Dissertation Phase-I

GUJARAT TECHNOLOGICAL UNIVERSITY, AHMEDABAD

A Dissertation Phase-I Presentation

On

“ Analysis of parameters for casting ductile iron pipe”

By
Karan Bhuvneshbhai Thacker

Enrolment Number 130850708001, M.E.(CAD/CAM)SEM-III

HJD INSTITUTE OF THECHNICAL EDUUCATION & RESEARCH,KERA.

Guided By
Mr. Hemanshu Joshi Mr. Shankar Rao
Assistant Professor, Manager,
Mechanical Engineering Department, Production Department,
HJD Institute of Technical Education & Research , Jindal Saw Ltd.,
Kera-Kutch Mundra-Kutch

130850708001 MECAHNICAL ENGINEERING DEPARTMENT, HJD KERA. KARAN THACKER

 Dissertation Phase-I

CONTENTS
1. INTRODUCTION

2. LITERATURE REVIEW

3. SUMMARY

4. PROBLEM DEFINATION

5. EXPERIMENTAL SET-UP

6. PROCESS PLAN

7. REFRENCESES
130850708001 MECAHNICAL ENGINEERING DEPARTMENT, HJD KERA. KARAN THACKER
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130850708001 MECAHNICAL ENGINEERING DEPARTMENT, HJD KERA. KARAN THACKER

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ABSTRACT
Foundry industries in developing countries suffer from poor quality and
productivity due to involvement of number process parameters.

Ductile iron pipes are casted centrifugally by using centrifugal casting machine.
Various defects like Metal laps, Pin holes, Body crack, Thick/Thin socket etc.
occur during the casting process, hence this casting process is also known as
process of uncertainty like other casting processes
These defects can be minimized by appropriate changing in parameters like
velocity, temperature etc. of molten metal. Also microstructure of the pipe can be
improved by maintaining proper temperature during the casting process.

In this study, an attempt has made to optimize the parameters like velocity of
molten metal during the casting process, temperature of the metal and the effect of
temperature on the microstructure of the ductile iron pipe to minimize the defects
and manufacturing a better quality of pipe. Also the Casting simulation software is
used to analyze and optimize the parameters.
130850708001 MECAHNICAL ENGINEERING DEPARTMENT, HJD KERA. KARAN THACKER
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INTRODUCTION
HISTORY OF PIPES

Around 150 years ago the supply of water was done by cast iron pipes. Cast iron
pipes have been used to transport drinking water as well as industrial water. Since
middle of the 19th century due to growth in population, the consumption of water
has been steadily rising.

Cast-Iron pipes were first used in the 15th century in Germany and France. Later
steel came along as an additional material. In order to meet the increased demand,
cast-iron pipe industries has developed new and more efficient production
process.

At First, cast iron pipes were not coated or lined but were installed in the same
condition as come out from the modules. In 1922 first cement lined grey iron pipe
was installed for water distribution.

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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…INTRODUCTION
DUCTILE IRON & DUCTILE IRON PIPE
Ductile Iron also referred to as “Nodular Iron” or Spheroid graphite iron was
patented in 1948. An unusual combination of properties is obtained in ductile
iron because the graphite occurs as spheroids rather than as graphite flakes as in
grey iron. . Grey cast iron providing a range of tensile strength about 150 to 400
N/mm2 while Ductile iron have tensile strength ranging from 350 to 1500
N/mm2 with good Elongation.

Ductile iron pipe have been produced since 1951. It is spheroidal graphite
formation which makes extreme malleability and stretching ability possible with
ductile iron pipes.

Generally, Standard length of ductile iron pipe should be kept from 4.0 m. to 6.0
m. The range of the diameters of the pipes are from 80mm to 1000mm. In India
as per the requirement of the customers they are classified in two classes on the
base of thickness and weight of the pipe, Which are K7 and K9.

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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…INTRODUCTION

Comparison of microstructure of gray cast iron pipes and ductile iron pipes

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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…INTRODUCTION

Ductile iron pipe

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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…INTRODUCTION
Table 1.1: Thickness and weight chart of ductile iron pipe:
DN(mm) Thickness(mm) Weights of pipes in kg.
4.0 5.0 6.0
80 5.0 44.612 54.915 65.218

100 5.0 54.375 66.894 79.413

125 5.0 67.297 82.696 98.095

150 5.0 80.219 98.498 116.778

200 5.0 106.462 130.503 154.543

250 5.3 140.417 171.971 203.525

300 5.6 177.621 217.376 257.131

350 6.0 221.519 270.974 320.428

400 6.3 265.319 324.323 383.328

450 6.6 312.915 382.143 451.372

500 7.0 368.510 449.938 531.365

600 7.7 487.395 594.418 701.442

700 9.0 660.592 805.965 951.338

750 9.7 760.762 928.252 1095.743

800 10.4 869.117 1060.764 1252.375

900 11.2 1056.827 1288.559 1520.291

1000 12.0 1263.130 1538.588 1814.046

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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…INTRODUCTION
MANUFACTURING PROCESS
 Ductile iron foundries usually melt the iron in cupola or blast furnace. Coke, oil or
natural gas is the fuel used here for melting the iron ore.

 Crystallisation of the carbon dissolved in liquid iron in the form of graphite nodules is
achieved by the addition of magnesium into the molten metal.

 Ductile iron pipe are manufactured by means of centrifugal casting.

 The rapid cooling applied in ductile iron pipe production by the means of heat treatment
of pipes is necessary in order to give them a ductile microstructure.

 Also the lining and protective coating is the part of production process.

 Throughout the entire production process there is defined control system of controls and
tests to guarantee the specified properties of the product.

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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…INTRODUCTION

Process of manufacturing the ductile iron pipes

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA KARAN THACKER
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…INTRODUCTION

CENTRIFUGAL CASTING PROCESS

In 1910, Otto Bride invented the moving casting machine. The mould is located
in a machine housing which can move longitudinally. At different points it rest
on rollers. Inlet-Outlet Water flow arrangement is provided between the housing
and mould for solidification of the pipe.

The mould rotates at required RPM around its longitudinal axis before starting
the casting process. The casting machine equipped is tilted towards the socket
side and is arranged on rails so that it can be moved longitudinally.

Hopper contains the liquid iron for a single or multiple pipes. After obtaining
required RPM, the hopper is tilted to pour the metal inside the running mould
from the Runner. Because of the interaction of movements, the iron is laid down
on the wall of the mould in helix which, in the liquid state, merges into
homogenous pipe.

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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…INTRODUCTION

CENTRIFUGAL CASTING PROCESS DUCTILE IRON PIPE

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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…INTRODUCTION

POST TREATMENT PROCESSES

 Heat treatment process( Annealing ) carried out after casting process to achieve the
ferrite structure from the cemented structure by rapid and slow cooling of the pipes.

 Zing coating is applied on the outer surface of the pipe by using spray gun, which
moves along the rotating pipe, to minimize the corrosive effect.

 Cement mortar lining is the process in which the desire thickness of cement mortar is
applied inside the pipe by using nozzle for the smooth and healthy flow of water.

 Polyurethane Coating is also known as “ bitumen” coating in which the polyurethane

of black colour is sprayed on the outer surface of the pipe.

 Natural curing is the process in which pipe with wetted outer surface is placed in open
space where it is dried by sunlight.

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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…INTRODUCTION

DEFECTS IN DUCTILE IRON PIPE

 Blowhole/pinhole: It is a kind of cavities defect, which is divided into pinhole and
surface blowhole. Pinhole is very tiny hole which can generate during the solidification of
metal inside the mould.

 Metal laps: It is the defect in which metal laps are seen on the outer surface of the
ductile iron pipe. Metal laps are caused due to the lower temperature of the liquid metal.

 Crack marks:. Crack marks are shown on the outer surface of the pipe. The cause of
this defect is also the lower temperature of molten metal before the casting or the improper
metal composition.

 Metal Fin: It is generated during the casting process and seen on the socket or spigot
section of the pipe.

 Thick socket: Due to change in machine down time during the casting, excess hopper
tilting or low temperature, excess metal gathers at the socket which causes this defect.

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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Author Year Out come of research

Rajesh Rajkhole 2014 This paper was dealing with the defects, causes and their
remedies in casting process. Different casting defects were
et al. studied by referring various research papers. Causes and
their remedies are listed. This study helped quality control
department. It also helped for improving productivity and
reducing rejection levels.

Madhusudan et 2013 He said that solidification rate greatly affect on the

microstructure, quality and mechanical property. By setting
al. 800 RPM. Of die in centrifugal casting machine the metal
poured was directly lifted and rapid solidification took
place and finer grain size can be achieved compare to 400
and 600 RPM of the die which improved the microstructure
of casting. Here grain size was also measurable.

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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Author Year Out come of research

Jitendra khare et 2013 This paper found the design of easy locking and un-locking
arrangement at the socket side during the casting process.
al. By modifying the covering plate productivity increased. It
was found after experiments that 77 more pipes could be
manufactured in one day. Also the shifting of equipment
could be possible because of simple mechanism was used
in the equipment.

Minghu Yunan et 2013 Numerical simulation of the effect of electromagnetic force

on the centrifugal casting process of high speed rolls was
al. studied. FLUENT was used to analyse the distribution of
temperature field . Result showed that under 0.15 T
electromagnetic field intensity, both absolute pressure of
metal flow to mould wall and metal flow velocity on same
location had some differences between electromagnetic
centrifugal casting and centrifugal casting.

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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Author Year Out come of research

Nan Nan Song 2011 In this paper Mould filling process in horizontal centrifugal
casting was analysed the effect of rotation speed on flow
et al. pattern were studied . It was found that in appropriate speed
results in, liquid drop during filling process, which leading to
casting defects. Result showed that at 350 RPM of machine,
liquid fills the mould as thread while this thread became so
wide that it formed a strip when RPM was set 600. So higher
rotation speed was better for formulation of refine grain in
centrifugal casting.

Madhusudan 2010 It discussed about the effect of mould wall thickness on the
rate of solidification of centrifugal casting. Result of this
et al. paper was as mould thickness increases, due to chilling effect
solidification time decreased. Rapid solidification showed
well distributed fine grains and slow solidification showed
coarse grains.

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA KARAN THACKER

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SUMMARY
Ductile iron pipes have been manufactured since 1951 and from that year many
successive improvements are carried out regarding the process, material,
manufacturing methods etc. Different researchers studied various methods and
suggested better ideas for implementation.

Different research papers suggested worth ideas to minimize the defects and
manufacturing a better quality pipe which are solidification rate of the liquid
metal during the casting, Effect of mould RPM on the microstructure of the pipe,
Easy Locking and Un-locking system at the socket side, Numerical simulation of
the effect of electromagnetic force on the centrifugal force, effect of mould
thickness on the solidification rate etc.

All these studies were about the suggestions of various changes during the
centrifugal casting process as many of the defects generated during the casting
process. Velocity or flow rate of the liquid metal, Temperature of the metal before
the casting process, effect of temperature on the velocity and dependency of
microstructure on the temperature and velocity were not studied which greatly
affect on the quality of the pipe and defects generation.

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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PROBLEM DEFINITION
Ductile iron pipes are most widely used for transportation of drinking and
sewerage water. So it is the prime responsibility of the industry to make the
defect-less ductile iron pipe for smooth and continuous transportation of water. It
has been seen that many of the casting defects occur during the casting process
of ductile iron pipe which are very difficult to cure or handle after the casting
process. Also the rejection level increases due to poor control of parameters
during the casting process.
Generally, the parameters like mould RPM, machine travel time, hopper tilting
time, inlet-outlet water flow rate are set by conducting number of trials, and
which give the best result, they are set for actual production process.

But liquid metal temperature continuously decreases with respect to time before
and during the casting process. Velocity and flow-rate are the parameters which
are depended on the liquid metal temperature. These parameters can not be
considered constant during the manufacturing of each pipe. If these parameters
can be analyzed, many of the defects can be encountered and a good quality pipe
can be manufactured.
130850708001 MECAHNICAL ENGINEERING DEPARTMENT . GEC BHUJ. KARAN THACKER
 Dissertation Phase-I
…PROBLEM DEFINITION

Analysis of parameters for casting ductile iron pipe is the study about the
various parameters like velocity, temperature and flow rate of liquid metal by
which various defects can be minimized and a good quality pipe can produce in
minimum time. It also studies the effect of temperature on the microstructure of
the ductile iron pipe. It also increases the production rate and optimize the
production time. It also helps to the quality control department for setting the
standards .

In this Study, the analysis of parameters are also studied by using simulation. It
is important because it reduces many shop floor trials. Also the result can be
achieved within minimum time period. Resources can be effectively saved and
optimized parameters can be implemented.

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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EXPERIMENTAL SET-UP

HOPPER AND PYROMETER MEASURING THE TEMPERATURE OF

ARRANGEMENT LIQUID METAL BY PYROMETER

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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EXPERIMENTAL SET-UP

Chemistry of metal in hopper :

Carbon 3.6 to 3.9% Minimum temperature required at
hopper :
Manganese 0.6% max.
 DN-100 to DN-200 – 13000C
Silicon 1.6 to 2.5%

Prosperous 0.10% max.  DN-250 to DN-400 – 12800C

Sulphur 0.02% max.  DN-450 to DN-1000 – 12600C

Magnesium 0.015 to 0.05%

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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EXPERIMENTAL SET-UP

CENTRIFUGAL CASTING MACHINE OF MANUFACTURING OF 200 MM.

JINDAL SAW LTD. DIAMETER PIPE

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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EXPERIMENTAL SET-UP

Specification of centrifugal casting machine

Pipe Size Traverse Down Time Hopper Up-time Motor RPM Minimum
(in mm) ( in Seconds) (in Seconds) (Reference) Mould RPM
DN Min. Max. Min. Max. Min. Max.
100 14 18 45 75 800 950 700
150 15 20 45 75 800 900 650
200 16 20 45 75 800 850 525
250 17 21 45 75 800 925 425
300 17 21 45 75 750 900 375
350 18 22 45 75 700 850 300
400 18 22 45 75 700 850 300
450 19 25 35 65 550 750 225
500 20 26 35 65 500 700 200
600 22 28 50 80 500 700 200
700 23 29 30 50 500 700 175
750 24 30 30 50 550 750 150
800 25 31 30 50 550 750 140
900 26 32 30 50 700 900 125
1000 27 33 35 55 700 900 125

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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[1] M. Jagdishwar, “Casing Feeder Design Optimization based on feed path and temperature analysis”,2012

[2] Guss –Rohrsysteme, Griesheim,”Ductile iron pipe system”, European association for Ductile iron pipe systems, 2004

[3] Anita Bisht, “Effect of Heat treatment procedures on microstructure and Mechanical Properties of Nodular iron”, 2009

[4] Charles W. Mooney, Jr. Dies, “The best of Ductile iron news”, 2001, IL 60016-8399

[5] Courtesy of Jindal saw Ltd.

[6] Sufei Wei, Steve Lampman, “Centrifugal casting”, ASM Handbook, Volume 15: Casting, 2008, P 667-673

[7] Rajesh Rajkhole, J.G. Khan,“Defects, causes and their Remidies in casting process”, volume 2, 2014, E-ISSN: 2321-9637

[8] Bishnu Prasad Mahto, “Characterization of Ductile iron Through Fractographic study”, 2014

[9] Madhusudan, Narendranath, G C Kumar, “properties of centrifugal casting at different rotational speeds of the die”, International Journal of
Engineering Technology and advanced Engineering Vol. 3, January 2013 ISSN 2250-2459

[10] Jitendra khare “Design and Development of Locking arrangement for centrifugal casting machine”,2013, international journal of pure and
applied research in engineering and technology, ISSN: 2319-507X

[11] Minghu yunan, Leilei cao, Yaozeng Xu, Xuding Song,”Numerical Simulation on effects of Electromagnetic force on centrifugal casting
process of high speed steel roll”, Modelling and numerical simulation of material Science,2013

[12] Yuwen Xuan-Xuan, Chen Ling, Han Yi-jie, “ Numerical Simulation of Casting Filling Process Based on FLUENT”, international conference
on future Electrical power and Energy system, 2012, 1864-1871

[13] Madhusudan, Narendra Nath S., G C Mohan, “Experimental Study on Cooling Rate of centrifugal casting based on Grain Size”,
International journal Scientific and engineering Research, Volume 3, Issue 1, January-2012 1 ISSN 2229-5518

[14] Nan Nan Song, Shi Ping Wu, Xiu Homg Kang, Dian Zhong Li1, “ Hydraulic experiments of mould filling Process in Horizontal centrifugal
Casting, Advanced Materials Research Vols. 154-155, 2011, pp 314-320

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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[15] R. Arbi Jeshvaghani, M. Shaminian, M. jaberzadeh, “Enhancement of Wear Resistance of ductile iron surface by stellite 6” , material and
design 32,2011, 2028-2033

[16] Madhusudan, Narendranath, Mohankumar G C 2, Mukunda P G, “Effect of Mould wall Thickness on rate of Solidification of centrifugal
casting” , International Journal of Engineering Science and Technology, Vol. 2, 2010, 6092-6096

[17] Shamanian, S.M.R. Mousavi Abarghouie,S.R. Mousavi Pour, “Effect of surface alloying on microstructure and wear behavior of ductile
iron”, Department of Materials Engineering, Isfahan University of Technology, Isfahan 84156-83111, Iran

[18] Cai Qizhou, Wei Bokang, “Recent Development of ductile cast iron production technology in china”, 2008, 02-0082-10

[19] Karl-Fredrik Nillson, darina Blagoeva, Pietro Moretto, “ An Experimental and numerical analysis to correlate variation in ductility to defects
and microstructure in ductile cast iron components”, engineering fracture mechanics 73, 2006, 1133-1157

[20] S. Konoplyuk T. Abe, T. Uchimonto T. Takagi, M. Kurosawa,“ Characterization of ductile cast iron by eddy current method, Institute of Fluid
Science, Tohoku University, Katahira 2-1-1, NDT&E International 38 (2005) 623–626

[21] J.M. Makar, R. Desnoyears,S. E. McDonald, “Failure Modes and Mechanism in gray cast iron pipe”, National Research Council
Canada,2001, NRCC-44218

[23] Ugur Sen, Saduman Sen, Fevzi Yilmaz, “ An Evaluation of some Properties borides deposited on boronized ductile iron”, Journal of
Materials Processing Technology 148 (2004) 1–7

[22] R. Zagorski, J. Oelezino, “ Pouring of Mould during Centrifugal casting process of high speed steel roll”, Modeling and Numerical
Simulation of Material Science,2014

[24] Uday A. Dabade, Rahul C. Bhedasgaonkar, “Casting Defect analysis using Design of Experiments and Computer Aided Casting Simulation
Technique”, CIRP Conference on Manufacturing Systems, 2013, 616- 621

130850708001 MECAHNICAL ENGINEERING DEPARTMENT . HJD KERA. KARAN THACKER

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