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PRESENTATION

ON
RING FOUNDRY SHOP
BY:- JASPREET SINGH
100041127825
RING FOUNDRY SHOP
Casting of piston rings is done there .

PROCESS FLOW

MOULDING
CASTING
SHAKEOUT
GRINDING
HEAT TREATMENT
SAND PREPARATION MELTING
SHOT BLASTING
SAND PREPARATION
Moulding sand is prepared with speed muller .This is fully automatic controlled
Machine. Silica sand is used for green sand moulding .
CONSTITUENTS OF MOULDING SAND
1.Fresh silica sand ---2 to 5%
2.Return sand /reused sand -----85 to 90%
3.Water --3 to 4 %
4.Bentonite powder(clay) --0.52 %
All above constituents are mixed in the muller for 7090 seconds .Then
prepared sand is transferred to moulding machines through belt conveyors.

PROPERTIES OF MOULDING SAND-
1.Moisture 3.13.6%
2.Green strength17002000 gm/cm2
3.Permeabilty Min. 40
4.Compacability 3040
5.Wet Tensile Strength -0.080.18 N/Cm2

MOULDING
Automatic squeeze moulding machines are used for moulding . Prepared moulds
Are placed over a trolley and 20 moulds placed over one another which is called
a stack . Then prepared stack moved over fix railing to the pouring zone.
Match plate patterns with fixed risers are used for
Moulding .Pattern is made of brass and pattern plate is of aluminium.
PARAMETERS OF MOULDING M/C
1.Mould hardness 8595 on B scale
2.Squeeze pressure 2540 kg /cm2
3.Pattern plate and squeeze plate temperature 5060 degree C
4.Mould thickness3841 mm

MELTING
There are 3 electric induction furnaces for melting each of 4 tonne capacity.All are of
medium frequency and 1500 kwh power. Only one furnace runs at a time and 2 remains
Idle.There are four grades of cast iron prepared named as K1,GOE13,IKA and KV1.First
Three are of grey cast iron grade and last one is nodular cast iron grade.
COMPOSITION OF ALLOYS-
1 .K1 2. Goe 13 3. IKA 4.KV1
C- 3.70-3.85% C- 3.65-3.78% C3.453.45% C3.803.90
Si- 2.45-2.55% Si- 2.45-2.60% Si2.35-2.45% Si1.801.90
Mn- 0.55-0.70 % Mn- 0.55-0.70 % Mn0.60.7 % Mn---0.10 Max
P- 0.4-0.5% P- 0.4-0.5% P---0.10.25% P---0.3% Max
Cr.0.10.3% Cr.0.25-0.35% Cr0.350.45 Cr---0.10 % Max
Cu0.10.3% Cu0.40.6% V0.08-0.14% Cu ---0.10 % Max
S -- 0.06--0.11% S -- 0.06--0.11% Ni0.7---0.80% S---0.02%Max
V0.050.2 % Mo--- 0.85__0.95%
Cu---0.720.82%
S 0.10 % Max
Pouring temperature for all the alloys is kept between 15201540 degree C





CASTING
In this process the molten metal from the furnace is taken in monorail
ladle . This ladle is driven by two workmen. Inside lining of ladle is
done by silica sand . After taking the molten metal this ladle is
brought to the pouring zone and metal is poured into the stacks .
Inoculant is added to the metal during metal tapping
from the furnace to ladle .A strontium based Inoculant which called
superseed is used .This is used to form the required microstructure of
casting .
SHOT BLASTING
After the lab check good rings are filled in a box. This box is placed in the
loader of shot blasting machine .In the m/c rings are blasted by steel shots
by two mechanical impellers ,which remove all the sand stick to the rings
The clean rings collected at the other end of the m/c and then supplied to the
Grinding table with the help of fork lifter for grinding .
GRINDING AND INSPECTION
The cleaned ring are grinded from inside and outside on two different grinders
For burr removal . Then these rings are inspected visually for foundry defects.
Good rings packed on trolleys and supplied to machine shop for further operations
FOUNDRY DEFECTS-
1.COLD RINGS
2.SAND INCLUSION
3.FLASH
4.BROKEN RINGS
5.EXTRA METAL INSIDE AND OUTSIDE

THANX