PROJECT REPORT

FOR

CASTING

IRON & COPPER

________________________

PROMOTER

PRODUCTION CAPACITY

20 tons per day of Casting Iron & Copper

CAPACITY UTILIZATION

14.5 tons per day of Casting Iron

3.5 tons per day of Casting Copper

LOCATION

RAW MATERIALS

1. Iron Scrap2. Copper Scrap

DIRECT EMPLOYMENT

75 to 80 persons

INTRODUCTION

Indian Foundry Industry Overview

The Indian Foundry industry produces approximately 7 Million MT of Casting

employing an estimated 5 lakh persons directly & another 1.5 million persons

indirectly. The growth of foundry industry is very important for

inclusive growth, other engineering sectors & the overall Indian Economy.

Foundry Industry is Major Feeder to following sectors:-

Automobiles & Auto Components

Railways

Power Sector

Tractor Industry

Earth Moving Machinery

Pumps, Compressors, Pipes Valves & Pipe Fittings

Electrical/Textile/Cement/Agro Machinery

Machine Tools & Engineering Industries

Sanitary Castings

Engineering Exports

Approximately 32% Output of Foundry Industry goes to Auto Industries &

Balance to other downstream Engineering Sector. Automotive Mission Plan

(AMP) 2006-2016 envisages 4 fold growth by 2016 i.e. from $34 Billion Industry

to $122-160 Billion Industry employing about 25 million people by 2016. AMP

2006-2016 will drive demand of Castings from Foundry Industry.

Corresponding Growth in Foundry Sector is vital to sustain growth in Auto &

other Engineering Sectors.

Graphs below depict sector wise consumption of casting in percentage, Types

of Metal Casting Share in percentage and Top Ten Casting Producing Countries

Sector Wise Consumption of Castings as % of

Total Production

Types of Metal Casting Share in %

Top Ten Casting Producing Countries

(Figures in Million MT)

70%

9%

12%8% 1%

Grey IronDuctile IronSteelNon-FerrousOthers

Now the fourth largest producer of metal castings worldwide, India has

increased its casting production by more than 100% since 2002. Expansion

stems from India’s rapidly growing economy, which has the potential to raise

its income per capita to 35 times current levels over the next 40 years.

According to Goldman Sachs, in 2059, India is expected to have one of the

three largest economies (by GDP) in the world, along with China (first) and USA

(second). The automotive sector accounts for 4.2% of India’s GDP and since

2002 production volume has a 16% compound and annual growth rate (CAGR).

Some economists believe India has the potential to own up to 7% of the

world’s components market.

Future

Due to growing expectations of OEM’s regarding the quality and quantity of

castings, India is expected to produce larger casting facilities over the next few

years. The size and scope of large plants are required to address investment

requirements. This means the manufacturers with latest technology of

equipments will have a bright opportunity in India.

About the Directors

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Machinery

Hot-chamber machines

Hot-chamber machines, also known as gooseneck machines, rely upon a pool

of molten metal to feed the die. At the beginning of the cycle the piston of the

machine is retracted, which allows the molten metal to fill the "gooseneck".

The pneumatic or hydraulic powered piston then forces this metal out of the

gooseneck into the die. The advantages of this system include fast cycle times

and the convenience of melting the metal in the casting machine.

Cold-chamber machines

These are used when the casting alloy cannot be used in hot-chamber

machines; these include aluminum, zinc alloys with a large composition of

aluminum, magnesium and copper. The process for these machines starts with

melting the metal in a separate furnace. Then a precise amount of molten

metal is transported to the cold-chamber machine where it is fed into an

unheated shot chamber (or injection cylinder). This shot is then driven into the

die by a hydraulic or mechanical piston.

Manufacturing Process:

It is a four step process in traditional die casting, also known as high-pressure

die casting; these are also the basis for any of the die casting variations: die

preparation, filling, ejection, and shakeout. The dies are prepared by spraying

the mold cavity with lubricant. The lubricant both helps control the

temperature of the die and it also assists in the removal of the casting. The

dies are then closed and molten metal is injected into the dies under high

pressure. Once the mold cavity is filled, the pressure is maintained until the

casting solidifies. The dies are then opened and the shot (shots are different

from castings because there can be multiple cavities in a die, yielding multiple

castings per shot) is ejected by the ejector pins. Finally, the shakeout involves

separating the scrap, which includes the gate, runners, sprues and flash, from

the shot. This is often done using a special trim die in a power press or

hydraulic press. Other methods of shaking out include sawing and grinding. A

less labor-intensive method is to tumble shots if gates are thin and easily

broken; separation of gates from finished parts must follow. This scrap is

recycled by re-melting it.

The high-pressure injection leads to a quick fill of the die, which is required so

the entire cavity fills before any part of the casting solidifies. In this

way, discontinuities are avoided, even if the shape requires difficult-to-fill thin

sections. This creates the problem of air entrapment, because when the mold

is filled quickly there is little time for the air to escape. This problem is

minimized by including vents along the parting lines, however, even in a highly

refined process there will still be some porosity in the center of the casting.

After the shakeout of the casting it is inspected for defects. The most common

defects are misruns and cold shuts. These defects can be caused by cold dies,

low metal temperature, dirty metal, lack of venting, or too much lubricant.

Other possible defects are gas porosity, shrinkage porosity, hot tears, and flow

marks. Flow marks are marks left on the surface of the casting due to poor

gating, sharp corners, or excessive lubricant.

Water-based lubricants, called emulsions, are the most commonly used type of

lubricant, because of health, environmental, and safety reasons. Unlike

solvent-based lubricants, if water is properly treated to remove all minerals

from it, it will not leave any by-product in the dies. If the water is not properly

treated, then the minerals can cause surface defects and discontinuities. There

are four types of water-based lubricants: oil in water, water in oil, semi-

synthetic, and synthetic. Oil in water is the best, because when the lubricant is

applied the water cools the die surface by evaporating while depositing the oil,

which helps release the shot. A common mixture for this type of lubricants is

thirty parts water to one part oil, however in extreme cases a ratio of 100:1 is

used.

Oil used is heavy residual oil (HRO). HROs are gelatinous at room temperature,

but at the high temperatures found in die casting, they form a thin film. Other

chemical additives are used to inhibit rusting and oxidation. Emulsifiers are

added to water-based lubricants, so that oil based additives can be mixed into

the water.