A Review on Issues Related To Manual Core Making Process in Foundry Industry

IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 11, 2016 | ISSN (online): 2321-0613

A Review on Issues Related to Manual Core Making Process in Foundry Industry Prof. Amarjeet R. Gupta1 Prof. Sanjay N. Aloni2 Mr. Raj Kumar H. Binzade3 1,2 Professor 3Manager 1,2 Department of Mechanical Engineering 3Department of Quality Control (QC) 1,2 Datta Meghe Institute of Engineering, Technology & Research Wardha 3Jayaswals Neco Ltd. (Automotive Casting) Butibori Abstract— Foundry industry is one of the major industries where castings are produced. 70% components of any automobile are produced with casting process. To produce such intricate shape hollow components cores are required which are produced in core shop. Cores are produced with different processes. In manual core making(MCM) process cores are produced manually and having ergonomic issues along with other problems that are; core rejection is more, man power requirement is more, less productivity, higher cost.

Key words: MCM Process, Manual Core

switches. In the four stations, the sub stations are: investment, preheating, after heating and ejection. Only one operator is required to operate the machine. The bucket elevator is installed on one side of the machine in which the sand is elevated to the top hopper for sieving. Below the top seiver hopper is mounted, with pneumatically operated butterfly valve.

I. INTRODUCTION Core making is an important branch in any foundry and the choice of core making depends on various factors. To name them are 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 in final product, depends on equipment used for production and energy source.

It gives foundries a capability that no other metalworking process offers: the ability to form external and internal contours, shapes, cavities, and passageways in one operation.

Foundries have always been interested in improving productivity and profitability. But, over the past few years competitive pressure and general industrial conditions have reinforced metal casters’ resolve to refine current processes and to develop new technologies that improve productivity and reduce costs II. COMMON TECHNOLOGIES USED IN CORE MAKING Following are the different types of machines used by core shop in foundry industries for core production, core baking in case of oil sand cores and core drying.

1) Shell sand Core Shooter Machine 2) Cold box Core Shooters.

3) Electric Core Oven 4) Oil Fired Core Oven Following are the most common core making processes used by foundry industry, they are 1) No Bake 2) Oil sand 3) CO2 4) Hotbox 5) Cold box A. Core Shooter Machine 1) Four Station Shell Moulding Machine The machine consists of square rotary tables and one match plate on each side of square. The rotation consists of fast speed and slow speed with brake system controlled by limit

Fig. 1: Four Station Shell Moulding Machine B. Two Station Core Shooter Machine This fully automatic machine so as to produce shell moulding twice as faster as the normal one. This machine needs only one operator. This machine is a top shooting type which allows the sand to reach the intricate shape of core boxes.

Fig. 2: Two Station Core Shooter Machine C. Cold Box Core Shooter Cold box Core Shooter is a proven design. It has given a foundry engineers an edge in the productivity of core

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A Review on Issues Related to Manual Core Making Process in Foundry Industry (IJSRD/Vol. 3/Issue 11/2016/084)

making. This process offers many advantages over the normal core shooters such as high productivity, energy saving, good dimensional accuracy, excellent break down properties, low gas evaluation etc. This process uses phenolic resin and an isocynate; it hardens instantly at ambient temperature under the action of gaseous catalyst (tri ethyl amine or di ethyl amine)  This process is most suitable for atomization.  PLC control.  Core Box Size - 300x300x250, 300x600x200  Max Core Weight - 15kg  With Air Drier Unit

This paper also aims to provide correct guideline to quality control department to find casting defects and will help them to analyze defects which are not desired.

A.P.MORE,DR.R.N.BAXI,DR.S.B.JAJU “Review of Casting Defect Analysis to Initiate the Improvement Process” Int J Engg Techsci Vol 2(4) 2011,292-295 In order to identify the casting defect and problem related to casting, the study is aimed in the project or research Work. Especially industry based problem is decides to study in detail Technical solution for minimizing various casting defects to improve the entire process of critical component manufacturing, is decided to work out during this project.

IV. MANUAL CORE MAKING PROCESS In Manual Core Making Process, sequence wise operations are given below  Clamping of core box along with proper positioning of loose pieces  The sand is mixed with the Binder and Dryer (Catalyst) using sand mixer.  The prepared sand is filled in Core box with proper ramming.  Core is allowed to become hard (curing time).  Strip out the core from the core box.

Clamp the core box and again follow the same steps for next core

Fig. 3: Cold Box Core Shooter III. REVIEW OF LITERATURE BINU BOSE V, K N ANILKUMAR, “Reducing rejection rate of castings using Simulation Model”, International Journal of Innovative Research in Science, Engineering and Technology Volume 2, Special Issue 1, December 2013 This paper helps to improve the defects and rejection in core making process using simulation software.

ANIRUDDHA JOSHI, PRITAM KADAM “An Application of Pareto Analysis And Cause Effect Diagram For Minimization Of Defects In Manual Casting Process” International Journal of Mechanical And Production Engineering, ISSN: 2320-2092, Volume- 2, Issue- 2, Feb.2014.

Mold shifting, Crushing, Lower Surface finish, Shrinkage, Porosity, Cold shut and Extra material are common casting defects due to various manual operations performed in foundries. These defects directly affect on productivity, profitability and quality level of organization.

In this paper all data presented is taken from one foundry.

This paper presents all data of manual metal casting operations and defects leads to rejection for this organization. The paper also represents analysis of these defects with Pareto and Cause and Effect diagrams to know correct cause and correct remedial factors to improve quality level and productivity of organization.

RAJESH RAJKOLHE, J. G. KHAN “Defects, Causes and Their Remedies in Casting Process: A Review” International Journal of Research in Advent Technology, Vol.2, No.3, March 2014

Fig. 4: Sand Mixer Machine

Fig. 5: Core Box

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A Review on Issues Related to Manual Core Making Process in Foundry Industry (IJSRD/Vol. 3/Issue 11/2016/084)

Fig. 6: Cores V. ISSUES RELATED TO MANUAL CORE MAKING PROCESS      

Core strip out time and core box clamping time is more in manual core making process.

Core rejection is more Productivity is lower Weight of Core box is more, sometimes up to 150Kg Ergonomic Issues Man power requirement is more VI. CONCLUSION

In many foundry industries big cores are manufacture using manual core making process. Due to this Core rejection is more in case of manual core making process. This affects on the productivity of core shop. So it is mandatory to improve the productivity of core shop by rectifying the different issues related to manual core making process.

REFERENCES [1] BINU BOSE V, K N ANILKUMAR,“Reducing rejection rate of castings using Simulation Model”, International Journal of Innovative Research in Science, Engineering and Technology Volume 2, Special Issue 1, December 2013 [2] ANIRUDDHA JOSHI, PRITAM KADAM “An Application Of Pareto Analysis And Cause EffectDiagram For Minimization Of Defects In ManualCasting Process” International Journal of Mechanical And Production Engineering, ISSN: 23202092, Volume- 2, Issue- 2, Feb.-2014 [3] Rajesh Rajkolhe, J. G. Khan “Defects, Causes and Their Remedies in Casting Process: A Review” International Journal of Research in Advent Technology, Vol.2, No.3, March 2014 [4] Kasim M. Daws et al (2008), “Selection of Metal Casting Processes: A Fuzzy Approach” Jordan journal of mechanical and Industrial engineering Vol 2 March 2008 ISS 1995-6665 Pages 45 [5] Dr. M.S.Deva Kumar et al (2012), “Modeling, simulation and analysis in manufacturing of a flywheel casting by S.G.iron” International Journal of Materials and Biomaterials Applications 2012; 2(4): 25-28.

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