Quality

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)

with hotplate and hot air oven along with digital scale. In this Picture our lab technician is checking GREEN COMPRESSIVE STRENGTH of prepared green sand.

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 machine for 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.

Metallurgical Microstructure

We have Metallurgical Microscope along with CCD Camera as well as Software to analyze the microstructure for Cast Iron of PROMETAL 3.3. Sample for metallurgical microstructure is taken out from heat as and when required by costumer and for our satisfaction. We prefer size of the Graphite Flakes which is 4 to 6 as per ASTM A-247 and distribution type ‘A’ i.e. UNIFORM DISTRBUTION – RANDOM ORIENTATION. After etching we will see that percentage of PERLITE around 90% & FERRITE around 10% as per phase analysis ASTM E-562. We can also check unwanted phases like Cementite, phosphide, carbides etc.

Dimension Checking

To check the dimension of castings in AS-CAST condition as well as MACHINED condition we have Surface plate form LUTHER. We have OPTIMA PLUS digital to check the dimensions accurately.

Hardness Testing

We are checking BRINELL HARDNESS on sample as well as small castings that can easily accommodate on BHN machine with the help of different type of attachments. Bigger castings hardness is checked with POLDI & DIGITAL hardness tester.