Air Vent mould finish Pressure dial Per day
6-7 kg/Sq.cm
Molding is the process of manufacturing by shaping raw material using a rigid frame called a
mold or matrix. This itself may have been made using a pattern or model of the final object.
Sand casting also known as sand molded casting, is a metal casting process characterized by
using sand as the mold material. The term "sand casting" can also refer to an object produced via

the sand casting process. Sand castings are produced in specialized factories called foundries.
Over 60% of all metal castings are produced via sand casting process.
A foundry molding machine having a squeeze table, and a squeeze piston supporting said
table, wherein the improvement comprises a ram extending through said piston to enable both
anvil or shockless jolt, said ram floating on the squeeze pressure to obtain shockless jolt during
squeeze. A foundry molding machine as set forth in claim 1 including a cylindrical extension on
said piston of said assembly and a cylindrical extension on said table, said table extension being
telescoped into said piston extension. A foundry molding machine as set forth in claim 2
wherein said table extension and the upper end of said ram form a jolt cavity, the end of said ram
exposed to such cavity being larger in area than the end exposed to such squeeze pressure. A
foundry molding machine as set forth in claim 3 including an exhaust port in said table extension
operative to vent such cavity as pressure therein relatively moves said ram and table. A foundry
molding machine as set forth in claim 4 including a second cavity formed by said ram and
piston-cylinder assembly between said first cavity and said piston, and means operative to
maintain said second cavity vented. A foundry molding machine as set forth in claim 5 wherein
said table extension extends into said second cavity, said last mentioned means being a vent
passage in said table extension. A foundry molding machine as set forth in claim 1 including a
cylindrical extension on said table, said ram being mounted for reciprocation in said table
extension. A foundry molding machine as set forth in claim 7 wherein said ram includes a
cylindrical extension of reduced diameter projecting through said piston. A foundry molding
machine as set forth in claim 8 including an extension on said piston supporting said table in one
position thereof, said ram and its extension being bottomed on the cylinder of said piston-
cylinder assembly and slightly clearing said table whereby air pressure between said ram and
table will elevate the latter to drop the same on said piston extension when said pressure is
vented to obtain an anvil jolt. A foundry molding machine as set forth in claim 1 wherein said
ram is bottomed on said cylinder of said piston-cylinder assembly and clears said table in the
lowermost position thereof, whereby air pressure between said ram and table will elevate said
table and drop the same on venting of such pressure to obtain an anvil jolt. A foundry molding
machine as set forth in claim 1 including a pair of arms operative to swing adjacent said table
facilitate lifting of a mold box A foundry molding machine having an upstanding cylindrical
housing, a table adapted to support a sand filled flask, and a piston in said housing supporting
said table for vertical movement, the improvement comprising a jolt ram cooperating with said
table and extending through said piston to enable both anvil or shockless jolt, said ram.
A foundry molding machine as set forth in claim 12 including a cylindrical extension
on table. A foundry molding machine as set forth in claim 13 including a cylindrical extension
on said table telescoping over said ram and forming therewith a jolt cavity on top of said ram. A
foundry molding machine as set forth in claim 14 wherein both said piston and said ram are
bottomed on said housing when there is no pressure beneath said piston whereby pressurization
and venting of such cavity will elevate said table and then drop the same to provide an anvil jolt.

A foundry molding machine as set forth in claim 15 wherein said ram clears said table
when bottomed on said housing so that said table strikes the top annular edge of the cylindrical.
A foundry molding machine as set forth in claim 12 including a pair of pivotally
mounted arms adapted to lift such sand filled flask from said table to facilitate .A jolt-squeeze
molding machine capable of producing an anvil or shockless jolt comprising a squeeze piston,
jolt means, a table, said squeeze piston supporting said table for movement toward and away
from a squeeze head, said jolt means comprising a ram operative to strike said table, said ram
including an extension projecting through said squeeze piston and into the pressure side chamber
of said piston. A jolt-squeeze molding machine as set forth in claim 19 including a cylindrical
extension on said piston supporting said table, and a housing in which said piston is mounted for
movement. A molding machine as set forth in claim 20 wherein both said squeeze piston and
said ram are bottomed on said housing in the lowermost position of said table. A molding
machine as set forth in claim 21 including a cylindrical extension on said table cooperating with
said jolt ram to form a jolt cavity above said ram, and means to pressurize said cavity to elevate
said table and vent said cavity to drop said table to obtain an anvil jolt. A jolt-squeeze molding
machine comprising a frame, a vertically movable table in said frame adapted to support a sand
filled mold box, an overhead squeeze head, a jolt mechanism in said table capable of jolting the
sand in such mold box prior to and during elevation of the latter against said head, a pair of arms
operative to lift such mold box from said table to facilitate inversion, said jolt mechanism
including means to provide an anvil jolt prior to elevation and a shockless jolt during elevation.
A jolt-squeeze molding machine as set forth in claim 23 wherein said jolt mechanism includes a
ram stationary for said anvil jolt and movable for said shockless jolt. A jolt-squeeze molding
machine as set forth in claim 24 including an expansible squeeze pressure chamber operative to
elevate said table, said ram floating on said squeeze pressure therein during shockless jolt.

Sand Additives:
Bentonite:
Bentonite is an absorbent aluminium phyllosilicate clay consisting mostly of

montmorillonite. Different types of Bentonite are as:
Sodium Bentonite
Calcium Bentonite
Potassium Bentonite
Aluminium bentonite
Sodium Bentonite:
Sodium bentonite expands when wet, absorbing as much as several times its dry mass in water.
Because of its excellent colloidal properties, it is often used in drilling mud for oil and gas wells
and boreholes for geotechnical and environmental investigations. The property of swelling also
makes sodium bentonite useful as a sealant, since it provides a self-sealing, low permeability
barrier. It is used to line the base of landfills, for example. Various surface modifications to
sodium bentonite improve some rheological or sealing performance in geoenvironmental
applications, for example, the addition of polymers.

Calcium Bentonite:
Calcium bentonite is a useful adsorbent of ions in solution, as well as fats and

oils. It is the main active ingredient of fuller's earth, probably one of the earliest industrial
cleaning agents.
Calcium bentonite may be converted to sodium bentonite (termed sodium

beneficiation or sodium activation) to exhibit many of sodium bentonite's properties by an ion
exchange process. In common usage, this means adding 5–10% of a soluble sodium salt such
as sodium carbonate to wet bentonite, mixing well, and allowing time for the ion exchange to
take place and water to remove the exchanged calcium. Some properties, such as viscosity and
fluid loss of suspensions, of sodium-beneficiated calcium bentonite (or sodium-activated
bentonite) may not be fully equivalent to those of natural sodium bentonite. For example,
residual calcium carbonates (formed if exchanged cations are insufficiently removed) may result
in inferior performance of the bentonite in geosynthetic liners.
Potassium Bentonite:
Also known as potash bentonite or K-bentonite, potassium bentonite is potassium-rich illitic clay
formed from alteration of volcanic ash.

Pattern:
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.
Pattern Making:
The making of patterns, called patternmaking (sometimes styled pattern-making or pattern

making), is a skilled trade that is related to the trades of tool and die making and mold making,
but also often incorporates elements of fine woodworking. Patternmakers (sometimes
styled pattern-makers or pattern makers) learn their skills through apprenticeships and trade
schools over many years of experience. Although an engineer may help to design the pattern, it is
usually a patternmaker who executes the design.
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. Sugar pine is the most commonly used
material for patterns, primarily because it is soft, light, and easy to work. Honduras Mahogany
was used for more production parts because it is harder and would last longer than pine. 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. True Honduras Mahogany
is harder to find now because of the decimation of the rain forests, so now there are a variety of
woods marketed as Mahogany. Fiberglass and plastic patterns have gained popularity in recent
years because they are water proof and very durable. Metal patterns are long lasting and do not
succumb to moisture, but they are heavier, more expensive and difficult to repair once damaged.
Wax patterns are used in a casting process called investment casting. A combination
of paraffin wax, bees wax and carnauba wax is used for this purpose.
Plaster of paris is usually used in making master dies and molds, as it gains hardness
quickly, with a lot of flexibility when in the setting stage.
Core :
Cover sealed
A core is a device used in casting and moulding processes 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. They are most commonly used in sand
casting, but are also used in die casting and injection moulding.
Material requirement :
Core sand
Bentonite clay
Pulverized coal
Resin oil

Advantages and disadvantages:
Cores are useful for features that cannot tolerate draft or to provide detail that cannot otherwise
be integrated into a core-less casting or mold
The main disadvantage is the additional cost to incorporate cores.
Requirements:
There are seven requirements for cores:
Green strength: In the green condition, there must be adequate strength for handling
In the hardened state, it must be strong enough to handle the forces of casting; therefore, the
compression strength should be 100 to 300 psi (0.69 to 2.07 MPa).
Permeability must be very high to allow for the escape of gases.
Friability: As the casting or molding cools, the core must be weak enough to break down as the
material shrinks. Moreover, they must be easy to remove during shakeout.
Good refractoriness is required as the core is usually surrounded by hot metal during casting or
molding.
A smooth surface finish.
Minimum generation of gases during metal pouring.
Types of cores:
Green-sand cores:
Green-sand cores 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

Green Sand Core
Dry sand cores:
The simplest way to make a 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. Any rough spots are filed or sanded down. Finally, the core is
lightly coated with graphite, silica, or mica to give a smoother surface finish and greater
resistance to heat. Single-piece cores do not need to be assembled because they are made in
a split core box. A split core box, like it sounds, is made of two halves and has at least one hole
for sand to be introduced. For simple cores that have constant cross-sections they can be created
on special core-producing extruders. The extrusions are then cut to the proper length and
hardened.
Core making process:
Hot box process:
Cold box process
1. Hot box process:
The hot-box process, which uses a thermoset and catalyst for a binder.
The sand with the binder is packed into a core box that is heated to approximately 230 °C
(446 °F) (which is where the name originated from). The binder that touches the hot surface of
the core box begins to cure within 10 to 30 seconds. Depending on the type of binder it may
require further baking to fully cure. Cores produced using this method are sometimes referred to
as "shell-core" because often, only the outside layer of the core is hardened when in contact with
the hot corebox. When the corebox is opened and the core removed, the uncured sand inside the
core is dumped out to be reused. This practice can also be observed in some cold-box
coremaking practices, though cold box shell-core making is much less common.
2. . Cold box process:
The cold-box process uses a binder that is hardened through the use of special
gases. The binder coated sand is packed into a core box and then sealed so that a curing gas can
be introduced. These gases are often toxic (i.e. amine gas) or odorous (i.e. SO2), so special
handling systems must be used. However, because high temperatures are not required the core
box can be made from metal, wood, or plastic. An added benefit is that hollow core can be

formed if the gas is introduced via holes in the core surface which cause only the surface of the
core to harden; the remaining sand is then just dumped out to be used again. For example, a cold-
box sand casting core binder is sodium silicate which hardens on exposure to carbon dioxide.
Allowances:
To compensate for any dimensional and structural changes which will happen
during the casting or patterning process, allowances are usually made in the pattern.
Shrinkage allowance:
Almost all metals shrink or contract volumetrically after solidification to obtain a

particular size of casting an amount is equal to the shrinkage or contraction.The metal will
undergo shrinkage during solidification and contract further on cooling to room temperature. To
compensate this, the pattern is made larger than the required casting. This extra size is given on
the pattern for metal shrinkage is called 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). 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. This was traditionally
accounted for using a shrink rule, which is an oversized rule.
Shrinkage can again be classified into liquid shrinkage and solid shrinkage. Liquid shrinkage is
the reduction in volume during the process of solidification, and Solid shrinkage is the reduction
in volume during the cooling of the cast metal. Shrinkage allowance takes into account only the
solid shrinkage. The liquid shrinkage is accounted for by risers.
Draft allowance:
When the pattern is to be removed from the sand mold, there is a

possibility that any leading edges may break off, or get damaged in the process. To avoid this, a
taper is provided on the pattern, so as to facilitate easy removal of the pattern from the mold, and
hence reduce damage to edges. The taper angle provided is called the Draft angle. The value of
the draft angle depends upon the complexity of the pattern, the type of molding (hand molding or
machine molding), height of the surface, etc. Draft provided on the casting is usually 1 to 3
degrees on external surfaces (5 to 8 internal surfaces).

Machining allowance:
The surface finish obtained in sand castings is generally poor

(dimensionally inaccurate), and hence in many cases, the cast product is subjected to machining
processes like turning or grinding in order to improve the surface finish. During machining
processes, some metal is removed from the piece. To compensate for this, a machining
allowance (additional material) should be given in the casting. The amount of finish allowance
depends on the material of the casting, size of casting, volume of production, method of molding,
and etc.
Distortion allowance:
During cooling of the mould, stresses developed in the solid metal may induce distortions
in the cast. This is more evident when the mould is thinner in width as compared to its length.
This can be eliminated by initially distorting the pattern in the opposite direction.
Casting defects:
Blow hole:
Blowhole is a type of casting defect mostly prevalent in castings, further divided into pin holes,
endogenous and exogenous blowholes. Entrapment of air resulting due to pouring of liquid metal
takes the form of rounded contours or spherical cavities. Surface blows or intergranuler cavities
appear in cope of the mould. Pinholes result when the hydrogen present in liquid metal evolves
due to less solubility during solidification resulting in triangular appearances, prevalent mostly in
thinner castings which are revealed after machining.

Shrinkage:
Shrinkage is a type of casting defect resulting due to formation of shrinkage cavity as such due
to lack of design and insufficient feed metal. Shrinkage results due to formation of a closed loop
at a specific point during solidification which creates a cavity because of absence of feed of
molten metal. Shrinkage can be classified into three types as open (macro porosity), closed
(internal/blind shrinkage) and axial shrinkage. Open shrinkage appear on the exterior of casting
surface resulting due to volume contraction from liquid to solid state. These are visualized as
shallow cavities on casting surface. Closed Shrinkage results due to dense network of dendritic
crystals which restricts void feeding of thick sections. Axial shrinkage is a result of long freezing
time at the centerline of casting due to high pouring temperature.
Hot tears:
Hot tears are predominant due to imbalance in temperature caused during solidification.
These appear to be sharp and broken jagged lines at the edges of casting.
Sand inclusion:

Sand Inclusion is one of the most common casting defects. Tearing of sand while preparing
mould section manifests itself near casting edges to cause such defect. Most of the sand inclusion
occurs at variable positions leading to a localized defect. Abrading away of sand by hot metal
flowing past the mould also forms a part of this defect. These inclusions are mostly accompanied
by CO bubbles and oxide particles. Sand inclusions stuck under the casting surface and are
mostly visible during the treatment.
5. Mismatch:
Mismatch is a defect in which shifting of top and bottom parts of a mould above or below the
centerline takes place causing the casting to be defective. Segments dislocated above the
centerline leads to this serious defect.
Machine shop is well equipped with advanced machines are as:
CNC turning lathe - 5Nos.
Vertical Machining Centers – 3Nos.
Vertical Turret Lathes - 3Nos.
Special purpose machines -3Nos.
Drilling machines – 1No.
After machining components to the required dimensions then inspection of components is done.
If component is within the given dimensions then it is passed to packaging and dispatch
department. If component is not within the given dimensions then it is rejected. Inspection tools
used are as bore gauge, snap gauge, master gauges etc.

Machine Shop Layout:

1. CNC turning lathe:
Specifications:
Control – Siemens
Chuck Diameter - 200 mm
Maximum Turning Diameter - 360 mm
Maximum Turning Length - 425 mm
No. Tool - 8 Station
Spindle Speed - 6000 RPM
Phase – 3Phase
Frequency – 50/60 Hz
Turning is a machining process in which a cutting tool, typically a non-rotary tool bit,
describes a helix toolpath by moving more or less linearly while the workpiece rotates. CNC
Machining is a process used in the manufacturing sector that involves the use of computers to
control machine tools like lathes, mills and grinders. To manufacture complex curved geometries
in 2D or 3D was extremely expensive by mechanical means so for this CNC machines are
used.Machining components with high Repeatability and Precision is possible. To improve
production planning and to increase productivity.

2. Vertical Machining Centre:
Specifications:
Table Size: 1200*510 Sq.mm
Traverses X,Y and Z axis: 1000*500*500
Rapid rate: 12(Standard) m/min.
Positioning accuracy: +/- 0.008 mm.
Repeatability: +/-0.004 mm.
Spindle speed: 60-6000rpm.
Spindle power: 3.5kw
ATC capacity: 24.
Tool change time: 3.5sec.
Control system: Siemens
A VMC is a type of CNC machine, typically enclosed and most often used for cutting metal.
They are usually very precise and very expensive. VMC stands for Vertical Machining Center.
In VMC, The workpiece is hold on the table base and the spindle which contains the cutting tool
is fixed on vertical spindle Z axis. The table moves in X and Y axis and spindle with cutting tool
moves in Z axis.

3. Vertical Turret Lathe:
Swing over bed: 800mm
Swing over carriage: 240mm
Maximum turning diameter: 425mm
Maximum turning length: 615mm
Maximum spindle speed: 2500 rpm
Turret type: Rotary tool turret
Overall dimensions: 1840*2210*2950
Vertical turret lathe works like an engine lathe turned upon end. Operations like
turning, facing, boring, internal and external threads are performed. Horizontal table or faceplate
that holds the work and rotates about a vertical axis. A side head that can be fed either
horizontally or vertically. The main advantage is that heavy parts are easier to handle as
compared to engine lathe.

4. Co-ordinate Measuring Machine:
Machine Design:
Bridge type measuring machine with fixed measuring table.
Measuring surface complies with DIN standards.
Rigid, light weight bridge.
Integrated design for small footprint.
Machine Technology:
Dynamic drive control with automatic drive features.
All axes wrap around air bearings.
Passive vibration damping is provided.
PC- based controller with real time operating system.
Measuring range is 700*700*600 or 700*1000*600
Maximum workpiece weight is 308 kg for 700*700*600 model and 402 kg for 700*1000*600
model.

Operation:
New standard control panel with motorized control.
Speed control for CNC measuring operations.
LCD display for stylus, coordinates etc.
Joystick security unlock buttons.
Software:
CALYPSO metrology software from Carl Zeiss is used.
Revolutionary cad based metrology software.
No time consuming and structural programming is possibl

SIX SIGMA:
Six Sigma is a quality improvement programme with a goal to reduce the number of
defects to as low as 3.4 parts per million. It relies on the use of Normal Distribution to predict
defective rates.
Six sigma quality is a benchmark of excellence for product and process quality, popularized
by Motorola based on zero defect concept introduced by Philip B. Crosby. It provides a
quantitative statistical notion of quality useful in understanding, measuring and reducing
variation.
A product is said to be of six sigma quality if there are no more than 3.4 non-conformities
per million opportunities at the part and process step level.
Six sigma is an overall strategy to accelerate improvements in its processes, products and
services. It is also a measurement of total quality to let the company know how effective it is in
eliminating, including those in operational, technical and customer excellence. It just applies to
every function in the company.
Six sigma is a statistical measurement, which helps us establish our course and gauge our
pace in the race for total customer satisfaction. It tells us how good our products, services and
processes. We can see where we need to go and what we must do to get there.
The sigma scale or measure provides us with a “goodness micrometer” for gauging adequacy of
our products, services or processes.
It is a business strategy which makes the customers more satisfied. It can greatly help us
to gain competitive edge. This is because, as we improve the sigma rating of the process, the
product quality improves and costs go down.
It is a philosophy. It is an outlook, a way that we perceive and work within the business
world around us. Essentially, the philosophy is one of working smarter, not harder. This
translates to making fewer and fewer mistakes in everything we do from the way we
manufacture products to the way we fill out a purchase order. As we discover and neutralize
harmful sources of variation, our sigma rating goes up. Again this means our process capability
improves and the defects go away.

Basic Steps Involved in the Application of Six Sigma:
The methodology of six sigma consists of five steps namely Define (D), Measure (M),
Analyse (A), Improve (I) and Control (C).
Define:
The primary aim is to identify, within each sub-process, the possibilities for defects or
quality problems which can be arrived at through the use of different statistical tools, such as
regression analysis, design of experiments and chi-square testing. The quality problem which
requires break-through solution has to be defined clearly in measurable terms. The problem
selected should consider the requirements of the customer and should have relevance to the
company’s business. In other words, its solution should ensure great customer satisfaction as
well as monetary gains to the company. If the company has developed its business strategies, the
problem should fall under any one of them. Generally any customer expects defect free products
and timely deliveries. Whatever form a quality problem takes- a wrongly marked invoice, a
defective spare, abnormally-high warranty costs – the Six Sigma strategy is to translate it into
measurable terms. Defining a problem in manufacturing area is easier when compared to service
areas.
Measure:
The second most important step is the establishment of the metrics that will be
improved using Six Sigma. It is also necessary to identify and rank the improvement
opportunities. First the CTQ (Critical To Quality) characteristics of the process have to be
identified in order to focus six sigma on areas that will have the greatest impact on customer
satisfaction. For instance, design might turn out to contain the crucial CTQ in a manufacturing
process while speed might be more relevant in the case of proceeding an order. The output of the
process, measured as multiples of its sigma under each CTQ has to be recorded so that Defect
Per Unit (DPU) is estimated in PPM. These will be used as the starting points for setting new
targets, and proceeding with the subsequent steps.

Analysis:
This is the stage at which new goals are set, and the route maps created for closing the
gap between current and target performance levels. It begins with bench marking key product
performance against the best-in-class so that the sigma levels attained be comparable processes
can be ascertained as the basis for new targets.
Then, a GAP analysis is conducted to identify the factors that distinguish best-in-
class processes from those being analysed so that the areas of change can be identified.
Statistical tools as well as conventional quality techniques like Brainstorming,

Root-cause Analysis, Fishbone Diagram, Pareto analysis etc., may be used for carrying out the
analysis.
Analysis is a key component of any defect reducing programme. The aim is to

identify what causes the defects in each sub-process so that they can be rectified, either by
redesigning the product or re-engineering the process.
Improvement:
The objective of this phase is:To conform the key process variables.Quantify their
effects on the CTQ.Identify the maximum acceptable ranges of the specification, and then tackle
the capability of the process.
If the existing quality level is < 3 sigma, efforts must be directed to improve the processes so as
to achieve at least 3 sigma.
The transition from 3 sigma to 6 sigma is done on the 2 fronts enlarging the design-width to
accommodate greater variability in the output and the second approach is to make improvements
in the process itself so that the chances of defects are eliminated. As already stated, this is
achieved by a well defined and implemented quality programme having a definite start and a
definite end. Of course, the output must be measured continuously to monitor the extent of
improvement along the CTQ parameters.

5. Control:
The final stage of Six Sigma implementation is to hold the gains that have been obtained
from the improve stage. Unless there is a good control we are likely to go back to the original
state. Hence, in this stage the new process conditions are documented, and frozen into systems so
that the gains are permanent. The process is assessed once more after the setting-in period in
order to check whether the improvements are being sustained or not.
If a quality programme has to achieve meaningful results, the changes have to be put into a
formal structure. Otherwise, workers may go back to the earlier processes.
POKA-YOKE (mistake-proof) devices can be set up to obviate the

inadvertent errors. The idea of POKA-YOKE is to respect the intelligence of workers by taking
over repetitive tasks that depend on vigilance or memory.

The 7 quality control tools are as:
1) Process Flow Diagram: It gives brief information about the relationships between the process
units.
2) Cause and Effect Diagram (Fishbone): By using Fish bone diagram, all contributing factors
and their relationship with the defects are displayed and it identifies problem.
3) Control Chart Analysis: Control chart analysis helps in the following ways. It helps in
monitoring quality in the process.To detect non-random variability of the process.To identify
assignable causes.
4) Check Sheets: Using check sheets data collection and analysis is easy. It also spots problem
areas by frequency of location, type or cause of the defect.
5) The Pareto Diagram: Pareto diagram is a tool that arranges items in the order of the
magnitude of their contribution. It identifies a few items exerting maximum influence.
6) Scatter Plot: For identifying a potential relationship between two variables Scatter Plot is
used. By using this plot, a positive, negative or no relationship between variables can be
detected.
7) Histogram: It represents a visual display of data observed frequencies versus the number of
defects are given in this histogram. The height of each bar is equal to the frequency occurrence
of the defects. The shape of histogram shows the nature of the distribution of the data.

Check Sheet:
The check sheet is a simple document that is used for collecting data in real-time and at
the location where the data is generated .The document is typically a blank form that is designed
for the quick, easy, and efficient recording of the desired information, which can be either
quantitative or qualitative. Rejection check sheets are generally large data sheets showing the
total information about rejected items. Following is the six month data of production per month.
Rejection of cover sealed is given in table:
Month Rejection Rejection per Month

Jan 23 409
Feb 126 1034
March 61 1021
April 94 812
May 268 2079
June 297 2269
Bar Chart:
350
300
250
200
150
100
50
0
Jan Feb March April May June .

Cause and Effect diagram:

Cause and Effect diagram for blowhole has been drawn and causes have been studied
as below:
The five categories like moulding process, material, pouring, melting process and design are
used in diagram. The brainstorming was held for finding different causes behind the blowhole
defect and identifying the main causes those are responsible for the damage. It consists of group
of members working in foundry. There are members in brainstorming session from different
foundry departments which include Lab In charge, Quality manager, Furnace supervisor,
Worker. We started with cause and effect analysis to find generalized reasons for blowhole
defect.

Process indicator Output

Wet sand 9
Sand permeability not sufficient 8
Too much binder 5
Metal composition 5
Metal temperature 5
Workpiece condition 5
Pouring too slow 5
Pouring too cold 5
High nitrogen contain in charge and 5
additives
Insufficient venting 8
Some factors responsible for blowholes are:
Wet sand
Sand permeability is not sufficient
Insufficient venting
Too much binder
Blowhole defect

Cause and Effect diagram for sand drop has been drawn and causes have been studied as
below:
The brainstorming session was held for finding different causes behind the Sand Drop
defect and identifying the main causes those are responsible for the maximum damage. We
started with cause and effect analysis to find generalized reasons for Sand Drop defect after that
we have shortlisted the critical causes that potentially giving impact to generate cause and effect
matrix. Cause and effect matrix is a tool which is used to prioritize potential causes by
examining their relationship with the critical to quality. Causes are placed on left side. Causes
are ranked in terms of importance. Cause with highest rank should be addressed first because
they will have the largest impact on the CTQ’s. Cause effect matrix for sand drop is shown in
below table.

Process Indicator Output Output Indicators
Improper moulding sand 9 90

properties.
Foreign material in 5 50
moulding sand
Loose ramming of mould 5 50

Loose sand in mould 5 50
Improper moulding sand 1 10
additives
Non parallel core setting 1 10

Worn out moulding box 0 0
bushes
Improper mixing of sand 5 50

Improper mould cleaning 5 50
Improper core cleaning 1 10
Improper box closing 5 50
Loose ramming of core 0 0
Use of repaired core 0 0
Scale: 0=None, 1=Low, 5=Modrate, 9=Strong

Sand drop defect
Some factors responsible for sand drop are:
Improper moulding sand properties
Foreign material in moulding sand
Improper mould cleaning
Improper mixing of sand
Solution towards wet sand:
Major cause found behind blow holes was detected as wet sand in casting mold. It
is because of the fact that sand contains a higher value of moisture content in it, approximately 6-
10% it is a bit high amount of moisture content in silica sand being use for grey cast iron
castings. Moulding sand is dried at a temperature of 105 to 110 degree Celsius by which time its
moisture content comes to level about 4.3 to 4.6%. Sand with moisture content ranging between
4.3-4.6 % is find to have optimum working range with effective green compressible strength and
permeability. Low moisture content in the moulding sand does not develop strength properties
and high moisture content decreases permeability.

Solution towards pouring practice:
Using of spur gear laddle in order to improve pouring practice. The hand wheel is
driven by spur gear. The hand chain hoist brake is locked and opened unconsciously and rotates
to pour molten metal. It features easy operation, low wearing and no head collision. Traditional
worm gear laddle is inefficient. After use, it creates wear and collision which leads to an
accident.

Conclusion:
Bar diagram for defects have been drawn and the major rejection are due to Blowholes and Sand
drop during the month of January and March % decreases and during the month of May and June
% increases.
Cause effect diagram have been drawn for blowhole and major causes are taken as wet sand,
insufficient venting, too much binder, sand permeability is not sufficient.
Cause effect diagram have been drawn for sand drop and major causes are taken as improper
moulding sand properties, foreign material in moulding sand, improper mixing of sand.

Department of Production Engineering, K.I.T's COE, Kolhapur

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Industrial Training at Chougule Industries 1

UNDER THE GUIDANCE OF

Department of Production Engineering, K.I.T’s COE, Kolhapur

Prof. S J Shaha PROF . S. M . Kadane

Dept. of Production Engineering Dept. of Production Engineering

Department of Production Engineering, K.I.T’s COE, Kolhapur

Achievements of Chougule industries are as:

Self Certified Supplier - from Tractors and Farm Equipments Limited.

Department of Production Engineering, K.I.T’s COE, Kolhapur

Department of Production Engineering, K.I.T’s COE, Kolhapur

SOP for MOISTURE TESTING:

Take 140 gm mould sand in weight pan.

After clamping ram the sand for 3 times.

After ramming the sand take reading of moisture % on tester dial.

Required % of moisture is 3.0-4.0 %.

Department of Production Engineering, K.I.T’s COE, Kolhapur

SOP for PERMEABILITY CHECKING:

Take 140 gm moulding sand.

Fill the specimen tube with sand.

Compact the sand with three blows of sand rammer.

Take reading on pressure manometer and compare with conversion table.

Required permeability is 102-140.

SOP for STRENGTH TESTING:

Fill the specimen tube.

After compact the sand with three blows of sand rammer.

Remove sample mould sand from tube.

Load sample mould on strength testing machine.

Required strength is 900-1200.

Department of Production Engineering, K.I.T’s COE, Kolhapur

SOP for COMPATIBILITY CHECKING:

Fill the specimen tube.

Remove excess sand from tube.

Compact the sand with three blows of sand rammer.

Compatibility measuring scale is used for checking rammed sand deep.

Required compatibility is 36-46.

MOULDING PROCESS PARAMETERS:

Parameters Specifications Checking Method Checking Time

Department of Production Engineering, K.I.T’s COE, Kolhapur

Department of Production Engineering, K.I.T’s COE, Kolhapur

Department of Production Engineering, K.I.T’s COE, Kolhapur

Bentonite is an absorbent aluminium phyllosilicate clay consisting mostly of

Department of Production Engineering, K.I.T’s COE, Kolhapur

Calcium bentonite is a useful adsorbent of ions in solution, as well as fats and

Calcium bentonite may be converted to sodium bentonite (termed sodium

Department of Production Engineering, K.I.T’s COE, Kolhapur

In casting, a pattern is a replica of the object to be cast, used to prepare

The making of patterns, called patternmaking (sometimes styled pattern-making or pattern

Department of Production Engineering, K.I.T’s COE, Kolhapur

Department of Production Engineering, K.I.T’s COE, Kolhapur

Advantages and disadvantages:

The main disadvantage is the additional cost to incorporate cores.

There are seven requirements for cores:

Permeability must be very high to allow for the escape of gases.

A smooth surface finish.

Minimum generation of gases during metal pouring.

Green-sand cores makes casting long narrow features difficult or

Department of Production Engineering, K.I.T’s COE, Kolhapur

Green Sand Core

Dry sand cores:

Core making process:

Hot box process:

Cold box process

1. Hot box process:

Traverses X,Y and Z axis: 1000500500

Overall dimensions: 184022102950

Measuring range is 700700600 or 7001000600