INDUSTRIAL TRAINING IN

Kirloskar Ferrous Industries Limited,

Solapur plant.

TRAINING REPORT

SUBMITTED BY:

Mr. Sikandar. J. Girgoukar

FROM

Department of Mechanical Engineering

Walchand Institute of Technology,

Solapur.

2012

ACKNOWLEDGEMENT

I am thankful and deeply indebted to the management of KIRLOSKAR FERROUS INDUSTRIES SOLAPUR for allowing me to undergo implant training during my Mechanical Course. I am grateful to Mr. Pangaonkar and Mr. H Kulkarni granted for the training. I am very much thankful to our Prof.Ekhande, who made it possible and helped me and guided me for this training session.

I would like to express my sincere gratitude to our Principal Dr. S. A. HALKUDE and Dr.K.H.JATKAR (Head of MECHANICAL Engineering Department) for giving me the opportunity to widen our knowledge and project Guide Prof. G.B.AGALAVE for giving much of their valuable time, precious guidance and constructive criticism for bringing out this report. Their moral support and kind co-operation enabled us to bring out, this report successfully.

I am also thankful to all the operators and supervisors for all the information given by them.

INDEX

SerialNo.TITLEPageNo.

1 Introduction Plant Layout4

2Departments of KFIL9

3R&D Department15

4B Plant Sand section Core section Moulding section Melting and pouring section Fettling section 202124282932

5Assembly Department Kalpak Pratik Ekatma 33343536

6HPML37

7Learning Points41

8Conclusion42

INTRODUCTION

INTRODUCTION

COMPANY PROFILE:

KIRLOSKAR FERROUS INDUSTRIES LTD , Solapur plant (KFIL-S) Shivashahi, Solapur formerly known as KIRLOSKAR OIL ENGINES LTD ,Casting Division (KCD) erstwhile M/s Shivashahi Works Ltd(SWL), was founded in 1900 by Dr. Vasudarao Kirloskar. During the initial years, SWL was engaged in the manufacturing of Iron ploughs, vices and other Agricultural impartments from 1934,SWL started manufacturing of Gray Iron Casting. SWL become a part of Kirloskar Group. In 1959, to expand its foundry activities for manufacturing of priming pumps and vice. SWL modernized its foundry facilities in 1969 with a semi mechanized mould handling line iatrical induction furnaces. In 1979 SWT collaborated with M/s Kitchener Manufacturing co. in USA in Investment Casting facilities in the plant. SWL was severely affected during past decade due to unprecedented slowdown in the Indian Economy and went into heavy losses. It has to restructure and downsize its operations and workforce in 1997. It was then amalgamated with KOEL in PUNE. In 2000 it was operating as its Casting Division I.E.-KCD. In the recent past KCD has been making consistent progress is stabilizing its operation. Looking at the excellent growth potentials in foundry industry in India, the group Chairman Mr. Atul Kirloskar in January 2007 envisioned Kirloskar group to become one of the leading foundry group in India and accordingly planned the synergy of the two big foundries in K-Group, KFINL and KCD. The two entities merged into one company in January 2007, with KFIL-Hospet acquiring the interest of KCD and designating it as KFIL-Solapur plant, spread over 80acres of land, KFIL-S has three manufacturing plants a pattern shop and a week equipped metallurgical and physical testing lab.

VISION AND MISSION OF KFIL:MISSION: A family committed to Growth and Prosperity of the organization through Leadership activities attributes and quality orientation of people and process that continuously satisfy the ever changing needs.a) The company is a family to growth and prosperity of the organization through team work.b) Family that is committed to growth prosperity Leadership is promoting tool.c) People and processes in place to satisfy customers and shareholder through continuous improvements.d) Committed to total quality through systems institutionalization.e) Integration of people and processes to bring about rate of internal changes faster than that of external change. They are: #Pumps #Automobiles #Engines and Compressors #Others The chemical composition of the product is the reason for production of different kinds of products. Mainly products are differentiated on the basis of silicon compensation. Company has got different kinds of customers varying between with high or low range of silicon contents.

VISION: To be a world class product leader through the state of art Manufacturing technologies and processes.

VALUES: To achieve the Mission and Vision, company derived following Value:1) Customer Orientation 2) Vender Development3) Development of HR4) Process and product excellence.

AWARDS OF KFIL-S:

The following are certificates of awards given to the company,# ISO 9000 Certification since in 1993.# TS 16949 : 2002 In the month of October 2008.# ISO 14001 : 2004 Certification in the month of September 2008

ORGANIZATION STRUCTURE OF KFIL-S: It is a part for specialization and coordination. It comprises of the basis organization of the company, its departments, reporting lines areas of expertise, and responsibilities the way in which the parts of a things are arranged or organized. The main theme of the organization structure comprehends all the possible dimensions of the organization structure as in developing the ability to these dimensions which are currently important to the organization evaluations.

WORKING STAFFS OF KFIL-S: MANAGERS : 85 STAFFS :5 TEAM MEMBERS :356 TOTAL EMOPLYEES :436PRODUCTS OF KFIL

14R 1040 Cylinder Head12P2 Crank Case

23R 1040 Cylinder Head13RB-33 Crank Case

3DM-14 Cylinder Head 14P1 Crank Case

4P1 Cylinder Head15Flywheel-03079

5BEML-140 Cylinder Head16Flywheel-03050

6NEF Cylinder Head 17692 Drum

7DM-10 Cylinder Head18Stiffener

8RV3 Crank Case19TKAP Transmission Plate

9HA2 Crank Case20Carrier

10RB-22 Crank Case21Bearing Cap

114R & 3R Crank Case22692 Disc

Table no.- : Products of KFIL

CUSTOMER OF KFIL

1K.O.E.L.

2Mahindra & Mahindra

3Tata

4Toyota

5Indian Railway

6H.M.T. Tractor

7Escorts

8Swaraj Mazda

9KBSA South Africa

10DLW- Waranasi

11Ashok Leyland

12Bajaj Tempo, Pune

13Kerala Agro Machinery

14Bharat Earth Movers, Banglore

Table no.- : Customers of KFIL

DEPARTMENTOFKFIL

DEPARTMENTS OF KFIL

A) Administrative Departments:

1) Personnel Department: This department is meant for employees development. This department organizes various activities like training, placement, recruitment and skill development to enhance the skill of employees in the industry.

Functional Area: Training, education and development of employee skills. Maintaining adequate employee supply. Maintaining satisfactory relations between employees and management. Recruitment of new employees in case of vacation or expansion.

2) Finance Department:

Finance department is one of the most important departments as it is all related to money or economic matters of concern. It provides finance to industry and audits of all financial activities going around. It is the responsibility of finance department to provide maximum possible finance to the industry and when required.

Functional Area: To raise adequate funds whenever required. To prepare the balance sheet maintain profit and loss account Keeping account. To prepare an account report for distribution amongst the management, shareholder and whoever related to industry. To invest the part capital to gain profit for the industry. To decide the wages or payment structure of employees and use part profit to pay them and audit it.

3) Purchase Department: Purchase is one of the major tasks during the commencement of the business. Generally industry has to purchase almost everything from the market such as raw materials, tools, machinery etc. It works 5R principal i.e. Right time. Right quantity. Right quality. Right price. Right source.Properly following these principles puts industry in more efficient position and also increase its profit.

Functional Area: Acquire different specifications from departments and place them for orders. Check supplier reliability. Plan the orders according to the requirements of production activity. Follow the order. Checking of goods as per order specifications. Payment of invoices.

4) Marketing Department: The marketing department is mainly focus on the activities of marketing products, pricing and promotion of products. These are activities collectively called as 4 Ps in marketing. a) Products: The company has following products in its products. They are: Basic grade pig iron. Foundry grade pig iron. Spherical grade pig iron.

b) Pricing: The name Kirloskar is the mark of quality for the customer. The company has left the opinion of transporting Pig Iron to the buyer. So one can buy the Pig Iron at the companys site or can order. The company has come across different prices terminology.They are: List price Discount Allowance Payment periods Credit terms

People prefer this company Pig Iron because the following reasons: High quality Fixed chemical position Test certificates are issued with every load.

c) Promotion :

The company has appointed number of dealers throughout India for its marketing purpose. Each dealer will get Rs 100 PMT, as commission for the pig iron is sells. Credit notes are given to these dealers for their commission.

d) Distribution: The company has got distribution network spread all over India in from of dealership and also through companys employees, the divided its market into 7 zones: Zone A) Karnataka: Belgaum, Shimoga, Bangalore. Zone B) Andhra Pradesh : Hyderabad, Vijay Wada Zone C) Maharashtra: Kolhapur, Pune, Mumbai, Nagpur, SolapurZone D) Gujarat: Ahmadabad, Rajkot, Surat Zone E) Rajsthan: Jaipur Zone F) Delhi: Faridabad, Kohinoor, Agra Zone G) Tamilnadu: Chennai, Coimbatore, Mtura

5) Security department : It is one of the important department of the industry. This department ensures security of available facility as well as of the goods in industry. A special team of guards is hired by in industry and employed for security purpose.

Functional area: Through checking and maintaining the records of visitors and employees entering or leaving in the industry. Through checking and maintaining the record of the vehicles carrying goods and empty vehicles entering or leaving in the industry. Keeping records of visitors and ensuring that they have got the permission for visit by querying to the respecting concern. To guide who enter new person in the industry to certain department.

B) Manufacturing Departments 1) Research and Development Department: This department is the most important department as far as efficient and effective manufacturing is concerned. It performs iterative design process and increase the productivity. The various activities like pattern design and development, metal composition checking, copy milling.

Functional Area: To develop the manufacturing processes for efficient and effective working. To check the properties of casting time to time. To assist the marketing department in performing contract review for technical aspects. To design equipment such as jigs and fixtures necessary.

2) Production Department : This department controls all the production activities carried out in industry. It performs activities such as planning, controlling etc. This department makes efficient plans for production process to satisfy the customer requirement and delivery of product. The functions duties and all the other details of this department. 3) Quality Control Department : KFIL is an ISO 9001 certificate organization. To maintain this status, industry people have to keep working for quality of products. This department applies various check points and critical examination the process to insure precise quality of product. The quality has to be maintained right from the beginning to the end of the process I.C. from raw material to final product. This department carries out vendor department program where it trains the supplies to enhance their quality and improve their standard. The material and finished goods products coming in and going out of industry are thoroughly checked to ensure these are of required quality and as per the specification.

4) Maintenance Department : The department plays an important role to keep the industries well functioning. Every process at its point only when it is properly maintained. Thus department works continuously for seven days of week to ensure high productivity.

RESEARCH & DEVELOPMENT

Research and Development Department

Perfect casting requires accurate dimensions of pattern on which moulds are made. The pattern designing with allowances is very important and responsible task is done in R&D department.

Working Procedure of R&D Department-:1) R&D department receive the drawing from customer through marketing department. 2) Drawing studied in details & position of cores, core prints etc are decided in drawing office.3) Contact review, method cards are filled in drawing office and submitted to marketing department, which are helpful in providing costing information.4) Pattern layout is made in the pattern development section.5) Sample pattern is manufactured. Gating system of pattern is designed in this department and sample casting is inspected.6) Correlation if necessary is made in the sample pattern and the actual production is started.

Sections of R & D :A. Drawing OfficeB. Pattern development & MaintenanceC. Pattern MachiningD. SpectrometerE. Sand testing

A. Drawing office: This is heart of R & D department. In this section, in details & decision regarding the customer requirement & satisfaction are taken by making contact review. a. Contact Review: It is nothing but written communication between the customer & company. All requirements of the customer are written on one side & what SWL can provide in that respect on other side. This also provides useful information in cost calculation. b. Method Card: It provides information about type machine used, type of moulding box, sand, core etc. This card also provide information about type of casting methods available, up to what tolerance parts can be manufactured in the company or not.

B. Pattern Development : In this section, after drawing received from drawing office, the pattern layout is decided. While designing the layout, all the allowances such as machining, draft, distortion & shrinkage are taken into consideration.

Selection of material for master pattern: First of all, master pattern is prepared. Generally, material used for pattern are thermo coal, wood & metal. Selection of material for finish pattern equipment is done considering below mentioned factors. Quality of casting to be manufactured. Life of pattern equipment. Production processes for which the equipment is made. a. Teakwood- up to 500 casting b. Aluminum- 50,000 to 75,000 casting c. C.I.- 75,000 to 1,50,000 casting d. Brasses/Gun metal- especially used for fine patterns & core boxes.e. Resin-up to 5000 approx. f. Thermo coal for only one casting.

The machines available in R & D Department for pattern making are,1. Two Drilling machines 2. Two Milling machines3. One Copy Milling machines4. Three Lathe machines5. Two Grinding machines 6. Engraving machine

C. Pattern Machining:

After deciding all the parameters marking is done on the metallic block from which pattern is developed, then machining is done in development stage using above mentioned machines. A sample pattern is prepared & sample casting is poured. After the penetration of sample casting, marking is done with height gauge. Check the casting. If the dimensions are less than those required, then metal is removed by machining. In R&D department properties of castings which are considered while designing are checked. Following apparatus is used for the testing.1) Universal testing machine-: When metal is melted in induction furnace, some metal is used to create a required for this machine. It is used to determine the tensile strength.2) Impact testing machine-: It test the impact or shock bearing capacity of the casting.3) Cutting machine-: In this machine, band saws are used to cut the casting. By cutting the casting we can detect the internal faults in casting such as cracks, blowholes etc. D. Spectrometer: Different kind of raw materials are involved in metal production. Variations of their compositions & impurities are directly reflect on the quality of metal alloys. Cores, raw materials as well as production accessories like coal anodes, refractoriness, coal & limestone need to be analyzed in advance to avoid any conflict on the process. The fast quality control of the final metal alloy is the second important analytical t ask, X ray tools are dedicated to serve in the best way. Due the different kind of materials, which have to be analyzed, a wide selection of element in changing concentration range need to be determined & several types of sample preparation techniques are involved. Wavelength dispersive X-ray spectrometer is the fast analytical method of control element concentration in metal alloys & flexible serve all the different analytical tasks beside routine. The ferrous industry is producing cast iron as well as different kinds of products like low & high alloys, stainless & tool steels. In process control, the accurate and fast analysis of iron & steel is important, but the process benefits as well from the reliable & fast determination of materials like slag, ferro alloys, refractorys & sinters. In non-ferrous industries, different kinds of elements are in the production of lead, cobalt, nickel or copper based alloys. Finally in the production of precious metals or high purity grades copper for highest conductivity fast and reliable trace analysis becomes the major task in process control.

E:Sand Testing: Green sand and core sand are test in laboratory. Sand testing is done at micro level. Following apparatus and machines are used for sand testing:1. Universal strength machine : In this machine compressive, tensile, shear strength are determined changing its apparatus.2. Hot tensile strength machine: This test carried out only for the resin coated sand.3. Shell Transverse Strength Machine : This test is used for HSLD( High Strength Low Deformation Resin coated sand) 4. Polishing machine: Sand polishing is test through various silicon carbide papers. There are different grids Si carbide papers. 5. PH meter6. Stick point apparatus 7. Clay washer 8. Muffle furnace : This furnace used to test specially the loss of ignition ( LOI ). Maximum temperature is 920c. 9. Carbon and sulpher apparatus / Strohlein apparatus: This is volumetric titration method for determining Carbon and Sulpher content in cast iron and steel.10. Sieve shaker : this is used for getting uniform grain structure. All properties of sand and the composition is determined in sand testing lab. The properties are checked after determined period

.

B

PLANT

B PLANT

In B plant mainly castings of various products are carried out .It consists of following main sections -: A) Sand sectionB) Core section C) Moulding sectionD) Melting and pouring section E) Fettling section

A) Sand section-: Sand is a basic material used for making cores and moulds. As the sand have a great property to sustain at high temperature called refractoriness. Green sand is used for mould making while beach sand is used for core making. Further this green sand is reused as a baking sand . a) Green sand -: We cannot use normal sand as it is for mould making. So to improve sand properties such as refractoriness, compressive, tensile, shear strengths, bench life, permeability etc;Some additives are added, as it has to face nearly 1420c temperature of molten metal with hardness about 90-95. Mixing of additives takes place in Pioneer Mixer for 2to3 minutes as follows proportion.

SrNo.Job NameReturnSand ( Kg )Coal Powder( Kg ) LustronPowder( Kg )BentoniteWoodPowder( Kg )Dextrine( Kg )Water ( lit )

1Pioneer Mixer unites sand & all m/c moulding sand

825To900

2To3

2To3

8To10

-

-

20To28

Green sand moulding composition.

The properties required for green sand moulding are given in following table. These properties are necessary for sand to sustain at high temperature.

SrNo.Sand TestRangeTesting TimeTesting Place

1.Green compressive strength.1300-1700Every daySand section

2.Permeability no100-160Every daySand section

3.Compactibility (%)38-45Every daySand section

4.Moisture (%)3.1-3.6Every daySand section

5.Total clay (%)11-14Every weekLaboratory

6.Active clay (%)8-11Every weekLaboratory

7.Dead clay (%)50 ( max )Every weekLaboratory

8.Loss of ignition (%) 4-5.5Every weekLaboratory

9.V.M. (%)3.0-4.0Every weekLaboratory

10.AFS No ( % in prepared sand )45-55Every weekLaboratory

11.AFS NO ( % in return sand )48-55Every weekLaboratory

12.Ph8-9Every weekLaboratory

Properties of green sand

The properties of sand tested in lab at the R & D department.

As the sand is reused, the flow path of sand which is return from various processes as shown below.-

Diagram: Flow path of sand.

b) Core sand-: Basically core sand is ordered from Goa, Andhra Pradesh, Arul. First core sand is separated from lumps, stones etc then sand gets dried in sand dryer to reduce moisture percentage for getting free flow.Afterwards sand is transferred to the bunker from where it goes to mixer. At mixer 0.8% resin & 0.8% hardner get added with sand and mixed finely, then sand is provide to core shooters.

Sand testing Range Testing timeSand testing place

A) Oil sand property 1)Tensile strength 2) Gas contentMin-15kg/cm2Max-20cc/gmEvery day one sampleLaboratory

B) Three part resin sand property 1) Compression strength 2) Gas content Min-15kg/cm2Max-26cc/gmEvery day one sampleLaboratory

C) Two part resin property 1) Compression strength 2) Gas content Min-30kg/cm2Max-26cc/gmEvery day one sampleLaboratory

D) CO2 sand property 1) Compression StrengthMin-4kg/cm2Every day one sampleLaboratory

Properties of core sand.

B) Core section-: Core is basically used for creating internal cavity in casting. For core formation beach sand is used, since the core has to sustain at high temperature and has to face molten metal pressure so it should be hard . In KFIL different types of cores are produced , as number of casting products are manufactured . To increase the productivity core shooter are used . In KFIL two types of processes are used for core making - 1) Cold box process ( using Amine gas ) 2) Shell core making

1)Cold box process-: Machines used for cold box process are, Compax 1 Compax 2 Compax 3 K20C core shooter K40C ( NEW )core shooter K40C ( OLD ) core shooter SUSHA core shooter Small to medium size cores are produced with the help of COMPAX-1, COMPAX-2, COMPAX-3 and SUSHA such as cores of Carriers, Dip case, cylinder heads. For making heavy cores up to 80 kg, K20C, K40C (OLD), K40C ( NEW) core shooters are used. All core shooters have same working principle and procedure. Core shooters- It is automatic core making machine. It is operated hydro-pneumatically. The core shooter consists following parts,1. Hopper ( 100 Kg )2. Air cylinder3. Amine shooting head / gassing chamber4. Sand chamber5. Core boxes6. Upgrading mandrel Process -: Operator gives signal to the trolley( 100 Kg ) for sand demand . As soon as trolley gets this input signal it goes to its home position from where it collects the mixed sand . Then trolley moves to the hopper of machine from where it got input signal and transfers sand to it. Air cylinder is used for maintaining required air pressure . The two boxes are closed by hydro-pneumatic force without any clearance. Sand mixture is filled in the core boxes with 5-8 Kg/ cm2 pressure from the sand chamber. Liquid Amine is vaporize at 70c to 90c and pass to the gassing chamber. This Amine gas 1st pass with LPP ( Low pressure purge) about 2-2.5 Kg/cm2 pressure , then it pass with HPP ( High pressure purge ) about 4-4.5 Kg/cm2 pressure . Due to LPP starting part of core gets hard to make next HPP operation easy. Amine purging time is about 15 sec. In this process resin polymerize and hold sand particles together with greater dry strength. The core boxes detaches and core is withdrawn on upgrading mandrel , and further carefully taken out. In one shoot 2 cores are taken out at a time. After each shoot, core boxes are cleaned using pressurized air. Also sometimes Garglene and Benzene Polish are used for cleaning any machine part. K20C means suitable capacity of core shooter is 20 kg.Similarly K40C has 40 kg suitable capacity. Maximum 80 kg core can be withdrawn.

Controlling parameters-:

1) LPP = 40 sec2) HPP = 50 sec3) Amine passing time = 10 to 15 sec4) Purging time = 40 sec 5) Frequency = 50 Hz

Electrical information:- All core shooter machines are connected to the Regulator power supply ( RPS ) Unit of 24 V , 5 A .This RPS has Central Processing Unit ( CPU ) .CPU consists EPROM which stores all programming of machine with input pins of 8.25 DC and bus system of 5 V supply .CPU has 3.6 V battery .Two types of sensor are used in the machines : 1. Inductive sensor - It gives signal when metallic material passes or comes in front of it . At the side of core boxes this sensors are used for getting idea about the sand shooting and gassing process . 2. Capacitive sensor - It gives signal when any liquid , metal or any plastic material passes or comes in front of it . At the resin and hardner pipes this sensors are used for getting correct proportion of them . These sensors require 24 V supply . Advantages of core shooter -:1) Higher productivity2) Energy saving 3) Good dimensional accuracy4) Superior surface finish 5) Excellent break down property6) Low gas evolution Cores are assembled in some cases such as, 4 pieces of cylinder and crank case casing are assembled using nut and bolt.The ready cores or core assembly are dipped into an arcopal 6172XLM tank for 14-16 sec. Arcopal is used for getting maximum refractoriness and to get good surface finish to the casting. Cores are then loaded to the baking chamber. At the core baking chamber cores are heated for 15 minutes under controlled condition and then unloaded . Then further the cores are shifted to core storage section.

2) Shell core making -: In this shell core making process resin coated sand is used named as HSLD ( High strength low deformation ). The resin coated sand when under goes high pressure and temperature , the core formation takes place .The temperature at which resin holds sand particles together known as curing temperature. Machines used for shell core making process is (2424) SUSHA. Core capacity varies from 3.1 gm to 8 kg. All operations of machine are done by hydro-pneumatically. Core boxes ( top and bottom sides ) are heated up to the curing temperature about hour known as preheating process. The core boxes are closed without any clearance. The sand is transferred to the core box with pressure . The air pressure required is 5-6 Kg . The process requires curing temperature is about 230-250c. The core setting requires some time to get core properties called as curing time. Generally, curing time is up to 3 min. Graphite spray is used to get better finish & improve the refractoriness. Cores are made in two types 1) Single piece core -: Sealing is not requires as it is a complete core.

2) Two piece core -: Sealing is requires for joining of 2 piece of cores. Porshako sealer powder is used for sealing purpose. Further the cores are kept in induction heating furnace to get well sealed cores.Thermo coals are used to control the temperature.

Core assembly -: After core making different types of cores get assembled to form core of single casting such as water jacket cores, cores used to get inlet and outlet holes and other small cores are assembled for 4R 1040 cylinder head casting & for critical cores. For joining purpose polyethylene ( PVC ) material is used.

C) Moulding Section -: There are three moulding lines according to their capacity. Each line has a push-off type machine which is used to get forward motion of the moulding boxes. These are operated hydro-pneumatically. SrNo.Type of lineCapacity( max Wt per box in Kg )

1.ARPA 900132

2.SM348

3.BQ332

Push off type machine capacity

Moulds are made on the simultaneous squeeze jolt pin lift moulding machine . There are two moulding machines for each line one for the drag part and another for cope part of mould boxes . In KFIL metallic patterns are used generally made up of Aluminum. Pattern is made from R&D department considering all allowances such as contraction , drag , machining , shrinkage etc and clearances . Process- The green sand is collected in the hopper of moulding machine and transferred in the mould box keeping around the pattern. The moulding boxes are kept on the machine with reference to moulding pins. The talcum powder spread around pattern. Some of facing sand spread around the pattern , then remaining space of moulding box is filled with baking sand ( from hopper ). First jolting operation is performed by high pressure air. Due to static and dynamic forces act on sand which the green sand packed around the pattern. After the simultaneous squeeze jolt operation performed by pneumatic process where the sand in the moulding box holds all around the inner surface of moulding box as well as the loose sand from upper side get compressed. Now the moulding box is ready. At last the moulding box get lifted by four cornered lifting pins slowly where hydro-pneumatic pressure is used. The heavy drag parts are inverted and transferred to the moulding line which moves forward using Push off machine. Then cores are kept at the proper position in drag part . Also the ceramic filter ( 10010022 ) inserted at the end of the down sprue . Cope parts are formed similar to that of the drag part. But the cope part consists gating system and riser with it . venting is done manually Further the cope part is kept on the drag part and are closed using three lockers inside it. 2 min&20 sec are required to get ready for one mould boxes.

D) Melting & pouring section -: In KFIL two types of materials castings are manufactured 1) FGI ( Flake Graphite Iron ) - Flakes of graphite are of plain type 2) SGI ( Spheroidal Graphite Iron ) Flakes of graphite are of spheroidal type.

In KFIL Induction furnace is used for melting purpose .Total there are three induction furnace, two of them are of 1 tone capacity and last one is of 3 tone capacity.

Induction furnace specification Medium frequency induction furnace Frequency - 300 Hz Capacity - 1-3 tone Power - 450 KW

Charging of furnace-: Cast Iron is basic material used for melting.To get required chemical composition different materials are added.

Sr no.Charge mixMaterial ( % )

1.CRCA Scrap30-60

2.TKAP Returns10-30

3.Pig Iron15-30

4.CPC ( Calcinised Petroleum Coke )3-4

5.Ferro Silicon1-2

6.Silicon Carbide0.5-1

7.Ferro Manganese0.8-1

Charging specifications

If TKAP scrap is not available the CRCA scrap and also CSIC scrap is used .

Chemical compositions of molten metal in terms of elements such as C , Si , Mn , Cr , Sb , Cu , Sn , S , p should be checked before pouring. Sample of molten metal in form of coin is checked in the spectrometer ( R&D department ) to get the detailed chemical composition .

Construction of the furnace -: The induction furnace consist following parts, Supporting yokes Water tubing copper coil Refractory cement Asbestos sheets Silica ramming mass The copper coils are supported with the help of supporting yokes. Since the water tubing copper coils are used water is circulated inside the coil for the cooling purpose. Refractory cement ( ALE Company ) named as Whytheat cement is used on copper coil upto certain thickness. Asbestos sheets are kept after the cement. Now the silica ramming mass is plastered on sheets as refractory lining. It sustains at temperature around 1600c.

Working of furnace -: 1st former of consumable type is kept inside the furnace and starting block is added to it. Supply of 11 KV is further step down to the required voltage and frequency is set . Current flowing through the copper winding produce magnetic field . The block cuts the magnetic flux which causes tremendous heat evolution and hence block starts to melt . Slowly former also get melted as it is a consumable type . It cup shape to the furnace . Further charge is added. It starts to melt causing the same principle. The temperature of molten is measured with the help of Deep Type Pyrometer which has a thermo tip use to sense the temperature . The metal has temperature about 1600c . It is not suitable for pouring hence to reduce the temperature sintering agent .Boric Acid is used as sintering agent . Slag coagulant powder is spread on the molten metal to bound the slag particles together . Inoculants are added in the molten metal for the following purpose - To improve the microstructure To reduce the chill To avoid white iron structure To improve the machinability Wedge test : It is carried out for checking Inoculation % or effectiveness.

Induction furnace uses hydraulic mechanism for its tilting operation at the time of unloading of furnace.The specifications of Hydraulic Unit Motor - 12.5 HP , 1440 RPM Tank - 2001 Capacity Oil - ENKLO 68Pouring station -: After unloading of induction furnace, molten metal is collected into the ladle of 1 tone capacity . This ladle is handled with the help of over hanging cross crane of capacity 5 tone . Silica ramming mass and Whytheat cement materials are used as refractory material for ladle . Before pouring of molten metal the coagulants are added to easy removal of slag from the ladle . Again the temperature of metal in ladle is checked using Deep Type Pyrometer . The ladle is closed during pouring with ceramic wool as it is heat resistive material and helps to maintain the temperature inside the ladle . Now the ladle is passed through the another crane which moves parallel to the moulding line . The ladle is tilted using hand-wheel at required angle .The molten metal is carefully poured into the basin of moulding boxes .

These mould boxes after pouring , are allowed to cool for 2 hours .

E) Fettling section -: In fettling following operations are carried out

1) Shake out - This operation consists separation of casting along with getting system from mould box, with the help of crane. Further the getting system is separated from casting .

2) Knocking - The separated castings are knocked out so that castings get cleaned from moulding sand .

3) Short blasting - In short blasting casting surface gets polished using Nickel shots. In shot blasting machine, nickel shots are bombarded on casting for 15 min. Shot blasting machines are provided with bucket elevator. This bucket elevator is used to collect the nickel shots for the further use, after the shot blasting process.

4) Muffle furnace - This operation is known as heat treatment process. In muffle furnace castings are heated at particular temperature to reduce the stresses occurred during process and to improve the strength of it .

After these operations , pneumatic grinding , cheeping and other finishing operations are carried out on casting . Further castings are painted and transferred to the machine shop after rough milling process.

ASSEMBLY

DEPARTMENT

ASSEMBLY DEPARTMENT

The castings from B plant are sent to the subcontractor for rough milling process . After rough milling , castings are transferred to the assembly department for further machining operation . The machining operation is done to get the accurate dimensions and good surface finish . Assembly department is divided in three parts - 1. Kalpak 2. Ekatma 3. Pratik 4. Suyash

1. Kalpak Kalpak consists single VMC and five HMC CNC machines with a single Booth cleaning machines.Machine specificationsa) VMC CHAKRA BMV 60 TC 20 Power supply 810 Watt Running current 2.8 Amp Voltage 230 Volt Single phase Ambient temperature 20c ( min ) to 45c ( max ) Input air pressure required is 6 bar 20 tool case .

b) HMC MAXPRO H440E Frequency 50 Hz 3 Phase Supply voltage 41.5 V AC Rated current 50 A Total controlled load 36 KVA Temperature range 20c - 50c 40 tool case

Booth cleaning machine: The castings after machining are transferred for the booth cleaning process. For booth cleaning , mixture of SUPRA cleaning oil and water is used . In this process casting is cleaned externally and internally. The borings trapped in the internal cavity of the castings are cleaned during this process. The time required to clean the casting is known as dunking time. It varies between 1 sec (min.) to 1 hour (max.). After booth cleaning casting passed for the water cleaning process. Further castings are cleaned using high pressure air and are sent to the dispatch line.

2. Pratik This is another important machining line in the assembly department. Pratik consist two VMC , single HMC , two drilling machines. VMC specification : ( BMV 60 TC 20 ) Voltage supply 415 V AC Power 15.5 HP Current 24.5 A Frequency 50 Hz Auxiliary voltage 24 V AC 20 tool collector HMC machines are of same specification . The top side drilling , reaming , spot facing operations are done using drilling machines . All VMC and HMC machines consist - - Two pallets named A and B - Tool pockets - Servo controlled voltage stabilizer ( max 480 V , current- 48 A ) - Trout Coolant Tank of 100 LPM capacity with pressure and frequency , 20 bar and 50 Hz respectively. Also an excess coolant tank is connected to this - A filter bag which separates the metal chips from coolant corresponds reuse of coolant . - A chip conveyor which collects the chips coming from filter bag.- Colored signals: Green signal indicates cycle start Orange signal indicates pallet change enable Red signal indicates emergency stop The different types of tools are set into the tool pockets to which the specified M Code are given . The program consists this M Codes corresponding to the different operations . Also the time required for particular operation is set already in the program . After this particular time Pneumatic hand is used to change the tools as per the given signal for the next operation .

3.Ekatma In this line castings are checked and get ready for dispatching. The castings are cleaned from all sides using water and high pressure air. Further closing of the unwanted holes using studs , finishing of the tapings of the holes such operations are done. Afterwards leakage testing is carried out on the castings. Leakage Testing : Casting is checked under 74-77 PSI air pressure .All the holes of different sizes such as oil holes , inlet exhaust holes etc in case of oil engines are checked . But the holes of 5mm size are tested separately . The process requires 4-5 minutes . After testing the OK castings are sprayed by the MICRODROPS to avoid rusting. Further the castings are packed and ready to dispatch.

HPML

HPML PLANT

HPML High Pressure Moulding Line. This HPML plant was planted in 29 August 2008 by Atul Kirloskar. The plant consist totally mechanized casting process, means reduced manual work. The main purpose of HPML plant is best quality castings with high productivity.

Sand section & Core Making:1. Sand section of HPML is similar to that of the B plant but all process are mechanized. All required additives are automatically added. Now this sand is transferred to the core making machines. 2. Core making is done machine. Cores are made by the cold box process. At a time 6 cores are prepared on this machine.3. Two robots are used for the further processing. The operation performed on these robots are as follows. 1st ROBOT: It collects the 4 cores from 2-side index table and make them assembled. The rod inserted manually and nut fitted automatically to this core assembly. The core assembly is transferred to the next robot. 2nd ROBOT: It picks the assembly of cores and deep into ARCOPAL tank to increase the refractoriness and good surface finish. Further it is transferred for the baking to the heating furnace. Before picking next core assembly it washes its hand with water.

As the robots are electronic machines, it is operated by program controlling. Perfect programming tends to efficient working of robot.

4. All OK cores are send to the quality gate for checking of dimensions & defects.

Moulding Line : For moulding purpose RUNKEL WAGNER moulding machine. On this machine both Cope & Drag parts of mould box are created simultaneously. They are prepared by changing the pattern position automatically & simultaneously. The assembled cores are kept in a drag part manually and cope part are kept over drag part with the help of ZL flask closing device. Then this mould boxes are transferred to the pouring station.

Melting Section or Pouring Section : Induction furnace is used for melting purpose. Induction furnace with inoculation hopper as inoculation increases metal fluidity. Pouring time is 10 min.

Fettling Section: Shake Out : The crane named as Andromat is used for shake out process of moulding boxes. Which helps to cut out the getting system in some extent. Shot Blasting : The machine named as DISA is used. For shot blasting MS shots are used.

Advantages : As all process are automatic , productivity is increases. It consumes less time for whole casting. The requirement of skilled labour as compared to B plant is very low. The robot can perform their operation non-stop. Robots are used to improve and to increase productivity. The Turnover of the company has increased in large amount. There are more chances of development at minute level. The casting have good surface finish . As labour work is reduced , cost of product is also reduced.

LEARNING POINTS

1) What company culture is & how a team in company works.2) Various departments in KFIL & their working.3) Role of an engineer in company. Various responsibilities of engineers in various departments.4) Discipline in regards with timing, dress code, punctuality, work culture.5) Various casting process in details like mould making, sand making, melting, fettling, machine shop etc.6) Relevance of our theoretical knowledge with practical things.7) Quality norms, safety standards, charts, various cards formats on shopfloor, dispatching method.8) Studied sales invoice, purchase invoice, internal memo, shift records, rejection records, SPC charts.9) Responsibilities of supervisor, purchase engineer, marketing engineer, R&D engineer.10) History, various products, customer of KFIL.11) Dependability of all departments on each other in company. 12) To get a small success huge team has to work together.

CONCLUSION

1) To get success in market , a good and healthy company culture is needed.2) Team work is most important in any achievement.3) To get a success disciplined, systematic approach is must.4) Contribution from all departments is necessary to achieve success.5) Engineer has to perform various duties in company.6) To get success in market quality & standard is must.

~ 2 ~