DCM ENGG..doc

INTRODUCTION

The journey of the DCM group began way back in the year 1889, with the establishment

of the Delhi cloth mills.

The DCM group set-up its engineering division in the year 1977, with the commissioning

of grey Iron foundry. This was subsequently hived off as independent company “DCM

Engineering Limited”.

The foundry is situated on Chandigarh-Amritsar highway near Ropar, around 55kms

from “city beautiful” Chandigarh in the state of Punjab in India.

The grey Iron foundry was established in 1977 with a molding capacity of 17,000MT

per year and today with a capacity of 50,000MT. It is the largest jobbing foundry in

India, producing automotive castings. The foundry specializes in the manufactures of

cylinder heads, cylinder blocks & housings.

The foundry has plans to increase its capacity to 70,000mt per year by September 2006.

ACKNOWLEDGEMENT

I, Sandeep Singh roll no. 130575351240 am highly indebted to DCM Engineering

Products.

The leading companies of our nation, for letting me undertake my 6 weeks

industrial training with them. It was the most valuable and exiting period of my life.

The satisfaction and happiness that accompany the successful completion of any

take is incomplete without the mention of contribution of all those who helped me in

accomplishing it.

I am grateful to the whole HRD staff that was so kind and helped me in every

possible way and were a source of inspiration for me as there energy level and attitude

were unmatched.

Last but not the least I would also like to thank my college staff and training and

placement Department for organizing such a training schedule witch have given my

conceptual ideas of a practical.

COMPANY PROFILE

DCM Engineering Products engaged in manufacture of Grey Iron automobile Casting

and is located at Asron, Tehsil Balachaur, and Distt. Nawanshahar Punjab.

DCM Egg. Products is spared over a total area of 74 acres and has work a force of About

1400 employees. The employees are distributed in different shifts (A, B, C and General).

Majority of these are present between 0800 hours to 1600 hours.

SITE ACCESSIBILITY

The site is easily accessible being situated on the Ropar Balachaur highway (About 5Kms

.from Ropar, Bus stand).

ACCESS TO BUILDINGS

The main entrance is situated towards South and is accessible via two gates i.e. Gate 1 &

2 for vehicles (car & buses etc) and third towards western side especially for Pedestrians

adjacent to Gate 1 & 2. In care of extreme emergency, there is another Gate No. 4

(located at south east corner) through P.S.E.B. Sub – station, which can not be used.

FASINATING TALE OF EXCELENCE

The journey for the DCM Group began way back in the year 1889, with the establishment

of Delhi cloth mills. As year passed by, it gradually emerged as one of the largest

industrial conglomerates, comprising of several companies in diverse areas, repeated for

there product quality, dynamism & business integrity.

Rightly anticipated the tremendous boom in automotive sector both nationally and

internationally, the DCM set up its engineering division in the year 1977, with the

commissioning of the grey iron foundry. A prestigious QS 9000 organization, with a

capacity of 40000 MT per annum of automotive castings.

Firstly DCM engineering products was having one plant which was setup by American

technology, but in 1993 they imported casting technology from Germany.

The company got quality standard:

ISO 9002: 1994 QS 9000 (THIRD EDITION MARCH 1998) IN ACCORDANCE WITH

QS 9000 APPENDIX B, CODE OF PRACTICE

SECTIONS IN DCM ENGINEERING

MARKETING

PROCESS ENGG. & PATTERN SHOP

COMPUTER SECTION

PRODUCTION

LAB.& SAND CONTROL

PRODUCTION CONTROL

QUALITY ASSURANCE

FETTLING

HUMAN RESOURCE & PERSONEL

PLANT ENGINEERING

DESINGN & INSPECTION

VARIOUS SHOPS

CORE SHOP

FETTLING SHOP

MELT SHOP

UTILITY

PAINT SHOP

MOULD SHOP

CORE MAKING

The department is engaged in preparing cores which are ultimately used in the ‘mould

assembly’ stage of foundry process of producing hollow cavities in castings. A ‘core’ is

simply defined as a sand shape, which form the contour of casting that is not molded with

a pattern.

The various steps involved in the process core shop i.e. from core making to core ready

for dispatch to mould is described as follows.

1. SHELL PROCESSThe coated sand which is prepared in the sand control is fed to the manufacture of

cores.

For some items, the percolated sand is fed to core shop .the core sand mix is fed to

hoppers, which are over the core making machine. The core sand mix is fed to the core

box from the blow plate over the core box with air pressure of about 2.5 to 6kg/m2. The

blow time varies from 3 to 7 sec .depending upon the size of core. The temp. Of cold box

is maintained between 300-350 degree centigrade. The core boxes are heated with the

help of electrical heating in case of U-200, Susha machine & with LPG in case of Sutter

machine. After the sand is blown the curing of sand starts. The curing time various from

60-300 seconds depending upon the size of core .after the curing is complete, core is

ejected out. For the easy removal of cores from core box, the use of releasing agent is

done.

2. HOT BOX PROCESS :

The hot box is prepared on Sutter machines. The basic process of core making is

same as that of shell except that the hot box sand is pushed or shot in the core box along

with the air at the blow pressure of about 3-6kg/cm2. Blow time varies 3-7 sec .curing

time varies from 20-120 sec the core box temp is maintained b/w 250-300 degree

centigrade. The core box is heated with the help of L.P.G. burners. The cores made with

hot box technology have gas evolution.

3. NO BAKE PROCESS:

This technology is an example of self setting core mixtures. Other self setting mixtures

prepared in the core shop are PEPSET. The machines employed for preparing no bake

mixture is pace master. Part A&B is mixed with base sand & Part C is mixed with base

sand in the respective primary mixtures. Then both are mixed together in the turbo

mixture & the final prepared sand is collected & is ready for manufacture of the core.

The mixture is filled in Aluminium alloy core boxes along with ramming which is done

by hand. For achieving strength reinforcement rods are placed in the core box. The cores

are either taken out of the core boxes by inverting it or by unclamping them. The setting

time varies from 6-10 minutes, depending upon the size of the core. Bench life of

prepared no bake sand is 2-5 minutes.

4. OIL SAND PROCESS:

This is the cheapest technology of the entire core making technologies. The oil sand

mixture is fed to the core boxes made out of alluminium alloy & mixture is later rammed

with hand. Bench life of prepared oil sand mix is 2-3 hours.

5. PEPSET PROCESS:

This is an example of self setting mixture. The batch of pepset sand mixture is prepared

of 100kg. Batch capacity the bench life of prepared sand mixture is about 1 min.

6. COLD BOX PROCESS:

Are prepared on Span machine. Cold box sand mixture is prepared in the sand control &

fed to the core shop. The sand mixture is blown into the core box with air pressure of 3-

6kg/cm2. TRIETHYLAMINE gas is passed to harden the core. The amount of TEA gas

to be passed to depend on the size of the core.

PROCESS OF FOUNDARY

PATTERN MAKING

SAND PREPRATION

CORE MAKING

MOULD MAKING

ASSEMBLING/CORE SETTING

FURNANCE POURING

CASTING PREPARED

FETTLING

FOUNDRY AND ITS PROCESS

The scope of the foundry industry encompasses a major segment of our economy. The

industry’s product, casting enters into every field in which metal serve man. Castings are

used in transportation, communication, agriculture, power generators, in aero space and

atomic energy application, & in other activities too numerous to describe. Because of

these wide spread use castings are produced almost every where that manufacturing

occurs.

Types of foundries

Foundries may be classified as ferrous or non ferrous, gray iron, steel, malleable, brass

and bronze or light metal (aluminum, magnesium)

Foundries are further classified according to the nature of work and organizational

framework. A jobbing foundry is one having a physical plant that usually contracts to

produce a casting or a small no. of castings of a given kind. A production foundry

however is a highly mechanized shop that requires large number of a given kind of a

casting to be made in order to produce them at a low cost. Semi production shops are

those in which a portion of the work is of a jobbing natural and the balance is production

casting. A captive foundry is one which is an integral part of the company and whose

castings are consumed mainly in the products of parent organization. An independent

foundry is usually a separate company that produces casting for any no. of customers.

The largest foundries, those employing more than 1000 people are, usually captive, but

the greatest no. of foundries, the smaller shops employing fewer than 1000 people are

usually independent.

INTRODUCTION TO FOUNDRY

Casting is probably one of the most ancient processes of manufacturing metallic

components. Also, with few exceptions, it is the first step in the manufacture of metallic

components. The process involves the following basic steps:

Melting the metal.

Pouring it into a previously made mould or cavity, which conforms to the

shape of the desired component?

Allowing the molten metal to cool and solidify in the mould.

Removing the solidified component from the mould, cleaning it and

subjecting it to further treatment, if necessary.

The solidified piece of metal, which is taken out of the mould, is called as “casting”. A

plant where the castings are made is called a “foundry”. It is a collection of necessary

materials, tools and equipment to produce a casting. The casting process is also called as

“Founding”.

Types of foundries:

All the foundries are basically of two types:

Jobbing foundries:

These foundries are mostly independent owned. They produce castings on

contract, within there capacity.

Captive Foundries:

Such foundries are usually a department of a big manufacturing company.

They produce castings exclusively for the parent company. Some captive

foundries, which achieve high production, sell a part of their output

Advantages of Metal Casting:

Casting is one of the most versatile manufacturing processes.

Casting provides the greatest freedom of design in terms of shape, size and the

product quantity.

Casting imparts uniform directional properties and better vibration damping

capacity to the cast parts.

Casting produces machinable parts.

Shapes difficult and uneconomic to obtain otherwise may be achieved through

casting process.

A product may be cast as one piece, there by eliminating the need of metal joining

processes.

Very heavy and bulky parts (like those pf power plants and mill housings), 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.

Castings can be designed for equal distribution of loads (on all members of a

product) 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.

Computer modeling and modern techniques for rapid prototyping can provide

powerful assistance in further reducing costs and lead times during the foundry

stages.

RAW MATERIALS FOR FOUNDRY

Raw materials for foundry are:

Metals and alloys

Fuels (for melting metals)

Fluxes

Raw materials for Melt Shop:

Cast Iron

Pet Coke

Ferro Silicon

Ferro Manganese

Ferro Chrome

Supersede

Ferro Molly

Nickel

Copper

Tin

Iron Sulphide

CPC

Gasket for P/Pour roof

BHELPHAR

Fire Wood

Boric Acid

Insulating Bricks

Fire Bricks

Raw Material for Sand Preparation:

Turpentine Oil

Releasing Agent

Z.W.T Powder

Y.D Powder

Foundry Thinner

Pep set Catalyst

Shell Resin

Various departments of DCM

Personnel department

Production and planning control

Sand control

Core Shop

Mould shop

Melt Shop

Laboratory

Fettling

Pattern shop

Process and design

Mechanical & electrical maintenance

Civil department

Stores

Inspection and quality control

Production Planning & Control Department:-

Production, planning & control consist of following.

Production:-

It consist of series of operations that convent the given material into desired item

of required quality and specification for this a combination of manufacturing process is

required.

Planning:-

It is the analysis of all the available data for preparing the plans and schemes to be

framed for the utilization of resources, so that desired target may be efficiently achieved.

Control:-

It involves the supervision, works and operation with the help of control

mechanism. The progress of the work in noted down and if there is any variation from the

planning, necessary modifications and adjustment is made.

Pattern shop

Pattern:-

A pattern is a replica of the object to be made by the casting process, with some

modifications

The main modifications are:-

The addition of pattern allowances.

The provision of core prints.

Elimination of fine details which cannot be obtained by casting and hence are to

be obtained by further processing.

To ensure accurate customer satisfactions and timely product development the

company has an in house pattern shop.

The high quality precision machines at the pattern shop including milling

machines and die sinking machines are there for the initial design and methoding

to pattern completion, including all jig and fixtures.

Melt shop

In order to be in touch with the latest technologies and high standard, the melt shop have

5 induction furnaces.

The iron is meted till the temperature of 1445degree Celsius (approx)

The induction furnace works on the principle of transformer. The furnaces contain a

refractory lined crucible surrounded by a water cooled copper coil. Water oil is the

primary and the secondary is the metal charge. When A.C. is passed through the copper

tubing, a magnetic field is set up.

This magnetic field induces eddy currents in the crucible charge which melts the metal.

For lining of refracting material the ramming mass with 1.2% boric acid is used

Fettling shop

The complete process of the cleaning of casting, called fettling involves the removal of

cores, gates and risers, cleaning of the casting surface and chipping of any of the

unnecessary projections on surface.

The shop is well equipped with shot blasting machines. Firstly the dry sand cores are

removed simple by knocking off with an iron bar, by means of a core vibrator.

The gates and rises can be removed by hammering, chipping or by frame or arc cutting.

After that the casting is passed through shot blasting machine in which shots (white. shot,

steel shot) are blown by fast rotating paddle wheel against the surface the casting. The

impact of the abrasive partials traveling at high speed, on the surface removes the

adhering sand and oxide scale. Then the surface of the casting is grinded for better

surface finished to remove the fins or parting lines. The finished casting under go quality

control checking before their final painting.

Inspection And Quality Control Department

The industry has to manufacture the items that have the highest possible quality. The

quality can be controlled by careful inspection.

Industry has inspection and quality control department.

Right from the raw material to the finished product, inspection is to be carried out which

is as follows:

Inspection of raw materials.

Process inspection or the inspection during manufacturing.

Metallurgical inspection.

Purchase part inspection.

Finished parts inspection.

Finished goods inspection.

Tool inspections.

After felting, firstly the casting is visually checked for the defects like blow holes, core

cracks, core lifts etc.Some of the castings are taken for the geometric dimensions

checking.

Cores For There Types Of Engine Blocks Of Maruti Udyog Limited Are

Made In Tpm.

F8D F8B F10D TECHNOLOGY

Crank core C/C C/C Shell

Oil Passage 1 OP1 OP1 Shell

OP 2 OP2 OP2 Shell

OP 3 OP 3 OP 3 Shell



LWJ LWJ OP 6 Shell

UWJ UWJ LWJ Shell

FW FW FW Shell

FE FE FE Shell

Backup Backup Backup Shell

All the cores are made on core making machines.

Name of Machines in the Maruti Line are:-

Susha 3, 4, 5,6,7,9

Span 2,3,4,5,6,7,8

Woo shin 9

Some Parameters For Core & Core Making Of F8d

As core box is mounted on Susha (m/c) shell

Then process parameters are:-

Blow pressure = 3.5-4.5 Kg/Cm 2

Curing time = 60-90 second

Investment time = 90-120 seconds

Curing temperature

Door side = 325.C – 375.C

Ram Side = 300.C – 350.C

Mandrel = 300.C – 350.C

Core weight = 9.125 Kg.

Visual Inspection of 100% cores is necessary for details.

Parameters For Oil Passage Core Of F8d .

As Core box on spam (shell) Machine.

There Process parameters are as below.

Blow Pressure = 2.5-3.5 Kg / Cm

Investment time = 15-20 seconds

Curing time = 60-90 seconds

Curing temp. = 250.C-300.C (Door)

= 225.C-275.C (Ram)

Core weight

Oil Passing 1 2 3 4 5

Wt./ Kg 0.164 0.194 0.164 0.142 0.165

Parameters for water Jacket core making (lower supper)

Core box on span (shell) M/C

The process parameters are as below

Below pressure =2.0-3.0 kg/cm

Investment time =15-20 Sec.

Curing time = 60-90 Sec.


= 200.C-250.C (Ram)

Water jacket core weight

0.703 kg. (Lower)

0.760 kg (upper)

Parameter for front end /refined making

As core box is mounted on H-25

Below pressure =2.05-3.5 kg/cm

Curing time = 90-120 Sec.


= 275.C-325.C (Ram)

Core weight front end = 1.500kg

Fly which end = 1.700 kg

CORE PROCESSING

Finishing and coating of cores:-

Before the cores are assembled they are subjected to additional treatment, bar

trimming sealing for correcting small diskettes and Sr. on were are trimmed by with files

wire core.

The coatings on the core surface percent metal penetration increase the surface

strength derveare of are and the flooded clean and smoothappieranc.the coatings consist

of material along with binding materials.

CORE ASSEMBLING

In the previous process the assembling of cores is done on specially made line having

trolleys. One trolley six no. of barracks are placed, first of all UWT is fixed on it and then

oil passage no. u & s and fixed. For that these assembling are inserted in ovens for drying

of gum for about 25-30 min, after drying these are taken out from over and they are

turned to bring these along side up now the LWJ and OP No. 1, 2, 3 are fixed with the

help of scene gum, and then are again deride for 25-30min. after drying they are taken out

and find cores are fixed with them.

In the Hot-Melt-Gum process the assembly is done on the jig. The hot-melt-gum & spec

bond gum is used in place of core fix gum. Hot-melt-gum has advantage that it does not

need drying it get hardened within10-15seconds at room temperature.

In these powers the LWJ is kept on jig and it is then fixed with barrel.

KUNKEL WAGNER LINE

INTRODUCTION:-

KW LINE is one of the latest technologies of making different sorts of castings. It

is a fully automatic line, costing about 30 cores and was imported from Germany in

December 1994 and installed in DCM ENGINEERING PRODUCT PLANT – II by the

engineers of KUNKEL WAGNER, GERMANY.

Some special features of KW Line are:

Presently the line is having a capacity of producing 90 moulds per hour, but the

capacity can be increased up to 120 moulds per hour.

All the processes involved in making moulds are performed automatically.

Many different types of castings are being prepared on this line and the types of

moulds can be increased further according to storage capacity of computer

system, which is operating K.W. Line.

Most of the operations are carried out by hydraulic actuators, which are controlled

by the proportional and servo valves. For example, patterns separating, sand

pouring, ramming etc. are controlled hydraulically.

Three cooling lines are provided for better cooling of castings on KW Line. Each

cooling line is having a capacity of 50 moulds.

KW Line is PLC (Programmable Logic Control) and is controlled by semantic S5

programs.

RSP (Reconditioning Sand Plant) is used for the preparation of synthetic foundry

molding sand to supply the molding plant which is prepared in rotary mixer WM

100 and is transported to molding plants through the conveyer belts. The RSP is

fully automatic for proving suitable mixture to KW Line,

The maximum output of RSP is about 80 tones of Sand per hour.

The RSP is a 7 storey sand plant, which provides appropriate mixture of sand

having fixed ratio of binders, moisture content and other additives as per

requirement.

In K.W Line the size of flask is 900 x 800 x 350 mm.

Problems associated with sand mixture, rejection of castings, breakdown is very

less.

KW LINE (FUCTIONS/PROCESSES)

The molding box from shake out zone where the casting is taken out and the box is

cleaned reaches the FM Station.

FM Station:-This unit is divided into two parts, which are explained as follows:

Pattern Exchange Unit:-

For one molding two patterns are required i.e. cope pattern and drag pattern. These

patterns are exchanges one by one revolving the patterns around the exchange table. After

exchanging the pattern it is lifted upwards and pressed against the cope/drag according

the cope and drag pattern.

Sand Pouring Unit: -

Sand is poured after uplifting of pattern against the mould box. Ramming is done after

the pouring of the sand. The squeeze action (ramming) is done with the help of

hydraulically operated feeds. There are 72 cylinders with positions to which the feeds

(rammers) are attached which compress the cope and the drag to imprint the shape of the

pattern on the sand. Near the pattern exchange unit a safety door is there which is opened

so as to remove any problem regarding pattern exchange.

Recondition Sand Plant

This plant is used for the preparation of synthetic foundry molding sand to supply the

molding plant. The moulding sand is prepared in a rotary mixer and transported to the

moulding plant via belt conveyers. The production is nearly 80 tone/hr of moulding sand.

Max. Production is 80 tones/hr.

Energy consumption is 535 KW (running)

Water pressure is 3.5 bars to 5.0 bars.

Compressed air is at 6 bars.

Air exhaust quantity is 1660 cubic meter. in

Process:-

Sand spillage from the shake out zone, box cleaning, FM Station etc. fall on a bolt

conveyer. Above the belts conveyers there are magnetic separators. The metal particles in

the sand are picked away by these magnetic separators. After these magnetic separators,

through many conveyers the sand reaches the aerator. Here the sand lumps are broken;

the sand is made powered form with the help of blades. Then the sand is lifted up by

bucket elevators to the polygon screen. The pieces of cores and the metal remaining in

the sand are removed here. It is of strainer type. Then the recycled sand is taken to sand

coolers. Water cooling is employed to cool the moulding sand: the water is sprayed.

MOULDING AND POURING LINE

Preparation of moulds is fully automatic. It is made on the German made “knuckle

wrangler” line. It has the capacity of 120 moulds /hour. After the moulds are made they

are properly vented manually with the help of drills. Then the cores are placed in the

moulds. After that the cope is placed on the drag and it is forward for pouring.

Pouring is done with the help of ‘press Pour’. The functioning of press pour is fully

automatic and it has the capacity of storing 5 ton of molten metal. It also maintains the

temperature of molten metal.

HOT MELT GUM APPLICATOR (GLUE GUN)

It is an electric device used to melt the gum and to apply on the required place.

It has a trigger, by pushing this trigger the piston before the gun cartridge pushes it

forward to wards the heating rods. The gum melts when it comes in contact with the rods

and this melted gum can be applied on the surface, through the nozzle provided.

The flow rate of the melted gum depends upon the quality of the gum and the temperature

maintained in the glue gun.

Usually the gun works on the temperature 195 degree Celsius but it is provided with the

temperature modulator and the temperature can be adjusted according to our need.

Temperature modulators are provided with the temperature range of 160, 180, 195, 215

degree Celsius.

Cost Reduction in Core Assembly Of Maruti Blocks By Using Hot Melt Gum

MATERIAL COST:

Hot Melt Gum Technology:

Cost of gum used (hot + cold) = Rs. 135/kg

Gum used/assy = 22gm

Gum cost/assy = 135*22/1000 = Rs. 2.97

Regular Gum Technology:

Regular gum consumption for 180 assemblies = 10 kg

Cost of regular gum/kg = Rs.20

Consumption/assy = 10/180 = 0.055 kg

Cost of gum/assy = 10/180*20 = Rs. 1.11

Additional cost by using hot melt gum = Rs. 1.86/casting

Saving by not using standard chaplet (8mm) = Rs. 0.21

Energy Cost:

Power consumed by infrared oven in 8 hours for assembling 180 assemblies = 36 kW

Power cost/assy = 36*8/180*4 = Rs. 6.4

Power consumed by thermal oven = 31 H.P = 31*0.746 = 23 kw

Cost for running thermax oven = 23*1.5* 4.0/400 = Rs. 0.345/assy

Fuel consumption in oven at K.W Line = 600 liters/24 hours = 25 liters/ hour

400 assemblies stored in 15 racks which take 1.5 hours

Fuel consumed/assy = 25*1.5*Rs.30/liter/400assy = Rs. 2.81--------------E

Rejection Cost:

Manpower saving in repairing = 1man/day

Repairing cost = 7000/28*540 = Rs. 0.46/assy

Saving in core rejection due to not opening of cores from assy = 3%

Saving/ assy = Rs. 4.80

Maintenance Cost:

Cost of one infrared lamp =Rs.140

Avg. consumption of lamps/month = 100 lamps

Savings/ month = Rs. 14000

Savings/ assy = 14000/30000 = Rs. 0.46

Total savings/ assembly = (B+C+D+E+F+G+H)

= Rs. 13.62/assembly

Monthly savings = Rs. 4.08 lakhs (For 30000 Blocks)

In addition to above other benefits are as below:

Better floor utilization

Zero delay in supplying assemblies to KW line

Maintenance cost of thermax oven will reduce

VARIOUS OILS & LUBRICANTS USED IN K.W. LINE

Parts to be lubricated Lubricants used

Power pack (hydraulic oil) Hydrol H.L.P 46

Scavenging gear Processal 100

Gear oil Amocam 320

Roohiling gear motors Lanthax e.p.7

Greasing of gear unit M.P geese

Oil for water warm gear Carbol 650,220

Cavex gear, gear oils Amocam 680,460

Pattern changing geared motor Hydrol 220

SUBMITTED TO SUBMITTED BY SANDEEP SINGHROLL NO. 130575351240

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