Intership Report

KUDALE IRON WORKS BELAGAVI
CHAPTER 1
INTODUCTION TO COMPANY
1.1 : Company Profile
Established in the year 1999, we are a well-established Firm engaged in the manufacturing
and supplying of graded gray iron castings. Our foundry located at Belgaum, which has staff strength
of 100 people. Our range, which includes valve casting, butterfly valve casting, coupling castings,
pulley castings, cast iron coupling, cast iron pulley, auto pumps and many other products that are
widely used in various segments such as motor industry, automobiles, and engineering industry.
We provide customized solutions to our valuable clients and package consignments as per their
specifications. Under the able guidance of our CEO Mr. Mahesh S Kudale, he enabled us to achieve
a remarkable progress in our field. Our efficient team coupled with advanced machineries helps us
to meet the bulk demands from the market. We have a huge client network throughout the country.
quality is our prime focus. Our quality auditors supervise every stage of production and conduct
various quality tests to ensure the supreme quality of our range. We are in process to the target of
achieving ISO certificate for the quality of our product. Our well-equipped manufacturing unit helps
to meet the huge demands from our clients. We have 2 manufacturing units, which are spread over
a large area of 40000 square meters for the sufficient production. Owing to these reasons we have a
wide client base all over the country.
1.2: Customers
 Rati – Trans power Equipment, Pune (Coupling Manufactures).
 Dell Valve – Pune (Valve Manufacturer).
 Pragati Automation (CNC machinery Parts).
 Normax Valve Pune (Non-Returning Valve)
 Alex Grinders Lonava, Mumbai (Machine Parts).
DEPARTMENT OF MECHANICAL ENGINEERING.

KLE SOCIETY’S KLE COLLEGE OF ENGINEERING AND TECHNOLOGY, CHIKODI. Page 1
1.3: Material Suppliers

Material suppliers of Kudale Iron Works are shown in Table No. 1.1.
Table 1.1: Material Suppliers.
SL Names of Address Items Basis of Types & Extent

No. Suppliers Supplied Approval of control
1. Deccan Traders Kolhapur Pig iron Past Inward Inspection

(Sesa Industries) Experience as per Quality
Coke
Plan
Past Inward Inspection
2. Chemon Belgaum Pig iron
Experience as per Quality
Enterprises
Plan
Belgaum Low Ash Coke Past Inward Inspection
3. Bengal Minerals
Kolhapur Manganese Experience as per Quality
Plan
Belgaum Past Inward Inspection
4. Binnery Udyog Low Ash Coke
Kolhapur Experience as per Quality
Plan
5. Konkan Sand Belgaum Silica Sand
Fine Sand Plan
6. N.S. Yadwad Lime Stone
Kankanawadi
Plan
7. Ahsapura Belgaum Bentonite
International Ltd Powder
Plan
8. Navjivan Mumbai Bentonite
Corporation Powder
Plan
9. Shiva Shakti Belgaum Resin and
Associates Hardener
Plan
10. Nova marketing Belgaum Resin and
Hardener
Plan
Silicon Past Inward Inspection
11. Oswal Minerals Bangalore
Nickel Experience as per Quality
Manganese Plan

1.4: Process Flow Chart

Moulding process of Kudale Iron Works is schematically shown in Fig. 1.1 and 1.2.
Fig. 1.1: Schematic representation Moulding process
Fig. 1.2: The production process flow of sand castings

CHAPTER 2
INTRODUCTION TO FOUNDRY
Fig. 2.1: Molten metal in cavity

A foundry is a factory that produces metal castings. Metals are cast into shapes by melting
them into a liquid, pouring the metal in a mold (Fig.2.1), and removing the mold material or casting
after the metal has solidified as it cools. The most common metals processed are aluminum and
cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used
to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.
2.1 : Types of Sand and Sand Preparation

 Silicate (Co2) Sand
Composition (for 304kg):
Fine Sand – 78.894% (240kg)
Rough sand – 21.10% (64kg)
Silicate – 5.92% (18kg)
 Procedure
 First clean the Muller machine.
 Pour the fine and rough sand in Muller machine.
 Rotate the Muller machine and slowly pour the silicate into it and rotate up to 3 minutes.
 Use the sand for 60 minutes.
 Use co2 gas for this sand mold.

 Green Sand
Return sand – 90% (360kg)
Fresh sand – 8% (32kg)
Bentonite – 1.125% (4.5kg)
C-coal – 0.625% (2.5kg)
Water – 15-30 liter
 Procedure
 Pour the return sand and fresh sand in Muller machine.
 Mix the water in to it and rotate the muller machine for 2 minutes.
 Mix bentonite and c-coal in to it and rotate the muller machine for 3 minutes.
 Then the sand is ready for use.
 Oil Core Sand

Fresh fine sand – 36.84% (112kg)
Fresh rough sand – 63.15% (192kg)
Bentonite – 0.328%(1kg)
Dextrin – 0.039% (12kg)
Core oil – 1.973%(6kg)
 Procedure
 Rotate the muller machine and slowly add core oil in to it.
 Mix bentonite and dextrin in to it and rotate for two minutes.
 Rotate the muller machine for 3 minutes.
 Then the prepared sand is ready for use.
 Noback core sand

Fresh fine sand –10.526%(32kg)
Fresh rough sand – 89.47%(272kg)
Resin – 3% (6.750ltr)
Hardener – 1%(3.750ltr)

 Procedure
 Then add slowly resin in to it.
 Rotate the muller machine for 3 minutes.
 Then the prepared sand is ready for use.
 As per the weight of core take the prepared sand and add some amount of hardener in to it,
mix it with hand and fill the core.
 As per the weight of core take the prepared sand and add some amount of hardener in to it,
mix it with hand and fill the core.

CHAPTER 3
SAND TESTING
3.1: Quality Plan for Green Sand and Sand testing
Quality plan for green sand is listed in blow table 3.1.
Table 3.1: Quality plan for green sand testing
Parameters Acceptance Criteria
Green compression strength 900 to 1300 gms/cm
Permeability 100 to 200
Moisture 3 to 4.2%
Dead clay Max 4%
Active clay 8 to 10
Total clay 11 to 13
Compatibility 40 to 50
 Moisture Content Test

Moisture is the property of the Moulding sand it is defined as the amount of water present in the
Moulding sand.
Low moisture content in the Moulding sand does not develop strength properties. High moisture
content decreases permeability.
 Procedure
 20 to 50 gms of prepared sand is placed in the pan and is heated by an infrared heater bulb for
2 to 3 minutes.
 The moisture in the Moulding sand is thus evaporated.
 Moulding sand is taken out of the pan and reweighed.
 The percentage of moisture can be calculated from the difference in the weights, of the original
moist and the consequently dried sand samples.
 Percentage of moisture content = (W1-W2)/ (W1) %
Where, W1- Weight of the sand before drying,
W2- Weight of the sand after drying
 Clay Content Test

Clay influences strength, permeability and other Moulding properties. It is responsible for
bonding sand particles together. and
 Procedure
 Small quantity of prepared Moulding sand was dried
 Separate 50gms of dry Moulding sand and transfer wash bottle.
 Add 475cc of distilled water + 25cc of a 3%NaOH.
 Agitate this mixture about 10 minutes with the help of sand stirrer as shown in Fig.3.1

 Fill the wash bottle with water up to the marker.

 After the sand etc., has settled for about 10 minutes, Siphon out the water from the wash bottle.
 Dry the settled down sand.
 The clay content can be determined from the difference in weights of the initial and final sand
samples.
 Percentage of clay content = (W1-W2)/ (W1) * 100
Where,
W1-Weight of the sand before drying,
W2- Weight of the sand after drying.
Fig. 3.1: Auto sand washer
 Grain Fitness Test:

The grain size, distribution, grain fitness is determined with the help of the fitness testing of
Moulding sands. The apparatus consists of a number of standard sieves mounted one above the
other, on a power-driven shaker as shown in Fig.3.2. The shaker vibrates the sieves and the sand
placed on the top sieve gets screened and collects on different sieves depending upon the various
sizes of grains present in the Moulding sand. The top sieve is coarsest and the bottom-most sieve
is the finest of all the sieves. In between sieve are placed in order of fineness from top to bottom.
 Procedure
 Sample of dry sand (clay removed sand) placed in the upper sieve
 Sand is vibrated for definite period
 The amount of same retained on each sieve is weighted.
 Percentage distribution of grain is computed.

Fig. 3.2: Sieve Shaker.
 Permeability Test
The quantity of air that will pass through a standard specimen of the sand at a particular pressure
condition is called the permeability of the sand.
Following are the major parts of the permeability test equipment, which is shown in Fig.3.3:
1. An inverted bell jar, which floats in a water.
2. Specimen tube, for the purpose of hold the equipment
3. A manometer (measure the air pressure)
 Procedure
1. The air (2000cc volume) held in the bell jar is forced to pass through the sand specimen.
2. At this time air entering the specimen equal to the air escaped through the specimen
3. Take the pressure reading in the manometer.
4. Note the time required for 2000cc of air to pass the sand
5. Calculate the permeability number
6.Permeability number (N) = ((V x H) / (A x P x T))
Where,
V-Volume of air (cc)
H-Height of the specimen (mm)
A-Area of the specimen (mm22)
P-Air pressure (gm / cm2)
T-Time taken by the air to pass through the sand

Fig. 3.3: Permeability meter
 Compression/Shear Test
Use: The instrument is used to determine various strength of specimen Fig. 3.4.
 Procedure
 Place the compression/shear pads in location.
 Put cylindrical specimen between two pads.
 Apply the load till it breaks
 Note down the pressure which indicates compression/shear strength of sand.
Fig. 3.4: Universal strength machine

CHAPTER 4
PATTERNS
Everything in the foundry has to start with a “pattern”. A pattern or tooling is a full-size
model of the part you are trying to cast. It is replica of the product and is shown in Fig. 4.1 and
4.2. Patterns can be made of various materials such as mahogany, metal, plastic or Styrofoam. It
is very important to have suitable pattern, for the quality of the casting is influenced by the quality
of the pattern.
Patterns are made in order to reach customer requirements. In KIW patterns are given by the
customers and as per the requirement of customer the products are made. The production is batch
type production where different products are produced in batches.
4.1 : Types of Patterns
There are three main types of patterns
 Loose Patterns
 A loose pattern is the wood counterpart of the casting, with the proper allowance in dimensions
for contraction and machining. A loose pattern may be made in one piece or it may be split
into the cope and drag pieces to make Moulding easier.
 Mounted Patterns
 Patterns fastened permanently to a flat board, called a match plate, are known as mounted
patterns.
 The main advantage of the mounted pattern over the loose pattern is that it is easier to use and
store. For these reasons, a mounted pattern is generally warranted when several of the castings
(say, five or more) are to be made during one "run" or when the casting is made at frequent
intervals.
 Another advantage of the mounted pattern is that a pattern of the gating system also can be
mounted on the match plate. This practice of Moulding the gating system eliminates the loose
sand that often results when gates are hand cut. As a result, the castings produced usually are
better than those produced with the loose patterns.
 Core Boxes Patterns
 Core boxes are actually negative patterns. When looking at a pattern, one sees the casting in
its actual shape. A core box on the other hand shows the cavity which will be created by the
core.
 Core boxes are used not only to make cores for holes in castings but also to make parts of a
mold.
 In some cases, a pattern cannot be made so that it can be drawn. In such a case, the part of the
casting which would hinder drawing is made as a core that can be placed in the mold after the
pattern proper has been withdrawn.

Fig. 4.1: Pattern
Fig. 4.2: Cavity created by pattern

4.2: Core Making
Core making is an important branch in any foundry and the choice of core making depends
on various factors. To name them depending on type of metal to be cast, depending on the size of
casting, choice based on complexity involved in a casting process, depending on the requirement
of quality is final product, depending on equipment’s used for production and energy source.
Following are the technologies involved in core making.
 Cold Box Core Process
Cold box core is prepared using ammonia gas and Co 2 sand in machine called core box core making
machine. These are shown in Fig.4.3. and cold box core in Fig.4.4 respectively.

Fig. 4.3: Cold box core making machine
Fig. 4.4: Cold box core
 Shell Core Process

Shell core is prepared by heating process using Shell core machine. Shell core machine and Shell
core are shown in Fig. 4.5 and 4.6 respectively.
 Noback Core
 Oil Core

Fig. 4.5: Shell core making machine
Fig. 4.6: Shell core

CHAPTER 5
MOULDING
Moulding is one of the earliest metal-shaping method known to human beings. It generally
means pouring molten metal into a refractory mould with cavity of the shape to be made, and
allowing it to solidify. When solidified, the desired metal objects are taken out from the refractory
mould either by breaking the mould or by taking the apart.
5.1: Types of Moulding
There are mainly three types of Moulding used in “Kudale Iron Work”
1. Green sand moulding
2. Silicate sand (co2) sand moulding
3. Shell moulding
5.2: Characteristics of Mould

 Strong enough to hold the weight of the metal.
 Resistant to the cutting action of the rapidly moving metal during pouring.
 Generate a minimum amount of gas when filled with molten metal.
 Constructed so that any gases formed can pass through the body of the mold itself rather than
penetrate the metal.
 Refractory enough to withstand the high temperature of the metal, so it will strip away
cleanly from the casting after cooling.
 Collapsible enough to permit the casting to contract after solidification
5.3: Moulding Terminologies

 Drag
The bottom half of the pattern, flask, mold, or core.
 Cop
The top half of the pattern, flask, mold, or core.
 Riser
An extra void in the mold that fills with molten material to compensate for shrinkage during
solidification.
 Parting Line
This is the dividing line between the two moulding flask that makes up the sand mould. In split
pattern it is also the diving line between two halves of the pattern.
 Core Print
The region added to the pattern, core, or mold used to locate and support the core.
 Pouring Basin
A small funnel shaped cavity at the top of the mould into which the molten metal is poured.
 Sprue
The pouring cup attaches to the sprue, which is the vertical part of the gating system. The other
end of the sprue attaches to the runners.

 Runner
The horizontal portion of the gating system that connects the sprues to the gates.
 Mould Cavity
The combined open area of the moulding material and core, where the metal is poured to produce
the casting.
 Core
An insert in the mold that produces internal features in the casting, such as holes.
5.4: Moulding Process

The pattern is placed in a bottom plate and a drag box is located around it. After taking care
about the positions of the runner, ingate etc. the thickness of sand around the casting is carefully
chosen. This should be about optimum. Otherwise if the thickness of sand layer around the pattern
is too much, it will provide too much of insulation and result in delay in the solidification of the
casting, and it will create back pressure during the escape of gases that evolve during the casting.
If it is too less, it will make the casting cool very fast and a chilling/ quenching effect will be
produced which may not be desirable at times. It is now time to fill the space between the pattern
and the mould box with sand. However, the sand which is adjacent to the pattern/mould cavity is
of a different quality than the sand away from it and near to the walls of the mould box. The inner
sand called facing sand is finer and outer sand called backing is coarse. Backing sand is not used
for facing because it cannot develop the required surface finish and fine details that are present on
the faces of pattern. A minimum of 30mm and up to 100mm of facing sand should be applied on
the inside surfaces to obtain an acceptable mould cavity.
The sand is gently rammed / patted to cover all grooves and fine patterns/markings/slots.
Rest of the volume of the drag box is then filled with backing sand and rammed. The top surface
is made level by cutting any heap/bump that might have formed on the drag box. Fig.5.1 and 5.2
shows and automized sand muller and Sand plant respectively.
The drag box is inverted and the cope half of the two-piece pattern is assembled to the drag
half. Cope box is made to sit on the drag box using alignment and closing pins. Parting powder is
sprinkled on the exposed sand surface of the drag box. Gating, sprue, runner, riser, etc. are placed
at appropriate positions around the pattern. Backing sand is again filled in the cope box and
rammed to set. Vent holes are provided for passage of gases.
Then drag and cope are separated. The pattern is removed with utmost care being taken so
as not to cause any damage to the mould cavity or any intricate profile. The cavity is inspected for
visible scar or recess created and is repaired if needed. Cores if necessary, are placed either solitary
or with the help of core-prints. Drag and cope halves are joined and locked with the help of closing
pins. Pouring basin is placed at the sprue’s open end. Sufficient load is placed on the cope to
prevent its lifting under the action of buoyant force when liquid is poured.

Fig. 5.1: Automatic sand preparation machine (automized sand muller)
Fig. 5.2: Automized Sand plant

CHAPTER 6
MATERAILS AND MATERIAL PROPERTIES
6.1: Materials
 Cast Iron (CI)
1. FG -150
2. FG-200
3. FG-220
4. FG-260
5. FG-300
 Spheroidal Graphite Iron (SG-Iron)

1. SG-400/15
2. SG-400/18
3. SG-450/10
4. SG-450/12
5. SG-500/7
6. SG-550/6
7. SG-600/03
8. SG-700/03

6.2: Material Properties

FG-150
 Chemical Properties
1. Carbon = 3.2 - 3.7%
2. Silicon = 1.50 - 2.0%
3. Carbon Equivalent = 3.64 -4.20%
4. Manganese = 0.4 -0.8%
5. Phosphorus = 0.06 -0.120%
6. Sulphur = 0.08% max
 Mechanical Properties
1. Tensile Strength = Min 15.00 kg/mm2
2. Brinell Hard Ness Number = 130-180 BHN
 Thermal Properties
1. Melting Temperature or Tapping Temperature = 1400-1450 °C
2. Pouring Temperature = 1330-1385 °C
 Micro-Structure
1. Ferelite = 85% min
2. Pearlite = 15% max
3. Nodularity =80% max
4. Nodal Count= 175 Max

FG-200
1. Carbon = 3.3 - 3.6%
2. Silicon = 1.50 - 2.20%
4. Manganese = 0.4 -0.8%
5. Phosphorus = 0.06 -0.120%
 Micro-Structure

FG-220
1. Carbon = 3.4 - 3.6%
2. Silicon = 1.80 – 1.95%
4. Manganese = 0.5-0.65%
5. Phosphorus = 0.06 -0.120%
 Micro-Structure

FG-260
1. Carbon = 3.10 - 3.40%
2. Silicon = 1.60 - 2.0%
4. Manganese = 0.6 -0.8%
5. Phosphorus = 0.06 -0.120%
 Micro-Structure

FG-300
1. Carbon = 3.10 - 3.25%
2. Silicon = 1.60 – 1.9%
3. Carbon Equivalent = 3.6-3.9%
4. Manganese = 0.6-0.9%
5. Phosphorus = 0.06-0.120%
7. Chromium = 0.2-0.8
 Micro-Structure

SG-400/15
1. Carbon = 3.4-3.8%
2. Silicon = 2.4-2.8%
4. Manganese = 0.15-0.3%
5. Phosphorus = 0.06% max
7. Magnesium =0.03-0.06% max
3. Yield Strength = Min 250.00 kg/mm2
4. Elongation = 15% min
 Micro-Structure
1. Ferrite = 90% min
2. Pearlite = <10%
3. Carbides = <5%
4. Nodal Count = 200-250 nodules/mm2

SG400/18
1. Carbon = 3.40- 3.8%
2. Silicon = 2.3 - 2.70%
4. Manganese = 0.4% Max
5. Phosphorus = 0.06% Max
6. Sulphur = 0.03% Max
7. Magnesium = 0.03-0.06% Max
1. Tensile Strength = Min 400.00kg/mm2
2. Yield Strength = 250.00 kg/mm2
 Micro-Structure
2. Pearlite = <10%
3. Carbides = <5%

SG450/10
1. Carbon = 3.4 - 3.8%
2. Silicon = 2.4 – 2.8%
4. Manganese = 0.4-0.4%
7. Magnesium= 0.03 – 0.06 max
1. Tensile Strength = 450 N/mm2 min
2. Brinell Hard Ness Number = 149 - 207 BHN
3. Yield strength = 310 N/mm2
1. Melting Temperature or Tapping Temperature = 1532 - 1570 °C
 Micro-Structure

SG450/12
1. Carbon = 3.40- 3.8%
2. Silicon = 2.3 - 2.70%
4. Manganese = 0.4% Max
5. Phosphorus = 0.06% Max
6. Sulphur = 0.03% Max
7. Magnesium = 0.03-0.06% Max
2. Yield Strength = 250.00 kg/mm2
 Micro-Structure
2. Pearlite = <10%
3. Carbides = <5%

SG500/7
1. Carbon = 3.30 – 3.7%
2. Silicon = 2.3 – 2.8%
3. Carbon Equivalent =4.10 – 4.45%
4. Manganese = 0.25 – 0.40%
7. Magnesium = 0.02 – 0.06 max
8. Cupper = 0.2 – 0.5%
2. Brinell Hard Ness Number = 160 – 246 BHN
4. Elongation = 07%
1. Melting Temperature or Tapping Temperature = 1530 – 1570 °C
 Micro-Structure
1. Ferrite = 40 – 60%
2. Pearlite = 40 - 60% min
3. Carbides = 80% min
4. Nodal Count = 175 nodules/mm2 min

SG550/6
1. Carbon = 3 – 3.6 %
2. Silicon = 2.20 – 2.9%
4. Manganese = 0.32 – 0.6%
8. Cupper = 0.3 – 0.45%
4. Elongation = 06%
1. Melting Temperature or Tapping Temperature = 1530 - 1580 °C
 Micro-Structure
1. Ferrite = 40 – 60%
3. Nodularity = 80% min

SG600/03
1. Carbon = 3.30 – 3.7%
2. Silicon = 2.2 – 2.7%
4. Manganese = 0.25 – 0.50%
8. Cupper = 0.5 – 1.57%
2. Brinell Hard Ness Number = 187 – 270 BHN
4. Elongation = 03%
 Melting Temperature or Tapping Temperature = 1530 – 1570 °C
 Pouring Temperature = 1330-1385 °C
 Micro-Structure
1. Ferrite = 15%
2. Pearlite = 85% min
3. Nodularity = 80% min

SG700/03
1. Carbon = 3 %
2. Silicon = 2.50%
4. Manganese = 0.4 – 0.75%
8. Cupper = 0.7 – 1.5%
4. Elongation = 03%
1. Melting Temperature or Tapping Temperature = 1530 – 1570 °C
 Micro-Structure
1. Ferrite = 40 – 60%
3. Carbides = 80% min

CHAPTER 7
MELTING
Melting, is a physical process that results in the phase transition of a substance from
a solid to a liquid. This occurs when the internal energy of the solid increases, typically by the
application of heat or pressure, which increases the substance's temperature to the melting point.
At the melting point, the ordering of ions or molecules in the solid breaks down to a less ordered
state, and the solid melts to become a liquid.
Substances in the molten state generally have reduced viscosity as the temperature increases.
An exception to this principle is the element sulfur, whose viscosity increases to a point due
to polymerization and then decreases with higher temperatures in its molten state.
Some organic compounds melt through mesophases, states of partial order between solid and
liquid.
Enoclent: Used to maintain Temperature of the molten metal.
Slag Powder: Used to remove slag from the molten metal.
Lime stone: Used to remove unwanted material. (only used in cupola furnace)
7.1: Furnace
A furnace is a device used for high-temperature heating. The name derives from Latin word
Fornax, which means oven. The heat energy to fuel a furnace may be supplied directly by fuel
combustion, by electricity such as the electric arc furnace, or through induction heating in
induction furnaces.
 Features
The design of the furnaces is in such a way to consume fuel and heat as less as possible in a given
time that requires low labor cost.
 Efficient Features
The amount of heat that is to be given is prior determined to the material. There exists a sufficiency
in the liberation within the furnace to heat the required stock. A proper heat transfer from the gases
to the surface of the heating stock takes pace.
Temperature should be uniform within the stock. The heat loss from the furnace is minimized to
the least possible. In the furnace the product of the flue gases directly comes in contact with the
provided stock.
7.2: Components of Industrial Furnace
In industrial furnaces it serves the purpose of heating i.e. it serves as a reactor to provide
heats to the reaction. The design of the furnaces varies however the basic features are most
common among all of them. Above Fig. 7.1 shows schematic diagram of industrial furnace.

Fig. 7.1: Schematic representation of industrial furnace

 The Basic Components of a Furnace are:
 Radiant section
 Convection section
 Radiant coil
 Burner
 Soot blower
 Stack
 Insulation
 Foundations
 Access doors
 Process
The fuel flows in the burner is burnt from an air blower. The furnaces can have more than
one burner. The furnaces can be arranged in cells with a particular set of tubes, or the burners can
be flooring mount, on wall or roof mounted depending on the design demand. The flame of the
burner heats up the tube those in-turn heats up the fluid that is present inside.
The first part of the furnace i.e. radiant section or fire box, where the combustion takes place
by the action of radiation of the tubes around the fire inside the chamber. The heat fluid heats up
to the desired temperature level. The gas that is formed from the combustion is known as flue gas.
After the fire box the flue gases enters convection section where the heat is recovered before their
vent into the atmosphere by convection.

In industries commonly, secondary fluids are heated in these furnaces with special additives
like anti rust and with high heat transfer efficiency. Thus, heated fluid is circulated in the whole
plant where heat is needed instead of direct heating of the stock material in the product line. The
material can be volatile or may be prone to cracking with the furnace temperature.
 Types:
 Blast furnace
 Open hearth Furnace
 Induction furnace
 Electric Arc Furnace
 Reverberator furnace
 Cupola Furnace
7.3: Induction Furnace
Induction heating of metal will provide heat required for the electrical furnace. Induction
furnace will provide clean, energy efficient and well controlled process of melting when it is
compared with other processes (Fig.7.2). In most of the modern foundries use this type of furnaces
instead of cupolas to melt cast iron as the former emits lots of duct along with other pollutants.
The capacity ranges from less than one kilogram to hundred tones capacity are used in melting
iron, steel, copper and aluminum and other precious metals. As the process does not use
combustion, material temperature is not higher than the required to melt it. This processing
prevents the loss of valuable alloying elements. The induction furnace lacks in the refining capacity
where the charge materials clean the oxidation products and the known composition. The alloying
elements may have a chance to lose alloying elements due to oxidation.
Fig. 7.2: Schematic representation of induction furnace
7.4 : Cupola Furnace

A cupola or cupola furnace is a melting device used in foundries that can be used to melt cast
iron, Ni-resist iron and some bronzes. The cupola can be made almost any practical size. The size
of a cupola is expressed in diameters and can range from 1.5 to 13 feet (0.5 to 4.0 m). The overall
shape is cylindrical and the equipment is arranged vertically, usually supported by four legs. The
overall look is similar to a large smokestack (Fig.7.3 and 7.4).

The bottom of the cylinder is fitted with doors which swing down and out to 'drop bottom'.
The top where gases escape can be open or fitted with a cap to prevent rain from entering the
cupola. To control emissions a cupola may be fitted with a cap that is designed to pull the gases
into a device to cool the gases and remove particulate matter.
The shell of the cupola, being usually made of steel, has refractory brick and plastic
refractory patching material lining it. The bottom is lined in a similar manner but often a clay and
sand mixture (bod) may be used, as this lining is temporary. Finely divided coal (sea coal) can be
mixed with the clay lining so when heated the coal decomposes and the bod becomes slightly
friable, easing the opening up of the tap holes.[3] The bottom lining is compressed or 'rammed'
against the bottom doors. Some cupolas are fitted with cooling jackets to keep the sides cool and
with oxygen injection to make the coke fire burn hotter.
Fig. 7.3: Cupola furnace using in KIW

 Operation
To begin a production run, called a Cupola campaign, the furnace is filled with layers of
coke and ignited with torches. Some smaller cupolas may be ignited with wood to start the coke
burning. When the coke is ignited, air is introduced to the coke bed through ports in the sides
called Tuyeres.
When the coke is very hot, solid pieces of metal are charged into the furnace through an
opening in the top. The metal is alternated with additional layers of fresh coke. Limestone is added
to act as a flux. As the heat rises within the stack the metal is melted. It drips down through the
coke bed to collect in a pool at the bottom, just above the bottom doors. During the melting process
a thermodynamic reaction takes place between the fuel and the blast air. The carbon in the coke
combines with the oxygen in the air to form carbon monoxide. The carbon monoxide further burns
to form carbon dioxide. Some of the carbon is picked up by the falling droplets of molten metal
which raises the carbon content of the iron.

Fig. 7.4: Schematic representation of cupola furnace
7.5 : Pouring process

In metalworking, casting involves pouring liquid metal into a mould (Fig.7.5), which
contains a hollow cavity of the desired shape, and then allowing it to cool and solidify. The
solidified part is also known as a casting, which is ejected or broken out of the mould to complete
the process.
Fig. 7.5: Molten metal pouring

CHAPTER 8
FINISHING AND INSPECTION
Finishing works castings mainly includes,
 Shot Blasting and
 Grinding
8.1 : Shot Blasting

 After each batch of casting clean the area of steel shots scattered on floored and stored in
container.
 Check the level of steel shot in machines.
 If steel shot level found less by half of the hoper level then put shots in the rotating table in
machine.
 Ensures current in the range 20-25amp.
 Put the castings in appropriate rotating table.
 Push the rotating table in machine.
 Close the door of machine.
 Start the machine.
 Open the door of the shots by manually.
 Shot blasts for 3 to 5 minutes.
 When machine stops wait for some times for shots to settle down.
 Open the door of the machine.
 Pull the rotating table outside of the machine.
 Inspect visually the casting.
 Take of casting from rotating table and keep on floor.
 More the castings for the further processing by hoist only.
 Don’t dump the casting on one another and on the floor to avoid the crack in casting.
8.2 : Grinding
To remove unwanted material from the casting, grinding process is used. Using grinding
machines unwanted material is removed and inspected. These products are ready for dispatch.

CHAPTER 9
LABORATORY
Machine used in the Lab is determined the sand testing methods used in your operation to
understand how those readings reflect both the consistency of your molding sand and the quality
of your castings.
 Equipment Used in Lab are,

 Micro Polish Machine
 Sand Rammer
 Sieve Shaker
 Clay Test Machine
 Permeability Meter
 Universal Strength Machine (USM)
 Moister Tester Machine
 Burette Stand
 Hot Plate Machine
 Microscope
 Spectrometer
9.1: Sand Rammer
This machine is designed for preparing AFS standard test specimens for the determination
of compression, tensile, transverse, shear and splitting strength by compacting a predetermined
weight of sand in a tube, or a core box of the required shape. This is achieved by dropping a known
weight a fixed distance, and using the energy produced to compact the sand.
 Test Producer
 Spray the tube conditioner swab with liquid release agent. This should be done as necessary
to maintain the swab in a slightly moistened condition.
 Slide the specimen tube down over the conditioner and back again, then place one cup over
the end of the tube and set up vertically with the cup at the base.
 Weigh out sufficient sand to form a test piece when rammed. Transfer to the specimen tube.
 Use the cam positioned on the left-hand side of the rammer to raise the plunger of the rammer.
 Rotate the cam to release the plunger head to enable it to enter the tube and come to rest gently
on the sand.
9.2: Sand Compression Strength Testing
Compressive strength or compression strength is the capacity of a material or structure to
withstand loads tending to reduce size, as opposed to tensile strength, which withstands loads
tending to elongate.

In other words, compressive strength resists compression (being pushed together), whereas
tensile strength resists tension (being pulled apart). In the study of strength of materials, tensile
strength, compressive strength, and shear strength can be analyzed independently.
 Test Producer
 Prepare the standard specimen of diameter of 50mm ×50mm height on std. sand rammer.
 Place the specimen between the compression pads (Universal Strength Machine) so that plain
surfaces of the specimen touch against the pads.
 Rotate the loading wheel clockwise until the load starts applying on specimen (this will be seen
by movement of the pressure gauge) needle till the specimen collapse with the forward
movement of needle. The red idle pointer also moves along with the needle.
 As soon as the sample collapse the needle returns while the red idle pointer remains at the
maximum reading before collapse of the specimen.
 Compression Strength scale (CS scale) indicated by the idle pointer i.e. compression strength.
9.3: Permeability Test Machine
Permeability is a property of foundry sand with respect to how well the sand can
vent, i.e. how well gases pass through the sand. And in other words, permeability is the property
by which we can know the ability of material to transmit fluid/gases. The permeability is
commonly tested to see if it is correct for the casting conditions.
 Test Producer
 Prepare the standard sand specimen of Día 2ˮ×2ˮ height with the help of std. Rammer.
 Take specimen tube with rammed specimen and place it inverted over the rubber sealing bush.
 Start the instrument indicator will glow and confirm that that permeability meter reads 100mm
on WC scale.
 Put the valve on P position and read the permeability number.
 Find the permeability number directly from the pressure gauge according to the orifice used.
Put the valve on O position.
 Whenever the air tank goes downward lift the air drum slowly up keeping valve in D position
to avoid any water entering the air tube.
 Repeat the producer three times by fresh sample of sand test each time and take the reading.
9.4: Sieve Shaker

A sieve analysis (or gradation test) is a practice or procedure used (commonly used in civil
engineering) to assess the particle size distribution (also called gradation) of a granular material
by allowing the material to pass through a series of sieves of progressively smaller mesh size and
weighing the amount of material that is stopped by each sieve as a fraction of the whole mass.

 Test Producer
 Take 50gm or 100gm of dry sand and place in the top sieve of a series and close the lid.
 Place the whole assembly of sieves on the vibratory sieve shaker and clamp it.
 Switch on the motor and allow the sieve assembly to vibrate for 5 minutes. Then switch off the
motor.
 Collect the sand particles retained in each of the sieve separately and weigh in Electronic
weighing scale and enter into the tabular column. Calculate the percentage weight retained by
each of the sieves. Multiply this value with the multiplier for each sieve.
9.5: Clay Test Machine
 Test Producer
 Take 100g of base sand in a wash bottle and add 475ml of distilled water and 25ml of NaOH
solution to it.
 Using the mechanical stirrer, stir the mixtures for about 5 minutes add distilled water to make
up the level to 6"height. Stir the mixture again for 2 minutes. Now allow the content of the
bottle to settle down.
 Siphon out 5” level of unclean water using a standard siphon.
 Add distilled water again up to 6" height and stir the content again. Allow the mixture to settle
down for 5minutes.
 Siphon out 5” level of water from the bottom of the bottle
 Repeat the above procedure for 3-4times till the water becomes clear in the wash bottle.
 Transfer the wet sand from the bottle in to a tray and dry in it in an oven at 110 o C to remove
moisture. Note down the dry sand weight accurately. Using the calculations find percentage of
clay.
 Result
Total clay content is listed in the table 9.1.
Table 9.1: The clay content in the given green sand is
Dead Clay 3 to 3.5
Active Clay 8 to 10
Total Clay 12 to 12.5
9.6: Microscope
A microscope is an instrument used to see objects that are too small to be seen by the naked
eye. Microscopy is the science of investigating small objects and structures using such an
instrument. Microscopic means invisible to the eye unless aided by a microscope.

 Test producer
 Grind the S.G. Iron sand to be tested.
 Make sure that sample surface is plain/ even.
 Rub the surface of sample with right grade of polish paper to remove the burr
 Then put water, Alumina paste on velvet macro polish meter platform for mirror finishing.
 Then clean the sample with cotton after mirror polishing.
 Keep the sample on microscope stage & adjust the focus to count the nodularity.
9.7: Moister tester
Moisture tester is used to measure the percentage of water in a given substance. This
information can be used to determine if the material is ready for use, unexpectedly wet or dry, or
otherwise in need of further inspection. Wood and paper products are very sensitive to their
moisture content. Physical properties are strongly affected by moisture content and high moisture
content for a period of time may progressively degrade a material.
 Test producer
 Weight the sample accurately by digital balance un-clamp the cap of the tester.
 Transfer the sand sample in the cap of the moister tester.
 Take one spoons of absorbent compound (Calcium Carbide)
 Transfer into the body of eh moister tester.
 Hold the body horizontally and place the cap in position.
 Bring the clamp in position and tighten the cap with screw. Shake the instrument vigorously.
 This ensure sample and the absorbent compound is mixed. Immediately the pointer of the
gauge moves.
 Keep the instrument in position. Observe the reading when pointer stops further movement.
 This will give the % of moister in the sample directly.
 Note the reading.
 Result
 Moister content in the given green sand material is 3 to 3.7%
9.8: Spectrometer
A spectrometer is a scientific instrument used to separate and measure spectral components
of a physical phenomenon. The capability of spectroscopy to determine chemical
composition drove its advancement and continues to be one of its primary uses. Spectrometers are
used in astronomy to analyze the chemical composition of stars and planets, and spectrometers
gather data on the origin of the universe.
Examples of spectrometers are devices that separate particles, atoms, and molecules by
their mass, momentum, or energy. These types of spectrometers are used in chemical
analysis and particle physics.

 Start-up Producer
 Switch on the instrument.
 Switch on the Organ Gas
 Switch on the computer and open the software by entering your name and password.
 Set the pressure on the regulator of the cylinder to 4 to 6 bar.
 By pressing FB on keyboard, check the flow on Organ flow meter located at the front side of
the instrument to 3 to 4 LPM.
 Instrument is ready for analysis after stabilization period 20 min.
 The next Spectro machine stabilization after 15 days.
 Analysis Producer
 On main screen select “Analyze” option.
 Select “Base” & matrix/ Types Matrix under which samples to be “Analyzed” & click on
“Finish”
 Enter sample ID, GRADE, HEAT NO, & CLICK ON “OK”
 Grind the sample to be burned on specimen preparation machine.
 Place respective sample on spark chamber.
 Press “Ctrl+F7” on the key board till preborn.
 The result will be displayed in few seconds.
 Take 2 to 3 burns on different spots of the sample.
 Save the burns & delete the bad burns by clicking that particular results and then click “Delete
Burn” Button.
 Select the print option for printing the Spectro result.
 Result
Percentage of different Chemicals present in FG260 Grade list is shown in
Spectro meter analysis table (Table 9.2).

KUDALE IRON WORKS

Unit II: - Machhe Industrial Estate, Machhe, Belgaum-590014 Karnataka (INDIA)
CERTIFICATE OF SPECTRO ANALYSIS

Sample Name: CAST IRON Date $ Time: 07/27/2018 01:00:28PM
Matrix: Global Fe Heat No: J-145
Grade Name: F G 260 Part Name:
Chemical Composition
Table 9.2: Chemical composition.
Elements Mean
C (%) 3.1614
Si (%) 1.9794
Mn (%) 0.6871
P (%) 0.1220
S (%) 0.0446
Cr (%) 0.0531
Ni (%) 0.1107
Mg (%) 0.0000
Al (%) 0.0000
Cu (%) 0.0305
V (%) 0.0101
Mo (%) 0.0000
Ti (%) 0.0608
W (%) 0.0000
Nb (%) 0.0000
Pb (%) 0.0000
Co (%) 0.0000
B (%) 0.0012
Sn (%) 0.0000
As (%) 0.0000
Fe (%) 93.7252
CE 3.8619
Lab Incharge QAD For KUDALE IRON WORKS

CHAPTER 10
CASTING DEFECTS, ADVANTAGES AND APPLICATIONS
10.1 : Defects in Casting
 Improper pattern design
 Improper mould and core construction
 Improper melting practice
 Improper pouring practice
 Because of moulding and core making materials
 Improper gating system
 Improper metal composition
 Inadequate melting temp and rate of pouring
10.2 : Advantages
 Molten metal flows into small ant section in the molten cavity. Hence any complex shape
can be easily produced.
 Practically any material can be casted.
 Ideal method is by producing small quantities
 Due to small cooling rate from all directions, the properties of casting are same in all
directions.
 Any size of casting can be produced up to 200 tons.
 Casting is the often cheapest and most direct way of producing a shape with certain
desired mechanical properties.
 Certain metals and alloys such as highly creep resistant metal-based alloys for gas
turbines cannot be worked mechanically and can be cast only.
 Heavy equipment like machine leads, ship’s propeller, etc. can be thrown easily in the
required size rather than fabricating them by joining several small pieces.
 Casting is best suited for composite components requiring different properties in various
directions. These are made by incorporating preferable inserts in a casting. For example,
aluminum conductors into slots in iron armature for electric motors, wear resistant skins
onto shock resistant components.
10.3 : Limitations
1. With normal sand-casting process, the dimensional accuracies and surface finish is less.
2. Defects are unavoidable.
3. Sand casting is labour intensive.

10.4 : Applications
1. Transport: Automobile, Aerospace, Railways and Shipping.
2. Heavy Equipment: Construction, farming and Mining.
3. Machine Tools: Machining, casting, Plastics Moulding, Forging and Extrusion and forming.
4. Plant Machinery: Chemical, Petroleum, Paper, Sugar, Textiles, Steels and thermal plants.
5. Defense: Vehicle, Artillery, Munitions, Storage and Supporting Equipment.
6. Electrical Equipment Machine: Motors, Generators, Pumps and Compressor.
7. Hardware: Plumbing Industry Pipes, Joints, Valves and Fittings.
8. Household: Appliances, Kitchen and Gardening Equipment.
9. Art Objects: Sculptures, Idols, Furniture, Lamp stands and decorative items.

CHAPTER 11
PRODUCTS
11.1 : Products of Kudale Iron Works
1. Valve Casting (Item Code: KIW-0001)

KIW manufactures various types of valves (Fig.11.1):
a) Non-return valve
b) Ball valve
c) Some of the salient features of valves are:
 Durability
 Dimensional Accuracy
 High tensile strength
 Pressure tight casting
 Anti-corrosive properties
Fig. 11.1: Valve
2. Butterfly Valve Casting (Item Code: KIW-0003)

KIW have a wide range of butterfly valve castings which are manufactured with green sand
process, no bake process, CO2 process & Shell sand, ranging from sizes 40mm to 600mm
(Fig.11.2).
Some of the salient features of valve are:

 Excellent surface finish
 Dimensional accuracy

Fig. 11.2: Butterfly Valve
3. Lubricated Plug Valve (Item Code: KIW-0002)

KIW manufacture lubricated plug valve body castings, plugs and covers ranging from ½’’ to 12’’
Size (Fig.11.3).
Some of the salient features of valves are:
 High Tensile strength
 High Ductility
 Good flexibility
Fig. 11.3: Plug valve
4. Machine Tool Casting (Item Code: KIW-0004)

Brackets:
We provide castings to CNC machine manufacturers & CNC machine tool changers, turrets, slides
& engineering instruments, manufactured in Co2 process, No bake process & Shell sand
(Fig.11.4).
Salient features
 High ductility
 Specific configurations

 Cost effective
Fig. 11.4: Machine Tool
5. Motor Body (Item Code: KIW-0005)

KIW provide castings to electric motor manufacturers such as motor bodies having Collin fins &
end cover in quantities to meet the client’s requirement, manufactured in green sand process, no
bake process & shell sand (Fig.11.5).
Salient features:
 Good surface finish
 Durability
 Cost effective
Fig. 11.5: Motor Body
6. Coupling Castings (Item Code: KIW-0006)

KIW produce C.I. Couplings in various sizes ranging from 1 kg to 250kgs as per designs of clients,
which are highly durable as the material poured is of high grade with a high tensile strength
(Fig.11.6).
Salient features:
 High ductility

Fig. 11.6: coupling

7. Pulley Castings (Item Code: KIW-0007)
KIW have a wide range of pulleys manufactured as per the customer design and requirement,
ranging from 1 kg to 250 kgs. These are widely used in industrial purposes (Fig.11.7).
KIW includes range of pulleys as:
a. Single groove pulleys
b. Multi groove pulleys
c. Conveyor Pulleys
d. Flywheels
Salient features:
 Durability
 Dynamically balanced
Fig. 11.7: Pulley
8. Engineering Part Castings (Item Code: KIW-0008)

KIW provide a wide range of engineering parts which are highly appreciated by the clients for
their excellent performance and durability (Fig.11.8).
Range of engineering parts includes:

a. Auto pumps
b. Motor covers
c. Hubs
d. DC motors
e. Engineering instruments
Salient features
 Durability
Fig. 11.8: Engine Parts
9. Castor Wheels & Trolley Castings (Item Code: KIW-0009)

KIW produce trolley wheels in various sizes as per client requirements in various sizes as per client
requirements in machined condition (Fig.11.9).
Fig. 11.9: Castor Wheels
10. Housing Flywheel for Diesel Engine (Item Code: KIW-0010)

KIW produce housing flywheel casting for diesel engines in the weight range of 50 kgs to 250
kgs, in grade FG 260 & FG 300 (Fig.11.10).
Salient features

Fig. 11.10: Housing flywheel
11. C.I. Gears (Item Code: KIW-0011)

KIW manufacture C I Gears required for Sugar Industry and other engineering industry purpose
(Fig.11.11).
Salient features:
Fig. 11.11 C. I Gears

CHAPTER 12
STUDENT ROLE AND CONCLUSION
12.1 : Student role

The training which I undertook in KUDALE IRON WORKS, Belagavi, eventually ended as
successful industrial training for me. I came across various instruments, Processes, Methods and
terms used in modern Foundry industries, and it helped me to understand manufacturing science
easily.
I studied various methods use to produce castings, how moulding process will be carried out to get
good quality casting products. Material used in Kudale iron works and its grades in detail. And
Melting process, Furnaces used for melting the SG-Iron and Cast-Iron materials. How pouring of
molten metal is done.
In laboratory, which instruments are there, how testing will be done using instruments. Sand testing
and standard stand parameters like fine ness, moisture, coal percentage etc. are studied. And
finishing and inspection methods used in Kudale iron works Belagavi.
I came to know Management system of Kudale iron works, behaviour of managerial staff with
labours. And how customers are giving orders to the company, what are the requirements of
customers from and organisation.
Finally, the aim of the study is to analyze the processes used in foundry to produce better quality
castings of cast iron and SG iron. The study has helped me to know the casting technologies and
its defects and problems associated with it. And how foundry industry is working, how product
finishing is takes place, how machining is done. It has also given opportunity to learn about
various casting methods and to analyze how it going to benefits to the organization.
The study was undertaken for four weeks. The study also aims at providing suggestions for
improving casting process and training to the workers and helping to develop the company.

12.2 : Conclusion
In review this internship has been an excellent and rewarding experience. I have been able
to meet and network with so many people that I am sure will be able to help me with opportunities
in the future.
One main thing that I have learned through this internship is time management skills as well
as self-motivation. When I first started, I did not think that I was going to be able to make myself
sit in an office for four hours a day, six days a week. Once I realized what I had to do I organized
my day and work so that I was not overlapping or wasting my hours.
I learned that I needed to be organized and have questions ready for when it was the correct
time to get feedback. From this internship and time management I had to learn how to motivate
myself through being in the office for so many hours.


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KUDALE IRON WORKS BELAGAVI

DEPARTMENT OF MECHANICAL ENGINEERING.

1.3: Material Suppliers

SL Names of Address Items Basis of Types & Extent

1. Deccan Traders Kolhapur Pig iron Past Inward Inspection

DEPARTMENT OF MECHANICAL ENGINEERING.

1.4: Process Flow Chart

Fig. 1.1: Schematic representation Moulding process

Fig. 1.2: The production process flow of sand castings

DEPARTMENT OF MECHANICAL ENGINEERING.

Fig. 2.1: Molten metal in cavity

2.1 : Types of Sand and Sand Preparation

DEPARTMENT OF MECHANICAL ENGINEERING.

 Oil Core Sand

 Noback core sand

DEPARTMENT OF MECHANICAL ENGINEERING.

DEPARTMENT OF MECHANICAL ENGINEERING.

 Moisture Content Test

 Clay Content Test

DEPARTMENT OF MECHANICAL ENGINEERING.

 Fill the wash bottle with water up to the marker.

Fig. 3.1: Auto sand washer

 Grain Fitness Test:

DEPARTMENT OF MECHANICAL ENGINEERING.

Fig. 3.2: Sieve Shaker.

DEPARTMENT OF MECHANICAL ENGINEERING.

Fig. 3.3: Permeability meter

Fig. 3.4: Universal strength machine

DEPARTMENT OF MECHANICAL ENGINEERING.

DEPARTMENT OF MECHANICAL ENGINEERING.

Fig. 4.1: Pattern

Fig. 4.2: Cavity created by pattern

DEPARTMENT OF MECHANICAL ENGINEERING.

Fig. 4.3: Cold box core making machine

Fig. 4.4: Cold box core

 Shell Core Process

DEPARTMENT OF MECHANICAL ENGINEERING.

Fig. 4.5: Shell core making machine

Fig. 4.6: Shell core

DEPARTMENT OF MECHANICAL ENGINEERING.

5.2: Characteristics of Mould

5.3: Moulding Terminologies

DEPARTMENT OF MECHANICAL ENGINEERING.

5.4: Moulding Process

DEPARTMENT OF MECHANICAL ENGINEERING.

Fig. 5.1: Automatic sand preparation machine (automized sand muller)

Fig. 5.2: Automized Sand plant

DEPARTMENT OF MECHANICAL ENGINEERING.

 Spheroidal Graphite Iron (SG-Iron)

DEPARTMENT OF MECHANICAL ENGINEERING.

6.2: Material Properties

DEPARTMENT OF MECHANICAL ENGINEERING.

DEPARTMENT OF MECHANICAL ENGINEERING.

DEPARTMENT OF MECHANICAL ENGINEERING.

DEPARTMENT OF MECHANICAL ENGINEERING.

DEPARTMENT OF MECHANICAL ENGINEERING.

DEPARTMENT OF MECHANICAL ENGINEERING.

DEPARTMENT OF MECHANICAL ENGINEERING.