PROJECT REPORT
FOR
CASTING
IRON & COPPER
________________________
PROMOTER
PRODUCTION CAPACITY
20 tons per day of Casting Iron & Copper
CAPACITY UTILIZATION
14.5 tons per day of Casting Iron
3.5 tons per day of Casting Copper
LOCATION
RAW MATERIALS
1. Iron Scrap2. Copper Scrap
DIRECT EMPLOYMENT
75 to 80 persons
INTRODUCTION
Indian Foundry Industry Overview
The Indian Foundry industry produces approximately 7 Million MT of Casting
employing an estimated 5 lakh persons directly & another 1.5 million persons
indirectly. The growth of foundry industry is very important for
inclusive growth, other engineering sectors & the overall Indian Economy.
Foundry Industry is Major Feeder to following sectors:-
Automobiles & Auto Components
Railways
Power Sector
Tractor Industry
Earth Moving Machinery
Pumps, Compressors, Pipes Valves & Pipe Fittings
Electrical/Textile/Cement/Agro Machinery
Machine Tools & Engineering Industries
Sanitary Castings
Engineering Exports
Approximately 32% Output of Foundry Industry goes to Auto Industries &
Balance to other downstream Engineering Sector. Automotive Mission Plan
(AMP) 2006-2016 envisages 4 fold growth by 2016 i.e. from $34 Billion Industry
to $122-160 Billion Industry employing about 25 million people by 2016. AMP
2006-2016 will drive demand of Castings from Foundry Industry.
Corresponding Growth in Foundry Sector is vital to sustain growth in Auto &
other Engineering Sectors.
Graphs below depict sector wise consumption of casting in percentage, Types
of Metal Casting Share in percentage and Top Ten Casting Producing Countries
Sector Wise Consumption of Castings as % of
Total Production
Types of Metal Casting Share in %
Top Ten Casting Producing Countries
(Figures in Million MT)
70%
9%
12%8% 1%
Grey IronDuctile IronSteelNon-FerrousOthers
Now the fourth largest producer of metal castings worldwide, India has
increased its casting production by more than 100% since 2002. Expansion
stems from India’s rapidly growing economy, which has the potential to raise
its income per capita to 35 times current levels over the next 40 years.
According to Goldman Sachs, in 2059, India is expected to have one of the
three largest economies (by GDP) in the world, along with China (first) and USA
(second). The automotive sector accounts for 4.2% of India’s GDP and since
2002 production volume has a 16% compound and annual growth rate (CAGR).
Some economists believe India has the potential to own up to 7% of the
world’s components market.
Future
Due to growing expectations of OEM’s regarding the quality and quantity of
castings, India is expected to produce larger casting facilities over the next few
years. The size and scope of large plants are required to address investment
requirements. This means the manufacturers with latest technology of
equipments will have a bright opportunity in India.
About the Directors
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Machinery
Hot-chamber machines
Hot-chamber machines, also known as gooseneck machines, rely upon a pool
of molten metal to feed the die. At the beginning of the cycle the piston of the
machine is retracted, which allows the molten metal to fill the "gooseneck".
The pneumatic or hydraulic powered piston then forces this metal out of the
gooseneck into the die. The advantages of this system include fast cycle times
and the convenience of melting the metal in the casting machine.
Cold-chamber machines
These are used when the casting alloy cannot be used in hot-chamber
machines; these include aluminum, zinc alloys with a large composition of
aluminum, magnesium and copper. The process for these machines starts with
melting the metal in a separate furnace. Then a precise amount of molten
metal is transported to the cold-chamber machine where it is fed into an
unheated shot chamber (or injection cylinder). This shot is then driven into the
die by a hydraulic or mechanical piston.
Manufacturing Process:
It is a four step process in traditional die casting, also known as high-pressure
die casting; these are also the basis for any of the die casting variations: die
preparation, filling, ejection, and shakeout. The dies are prepared by spraying
the mold cavity with lubricant. The lubricant both helps control the
temperature of the die and it also assists in the removal of the casting. The
dies are then closed and molten metal is injected into the dies under high
pressure. Once the mold cavity is filled, the pressure is maintained until the
casting solidifies. The dies are then opened and the shot (shots are different
from castings because there can be multiple cavities in a die, yielding multiple
castings per shot) is ejected by the ejector pins. Finally, the shakeout involves
separating the scrap, which includes the gate, runners, sprues and flash, from
the shot. This is often done using a special trim die in a power press or
hydraulic press. Other methods of shaking out include sawing and grinding. A
less labor-intensive method is to tumble shots if gates are thin and easily
broken; separation of gates from finished parts must follow. This scrap is
recycled by re-melting it.
The high-pressure injection leads to a quick fill of the die, which is required so
the entire cavity fills before any part of the casting solidifies. In this
way, discontinuities are avoided, even if the shape requires difficult-to-fill thin
sections. This creates the problem of air entrapment, because when the mold
is filled quickly there is little time for the air to escape. This problem is
minimized by including vents along the parting lines, however, even in a highly
refined process there will still be some porosity in the center of the casting.
After the shakeout of the casting it is inspected for defects. The most common
defects are misruns and cold shuts. These defects can be caused by cold dies,
low metal temperature, dirty metal, lack of venting, or too much lubricant.
Other possible defects are gas porosity, shrinkage porosity, hot tears, and flow
marks. Flow marks are marks left on the surface of the casting due to poor
gating, sharp corners, or excessive lubricant.
Water-based lubricants, called emulsions, are the most commonly used type of
lubricant, because of health, environmental, and safety reasons. Unlike
solvent-based lubricants, if water is properly treated to remove all minerals
from it, it will not leave any by-product in the dies. If the water is not properly
treated, then the minerals can cause surface defects and discontinuities. There
are four types of water-based lubricants: oil in water, water in oil, semi-
synthetic, and synthetic. Oil in water is the best, because when the lubricant is
applied the water cools the die surface by evaporating while depositing the oil,
which helps release the shot. A common mixture for this type of lubricants is
thirty parts water to one part oil, however in extreme cases a ratio of 100:1 is
used.
Oil used is heavy residual oil (HRO). HROs are gelatinous at room temperature,
but at the high temperatures found in die casting, they form a thin film. Other
chemical additives are used to inhibit rusting and oxidation. Emulsifiers are
added to water-based lubricants, so that oil based additives can be mixed into
the water.
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