INDUSTRIAL TRAINING REPORT

ON
METAL CASTING

ISGEC HEAVY ENGINEERING LTD.

AT MUZAFFARNAGAR
(FORMERLY UP STEEL)
SUBMITTED TO SUBMITTED BY-
MR ANV KUMAR GAURAV GANGANIYA
(AST. PROFFECER) (1409140906)
 Overview of Isgec
Ranked among top 300 companies in India ( ET Fortune 500 listings )

Group Turnover over US$ 500 Million

Total Employee Strength over 5500.

80 years in Business, 48 years in Boilers

Strong presence in Captive Power Plants

Supplied over 600 High Pressure Boilers.
 Locations
Yamunanagar
Main Plant & Sugar Mill International Offices:
200 km (125 Miles) from New Delhi California, USA
Dusseldorf, Germany
Ratangarh
200 km (125 Miles) from New Delhi
70 International Agents
Noida
HO & Isgec Offices in
Suburb of New Delhi New Delhi
Bawal
100 km (62 Miles)
from New Delhi

Muzaffarnagar
115 km
(71 Miles) from New Delhi
INDIA Kolkata
Dahej
Our Coastal Plant Regional Mktg.

Mumbai
Branch Office
Bhubaneshwar
Pune Regional Mktg.
Design Centre Arabian Sea Bay of Bengal
Regional Mktg
Chennai
Design Centre
Regional Mktg
 Isgec Global Presence
75 Countries across 6 Continents

Algeria Argentina Australia Bahrain Ban gladesh Barbados Bosnia Bra zil Bulgaria Cambodia

Ca nada Chile Chin a Colo mbia Cyprus Czech Rep ublic Dominican Republic Ecuad or Egypt

El Salvad or Ethiopia Finland France G ermany G uya na Hond uras India Ind onesia Iran

Iraq Ita ly Jamaica Japa n Jordon Kenya Kazakh sta n Kuwa it Malaysia

Malta Mauritiu s Mexico Mozamb iqu e Ne pal Nigeria O man Pakistan Peru Philippine s

Qatar Romania Sa udi Ara bia Senegal Sin gapore South Africa South Korea Spain Sri lanka

Sud an Sweden Syria Tanza nia Th aila nd Trinidad & Tabag o Turke y UAE Ug anda

UK USA Uzbekistan Venezuela Vietnam Yemen Zambia Zimbabwe

4
 Introduction:

Metal Casting is one of the oldest materials shaping

methods known. Casting means pouring molten metal into a
mold with a cavity of the shape to be made, and allowing it
to solidify. The solidified object is called the casting.

The mold, into which the metal is poured, is made of some

heat resisting material. Sand is most often used as it resists
the high temperature of the molten metal. Permanent molds
of metal can also be used to cast products.
 Heavy Engineering
Corporation

Foundry Forge Plant Heavy Machine Building Heavy Machine Tool

(FFP) Plant Plant
(HMBP) (HMTP)
Pattern Shop
Turning, Boring, Facing, Grinding,
Grey Iron Threading etc. Machining Operations
Foundry
Steel Foundry Milling, Grinding, Gear
Assembly of Machine
Hobbing, Heat Treatment
Fettling Shop Tools like CNC machine
CNC gas cutting, Sheet
Forge Shop metal work, Welding
Machine Shop
Fabrication & Assembly
 Flow Chart of Casting

Method
Pattern Allowance, Gating
Product Requirement Pattern Making
System, Machining Allowance
etc.

Mould & core

Mould & Core Moulding & Core
assembly and Drying in oven
Painting Making
Closing of Mould

Clamping & Pouring of Liquid Cooling & Shake Cleaning &

Loading Metal out Fettling

Final Product Machining Shop Stress Relieving


Charging Unit
Preparation of metal
scraps mainly for Plane
carbon steel, Alloy Steel
and Cast Iron Materials.
Basic components of melt
contains C, Si, Mn, P etc.
Metal is alloyed with
different alloying elements
Cr, Ni,Mo,V etc.
Melting Section
Melting Unit Die and pit Unit
Molten metal is
Electric Arc Furnace, Induction
poured into mold
Furnace and Vacuum Arc
cavity for casting
Degassing Furnace.
using ladle
furnace with the
help of E.O.T.
crane.
 Furnaces

Induction Furnace

Electric Arc Furnace

Vacuum Arc Degasing Furnace (VAD)

Vacuum Degasing Furnace (VD)

 ELECTRIC ARC FURNACE

It is powered by a 3 phase electrical system and has three electrodes.

Arc is formed between the charged metal and the electrode.
The charge is heated both by current passing through the charge and by the radiant energy
evolved by the arc.
Electrodes can move up and down automatically for regulation of the arc.
To protect the transformer from heat, it is installed in a vault.
It is cooled via pumped oil exchanging heat with the plants water cooling systems.
It is built on a tilting platform to pour molten metal into another vessel for transport.
Casting steps (Schematic)
Schematic diagram of casting mould:
 pattern and product

pattern product
product
 Heat Treatment Process

Controlled heating &

cooling of materials for
the purpose of altering
their structures and
properties
Annealing

Normalising

Quenching

Induction Hardening
 Annealing

In this process, hypoeutectoid steels (less than 0.77 % C) are heated to 30o to 60oC above
the upper recrystallization temperature held for sufficient time to convert the structure to
homogeneous single phase austonite of uniform composition and slowly cooled at a
controlled rate through the lower crystallization tem.
Cooling is done in the furnace by decreasing the tem by 10oC to 30oC per hour to at least
30oc below 727oC.
After that metal can be cooled at room tem.
Annealing produce softer material.
 Normalizing

The steel is heated to 60C (100F) above the upper recrystallization Temp

(hypoeutectoid) or lower recrystallization Temp (hypereutectoid) , held at this

temperature to produce uniform austenite.

It is removed from the furnace and allowed to cool in still air.

The resultant structures and properties will depend on the subsequent cooling rate.

Wide variations are possible, depending on the size and geometry of the product,

but fine pearlite with excess ferrite or cementite is generally produced

 Machining Processes

Turning
Boring
Facing
Grinding
Vertical & Horizontal
Milling
Planning
Grooving
Threading
Parting
Slotting
Trepanning
Gear Hobbing,
Heat Treatment
 Applications of Casting:

Transportation vehicles
Turbine vanes
Power generators
Railway crossings
Agricultural parts
Aircraft jet engine parts
Sanitary fittings
Communication, Construction and Atomic Energy applications, etc..
 Advantages of metal casting:

Casting is one of the most versatile manufacturing

process.
Casting provides the greatest freedom of design in terms
of shape, size and the product quantity.
Casting imparts uniform directional properties and better
vibration capacity to the cast parts.
Casting produces machinable parts.
Shapes difficult and uneconomic to obtain otherwise may
be achieved through casting process.
( Contd..)
 A product may be cast as one piece, there by eliminating the need of metal joining
processes.
Very heavy and bulky parts which are otherwise difficult to get fabricated may be
cast.
Metals (like cast iron) difficult to be shaped by other manufacturing processes may
be cast.
Casting can be designed for equal distribution of loads and for minimum stress
concentration in order to achieve more strength and increased service life.
Casting process can be mechanized and usefully employed for mass production of
components.
 Limitations of metal casting:
Dimensional accuracy and surface finish of the castings made by sand
casting processes are a limitation to this technique.
Many new casting processes have been developed which can take into
consideration the aspects of dimensional accuracy and surface finish.
Some of these processes are die casting process, investment casting
process, vacuum-sealed molding process, and shell molding process.
The metal casting process is a labor intensive process
Thank
You