A leading Gray, S.G. and Alloy Cast Iron Casting Manufacturing FOUNDRY Unit.
Casting Process › Technical Overview
Technical Overview of Casting Process ›
Casting Simulation & Pattern Development
We have tie-up with Oriental Software Pvt. Ltd. Bangalore for their SOFTCAST SERVICES. We are able to develop our product faster with the help of Casting Simulation Service from them. We can increase the percentage of yield then our competitor as well as reduce the percentage of REJECTION by effective methoding. We have tie-up for new PATTERN development along with INNOVATIVE MOULDING WORKS, who has CNC & VMC machines to develop the same faster as well as accurate.
Core Making Facilities
We have 7 Nos. SUSHA make shell moulding machines to make critical cores through shell core shooters. We also have 8 Nos. 500 Kgs. regular core mixtures in which we make sand of CO2, No-Bake two part and three part as well as Oil core sand as and when requires to make their respective cores from it.
Full Mechanised Automatic Green Sand Plant
This is front and back view of fully mechanized automatic SAND PLANT with cooling system for preparation of green sand installed in RAJAVIR INDUSTRIES. We have two numbers of 500 kgs INCENTIVE mixtures to prepare green sand in this plant. This automatic green sand plant provide us green sand as and when required on match plate, where our patterns are fitted as well as mould box kept on it to prepared mould by just pulling chain by machine operator. After knock out of moulding boxes, used sand will goes on conveyer belt for magnetic separator and cooling. It will transfer to mixer again in a proportion we need by bucket elevators, to prepare green sand.
Moulding, Core-setting & Closing Station
This is a station where we can see, set of JOLT/SEQUES Moulding machine which is equivalent to ARPA 450 machine. We can mould COPE & DRAG on individual machine at a time. After moulding drag will goes to CLOSING TRACK, where cores are set as well as if necessary Graphite coating is also done. Then COPE is closed on DRAG with the help of closing pins. Closed mould boxes are transferred to pouring tracks.
Sand Testing Laboratory
We have fully equipped SAND TESTING laboratory from KELSONS, with equipments like- (a) Set of mechanized Sand Sieves
- (b) Rapid moisture taster
- (c) Universal strength testing machine
- (d) Permeability meter
- (e) Mould hardness tester
- (f) Core hardness tester (Scratch hardness tester)
Temperature Measurement
We have 2 Nos. ELECTROTHERM make 350 KW, 1000 Hz, Medium Frequency Induction Furnace along with 500 Kgs. Crucibles to melt Grey and Alloy Cast Irons. In this picture our staff is checking Temperature of liquid metal in Induction Furnace itself before tapping the same. We kept our pouring temperature depending on metal specification as well as casting section thickness.
CE Meter
As soon as, we will pour the liquid metal into the cup of CE METER, within couple of minutes, it will give us CARBON EQUVIVALENT, % of Carbon, and % of Silicon, along with pouring temperature, liquids temperature and solids temperatures. Depending on grade of castings we adjust the same and alter in liquid metal itself before pouring in to the moulds. In this picture we can see CE is 4.09, % of Carbon 3.42 and % of Silicon is 1.80.
Wet Lab Set-up
We have full flanged WET LAB analysis instruments from CARLOS EQUIPMENTS. We take out the sample from each heat. We do check % of Manganese, % of Sulphur and % of Phosphorous as well as alloys we had added like % of Chromium, % of Nickel and % of Molybdenum. We can also cross check % of Carbon and % of Silicon observed in CE Meter.
Pouring of Liquid Metal
After confirmation received from Quality acceptance department, for metal temperature and composition, we INOCULATE our iron along with stream of liquid metal when tapped from Induction furnace to the ladle as we can see in front of our Boucher. This liquid metal ladle will come to monorail over track of moulding box by electric hoist. After receiving the same on monorail Ladler can move it up or down as we want and skilled manpower will pour the liquid metal in to pouring cup of mould box as we can see in this picture. We are using only Tea-pot ladles to reduce the defects like slag inclusions in our castings.
Casting Knock-out
We have VIBRATORY KNOCK-OUT machine, which will separate, molding boxes. That can be lift up by crane and can be use for Re-Molding. Used sand will goes down in a plant for magnetic separator as well as screening. Then it will lift up to the incentive mixer by Bucket Elevators, through cooling if necessary by conveyer belt system. Castings will be collected from other end of Vibratory Knock Out machinefor further operations like Cleaning, Grinding as well as Shot Blasting processes.
Shot-Blasting Facilities
We have 3 Nos. of Shot Blasting machines:1. Hanger type shot blasting machine for bigger size castings.
2. Table type shot blasting machine for medium size castings.
3. Tumbling Barrel type shot blasting machine for small size castings.
