DEPARTMENT OF MECHANICAL

ENGINEERING

Muffakham Jah College of Engineering and

Technology
Mount Pleasant, 8-2-249, Road No. 3,
Banjara Hills, Hyderabad - 500 034,
Telangana, India
(Affiliated to Osmania University)

SUBMITTED BY

MOHAMMED ABDUL MUQEEM

1604-16-736-066

1
 INTERNSHIP REPORT

ON

MANUFACTURING

OF GRAVITY CASTED DIES COMPANY

2
 ACKNOWLEDGEMENT

I take great honour in submitting this Internship report of my Internship

Training completed successfully at ACMI Industry.

I am debited to the Managing Director of the Company, Mr. Mohammed

Qayyum Rabbani, for providing me an opportunity to grasp the
practicality of the manufacturing subject in his privileged company.

I am very thankful to the management of the ACMI Industry for giving

me the opportunity to be trained in their esteemed organization & for the
completion of the training within such a short period of time.

This report would not have been completed without the assistance, co-
operation and enthusiasm taken by Mr. Mohammad Ashfaq Ali for his
warm guidance throughout the training period.

I would like to thank the employees and the workers of the ACMI
Industry for showing me the way and the workings of the industry and
the engineering involved in the running of such a vast commercial and
impactful industry.

3
 Abstract

ACMI Industries is a small scale manufacturing company which mainly

manufactures Aluminium Gravity Die Castings. The industry involves
the complete process of getting the raw material and melting it to
inspecting the final product and dispatching it to the authorized
customer. The processes that take place in the industry are Designing,
Raw Material Inspection, Melting the raw material, Testing of alloy,
Pouring, Cutting/Fettling, Solution treatment, Mechanical testing, Heat
treatment, Shot blasting, Machining, Leak testing, Inspection and
Packing & Dispatching. Regular Customers of the company are
Siemens, Toshiba, Suretech Assembly Inc. etc. The Industry is well
equipped with good testing and inspection machines such as the
SpectroMax, Universal Testing Machine and also equipped with
different CNC Machines and Leak testing apparatus due to which some
other small industries also approach the industry for help.

4
 CONTENTS

1. Introduction
2. Introduction to Manufacturing
3. Procedure
4. Results And Discussion
5. Conclusions

INTRODUCTION
5
ACMI Industry is a manufacturing company which mainly manufactures
Aluminium Gravity Die Casted parts.

It is located in D-47, Phase IV (Extn.) I.D.A, Jeedimetla, Hyderabad,

Telangana. ACMI INDUSTRIES History starts with Rama Enterprises
founded in 1973 for manufacturing Aluminium Gravity Die Castings.
ACMI is under one roof complete solution provider for Tier One and
OEM customers. As the speed of innovation escalates, ACMI
continuous to outperform their competitors with unique and innovative
cast, machined and assemble components.

ACMI believes that open communication and collaboration form a

critical part of the process where we can collectively identify objectives
and expectations and assess the operational and functional relationships.

The main aim is to become a market leader with sustainable growth and
customer satisfaction by meeting the fast growing demands of
developing economies.

INTRODUCTION TO MANUFACTURING

6
Manufacturing is the production of products for use or sale using labour
and machines, tools, chemical and biological processing, or formulation.
The term may refer to a range of human activity, from handicraft to high
tech, but is most commonly applied to industrial design.

Manufacturing process are the steps through which raw materials are

transformed into a final product. The manufacturing process begins with
the product design, and materials specification from which the product is
made. These materials are then modified through manufacturing
processes to become the required part.

The different types of processes in manufacturing are:

1 Casting

2 Imaging and coating

3 Moulding

4 Forming

5 Machining

6 Joining etc.

PROCEDURE
7
With the aim to supply ready to assemble Gravity casted parts, the
industry established all processes under one roof. These processes
include Casting Simulation, Designing, Foundry, Heat Treatment, Shot
Blasting, Machining-CNC, Lathe & Drilling and Leak testing (Pressure,
Pneumatic and Helium) which are added as forward integration.

The process starts with designing and simulation of the product after
which the raw material is inspected and melted in some calculated
proportions. The so formed alloy is then taken for inspection and if no
deviations are found then further melting is carried out and finally the
alloy is poured into the required die/mould. Once the alloy takes the
shape of the die, then the excess part is removed from the required cast
by cutting/fettling. This step is followed by Solution
treatment/Ageing. Once ageing has been done, it is necessary to verify
the Mechanical Properties of the alloy using a Universal Testing
Machine.

Heat Treatment is carried out which is followed by the Shot Blasting

Process using Stainless Steel Shots. Afterwards Machining is done
which comprises of process going under CNC, Lathe machine and the
drilling process to get the required dimensions. Finally Inspection of
the product is done and if no faults are found then the product is packed
and dispatched to the authorized customer.

8
 DESIGNING & SIMULATION

Design for manufacturability (also sometimes known as design for

manufacturing or DFM) is the general engineering practice of designing
products in such a way that they are easy to manufacture. The concept
exists in almost all engineering disciplines, but the implementation
differs widely depending on the manufacturing technology.

DFM describes the process of designing or engineering a product in

order to facilitate the manufacturing process in order to reduce its
manufacturing costs.

Manufacturing simulation is the computer-based modeling of a real

production system. Simulation allows organizations in the
manufacturing industry to analyze and experiment with their processes
in a virtual setting, reducing the time and cost requirements associated
with physical testing.

9
 RAW MATERIAL INSPECTION

An inspection is the verification of product quality and quantity to pre-

identified specifications before, during or after the production process.
Prior to the manufacturing process, raw materials can be inspected to
identify if the materials themselves meet specifications.

All raw materials must be tested for purity, identity and quality. A

conservative approach would be to perform complete analysis of each
lot of raw materials received.

10
Raw material consists of Aluminium Ingots, Magnesium blocks,
Manganese, Silicon Metal, and Iron.

AL INGOTS SI PIECES

IRON BLOCKS

MELTING

Melting or fusion, is a physical process that results in the phase

transition of a substance from a solid to a liquid. This occurs when the
internal energy of the solid increases, typically by the application of heat
or pressure, which increases the substance's temperature to the melting
point. At the melting point, the ordering of ions or molecules in the solid
11
breaks down to a less ordered state, and the solid melts to become a
liquid. Substances in the molten state generally have reduced viscosity
as the temperature increases.

A furnace is a device used for high-temperature heating. The name

derives from Latin word Fornax, which means oven. The heat energy to
fuel a furnace may be supplied directly by fuel combustion, by
electricity such as the electric arc furnace, or through induction heating
in induction furnaces. The furnace has an inner brick lining which can
withstand high temperature and pressure. Furnace designs vary as to its
function, heating duty, type of fuel and method of introducing
combustion air. Fuel flows into the burner and is burnt with air provided
from an air blower. There can be more than one burner in a particular
furnace which can be arranged in cells which heat a particular set of
tubes. Burners can also be floor mounted, wall mounted or roof mounted
depending on design.

The flames heat up the tubes, which in turn heat the fluid inside in the
first part of the furnace known as the radiant section or firebox. In this
chamber where combustion takes place, the heat is transferred mainly by
radiation to tubes around the fire in the chamber.

The main metals that are to be melted are Aluminum, Silicon,

Magnesium, Iron, Titanium, Strontium etc. Melting is done in a furnace

12
in which the ignition of the material is carried out by a conventional
method having a unit consisting of oil tank, blower and pump.
Aluminium Ingots are melted in these furnaces at high temperatures.
During the melting, Silicon is added first in the furnace whereas
Magnesium is added at the last. These materials increase the properties
of the alloy.

ALLOY TYPES

There are two types of Alloys namely:

1) LM9 - AlSi10MgKT6(Brittle)
2) LM25 - AlSi7Mg0.3KT6(Ductile)

13
The following table indicates the metal composition in these alloys:

ELEMENTS AlSi7Mg AlSi10Mg

Silicon 6.5 to 7.5% 9 to 11%

Magnesium 0.25 to 0.45% 0.2 to 0.45%

Manganese 0.1% Max 0.45% Max

Aluminium Remainder Remainder

ALLOY INSPECTION

Alloy Inspection is done by using Spectromax-spectrometer. Sample

material is vaporized on the spark stand by an arc or spark discharge.
The atoms and ions contained in the atomic vapour are excited into

14
emission of radiation. The basic function of a spectrometer is to take in
light, break it into its spectral components, digitize the signal as a
function of wavelength, and read it out and display it through a
computer. The alloy is then passed for further production.

Each metal composition in the alloy plays a vital role in shaping up the
properties of the alloy. Iron composition should never exceed the given
range as more percentage of iron can cause an adverse impact on
ductility and it causes more chance of failure during testing. Magnesium
is responsible for giving the hardness property to an alloy, so low
percentage of Mg can cause low hardness in the alloy. The percentage of
Silicon should also be kept under control as Si is responsible for the
porosity of an alloy thus if an alloy exceeds its Silicon composition then
the alloy can go under porosity defects. Metals such as Strontium and
Titanium help in refining the grain structure of an alloy.

15
SAMPLE REPORT

16
 POURING

When manufacturing by metal casting, pouring refers to the process by

which the molten metal is delivered into the mold. It involves its flow
through the gating system and into the main cavity (casting itself).

The inspected alloy is then poured into different sized dies which are to
be produced. The pouring is carried out with the means of a crucible
made out of clay-graphite or silicon-carbide which has a higher melting
point than that of the material to be melted.

The factors to be considered during pouring are:

1) Pouring Temperature : Maximum permissible - 680℃

2) Die Temperature : Minimum Permissible - 425℃
3) Pouring Time : Minimum 40 Sec
4) Solidification Time : 5 Minutes

Cutting/Fettling
17
Cutting has been at the core of manufacturing throughout history. For
metals many methods are used and can be grouped by the physical
phenomenon used. It is the process of producing a work piece by
removing unwanted material from a block of metal in the form of chips.
Fettling is the means by which a crude casting is turned into a cost
effective quality component that meets all the standards required by the
customer.

In context with the casting process, fettling means the removal of

unwanted metal from the product i.e. flashings, risers etc.

Solution Treatment/Ageing

18
Solution treatment is the heating of an alloy to a suitable temperature,
holding it at that temperature long enough to cause one or more
constituents to enter into a solid solution and then cooling it rapidly
enough to hold these constituents in solution. Its purpose is to relieve
internal stresses that are developed during the casting process.

Age Hardening is a relatively low-temperature heat treatment process

that strengthens a material by causing the precipitation of components or
phases of alloy from a super-saturated solid solution condition.

Mechanical Testing

19
A universal testing machine, also known as a universal tester, is used to
test the tensile strength and compressive strength of materials.
Mechanical properties are checked on UTM with test bars poured
ensuring the tensile strength and compressive strength of sample alloy.
An earlier name for a tensile testing machine is a tensometer.

S.No. PROPERTY ACCEPTED VALUE

1 TENSILE STRENGTH Min 250 N/mm^2
2 YIELD STRENGTH Min 220 N/mm^2
3 ELONGATION Min 1
4 HARDNESS 90-105 BHN

Heat Treatment & Shot Blasting

Heat treatment is done to achieve desired mechanical properties in

castings. State-of-the art bottom quenching furnace ensures 100%
quality of heat treatment by quenching jobs in less than 30 seconds time.
Total 4 furnaces and 2 aging ovens are available to meet any quantity
requirements.

20
Shot blasting is done using SS shots to give castings uniform matt finish.

Graphs are plotted online for the heat treatment process with memory
backup.

Machining

Machining is a term used to describe a variety of material

removal processes in which a cutting tool removes
unwanted material from a work piece to produce the
desired shape.

21
Lathe machines, Drilling etc.

VMC AND CNC lathes provides strength to supply parts

of any criticality with consistency.

LEAK TESTING

Leak testing is the process of checking a system for leaks i.e. a defect

which can be achieved using various leak detection methods.

It is employed to test for defects in products to ensure the proper

function and maintenance of industrial systems and pipelines.

22
Mainly two types of testing are carried out:

 Pneumatic Leak Testing

 Helium Leak Testing

INSPECTION

Inspection rooms with controlled temperature enables to measure

dimensions accurately without interference of external atmosphere.

Controlled temperature inspection room with all inspection instruments

are important in meeting customer quality requirement.

23
Qualified and experienced team of quality engineers to ensure products
supplied meeting all quality requirements of customers.

PACKAGING & DISPATCHING

After all the steps, the final step is packing the product and dispatching it
to the authorized customer.

The box-like container, wherein the product is stored to protect it from

any physical damage and at the same time attracting the customer
through its appeal is called as packaging.

24
CONCLUSION

25