YIELD IN ENGINEERING CASTING

“Assessment of various ENGINEERING CASTING”

At
JAMSHEDPUR ENGINEERING AND MACHINE MANUFACTURING COMPANY

(A DIVISION OF ISWPL & A SUBSIDIARY OF TATA STEEL LTD)

Project Report submitted in Partial Fulfillment of the requirement for the

SUMMER INTERNSHIP of

BACHLEOR OF Technology

In

MANUFACTURING ENGINEERING

Submitted by

RAHUL RANJAN

&

SANTAN KUMAR JHA

NATIONAL INSTITUTE OF FOUNDARY AND FORGE

TECHNOLOGY, HATIA

RANCHI, 834003
 JAMSHEDPUR ENGINEERING AND MACHINE MANUFACTURING COMPANY

A DIVISION OF ISWP, SUBSIDIARY OF TATA STEEL

CERTIFICATE

This is to certify that the project entitled ‘YIELD IN ENGINEERING CASTING’

is a record of independent bonafide project work carried out by Mr. Rahul Ranjan
and Mr. Santan Kumar Jha during the period of summer intern from 29th May 2017
to 30th of June 2017 under our supervision at JEMCO, a division of ISWPL & a
subsidiary of TATA STEEL Ltd. No data/information should be shared with any
other agency or no communication should be there in any journal/patent body.

It is presented in satisfactory manner to warrant its

acceptance as a prerequisite in the completion of their vocational training.

P.C UPADHYAYA AMIT KUMAR

 TO WHOMSOEVER IT MAY CONCERN

This is to certify that Rahul Ranjan (BTE00033/15) and Santan kumar Jha,
(BTE00007/15) students of National Institute Of Foundry And Forge Technology,
Ranchi has successfully completed four weeks (29TH May 2017 to 3oTH June 2017)
internship programme at JEMCO a division of INDIAN STEEL & WIRE
PRODUCTS LTD, Jamshedpur.

It is also certified that this project entitled –YIELD IN ENGINEERING

CASTING ‘Assessment of engineering casting at foundry section’ submitted by
Mr. Rahul Ranjan & Mr. Santan Kumar Jha in partial fulfillment for the award of
Bachelor of Technology, National Institute Of Foundry And Forge Technology is
his original work and does not form any part of the projects undertaken previously.

The project represents the original work on the part of the candidate.

Place: Ranchi

Date:

Signature

AMIT KUMAR

[ Assistant Manager]
 DECLARATION

We RAHUL RANJAN & SANTAN KUMAR JHA, hereby declare that the
Project Report entitled, “YIELD IN ENGINEERING CASTING”, submitted in
partial fulfillment of the requirements for the SUMER INTERNSHIP of the
Degree of BACHLEOR of Technology in MANUFACTURING
ENGINEERING is a record of original training undergone by us during the
period MAY‟29-JUNE‟30, under the supervision and guidance of Mr. AMIT
KUMAR, [Assistant Manager] Foundry & Melting Division, Jamshedpur,
Jharkhand and it has not been copied from anywhere or formed the basis for award
of any other Degree/Diploma/Fellowship or other similar title to any candidate of
any University.

Place: RANCHI Signature

Date: RAHUL RANJAN

&

SANTAN KUMAR JHA

 ACKNOWLEDGEMENT

The internship opportunity we had with THE JAMSHEDPUR ENGINEERING &

MACHINE MANUFACTURING COMPANY which is a division of INDIAN
STEEL & WIRE PRODUCTS LIMITED JAMSHEDPUR was a great chance for
learning and professional development. Therefore, we consider ourselves as very
lucky as we were provided with an opportunity to be a part of it. We are also
grateful for having a chance to meet so many wonderful people and professionals
who led us though this internship period.

We wish to Extend my sincere and heartfelt gratitude to our guide Mr. Amit
Kumar [Assistant Manager], JEMCO. Who guided, supported and encouraged us
during the entire tenure of the project and our mentor Mr. P.C Upadhayay [A.G.M
Operation] without whose help it would have been difficult to finish this journey.
We would like to take this opportunity to thank Ms. Shilpi Shiwangi [Sr.
Manager(HR/IR), ISWP LTD]. And all the employees for their support throughout
the course of project. We are able to say with conviction that we are immensely
benefited from auspicious and prestigious association as a summer intern with
JEMCO a division of ISWP Ltd.

We express our deepest thanks to our faculty mentor, Mr. A.K.SOOD

[Professor, Department of MANUFACTURING] for allowing us to do the
project in such renowned company and taking part in useful decision & giving
necessary advice and guidance. We choose this moment to acknowledge his
contribution gratefully which were extremely valuable for our study both
theoretically and practically.

We also wish to thank all people in the Foundry department of JEMCO for their
constant support and help in accomplishing the objectives of the project. There are
many who we may have left out in the acknowledgement, but whose co-operation
no doubt went a long way in the project completion.

Above all, We thank GOD, Almighty for the immense wishes and blessings that
gave us motivation and confidence to complete this project on time.
 CONTENTS

CERTIFICATE……………………………………………………………2

DECLARATION………………………………………………………….4

ACKNOWLEDGEMENT………………………………………………...5

CHAPTER-1:
INTRODUCTION…………………………………………………….......6

CHAPTER-2: ABOUT THE COMPANY…………………………….....8

2.1 INTRODUCTION OF THE COMPANY………………………..….10

2.2 ORGANIZATION STRUCTURE……………………………..…....15

2.3 FUNCTIONING AND PROCESSES………………………………16

2.4 BUSINESS ENVIROMENT………………………………………..35

CHAPTER-3: BACKGROUND OF THE PROJECT…………………40

3.1 OBJECTIVE OF THE PROJECT…………………………………..40

3.2 GENESIS OF THE PROBLEM…………………………………….45

3.3 YIELD IMPROVEMENT OF POWERPLANT CASTING……….47

3.4 YIELD IMPROVEMENT OF H.S BALL………………………….53

3.5 YIELD IMPROVEMENT OF ENGINEERING CASTING……….56

CHAPTER-4: CONCLUSION

4.1 YIELD OF DIFFERENT CASTINGS……………………….……..57

4.2 SUGGESTION……………….……………………..…….….……..58

REFERENCES…………………………………………………………59
 CHAPTER 1

INTRODUCTION CHAPTER

As per the norms set by the B.TECH programe every students have to undergo an
Industrial Training in any Industry to get acknowledged with the conventional
practices being followed. It helps, the students to apply their theoretical knowledge
in the practical situation to get crystal clear idea about the technicalities involved in
performing a job. As it is beautifully said by Tata Steel Ltd that ―our values are
stronger than steel, such a working environment helps students to understand the
desired level of value system required to work in any industry.

Through this four weeks journey in JEMCO a division of ISWP Ltd, Jamshedpur
We were privileged to visit various Plants to understand the procedure and conduct
Equipment effectiveness of Foundry division and later the outputs were used to
find out and to compare with the world class products. In addition to it the proposal
for yield improvement was given by us. While, visiting different sections we
learned the standard operating procedures required to carry out a job.

Working in JEMCO as a trainee We were involved in Various Engineering Casting

and also learned about the standards needed for Daily Management activities.
 CHAPTER 2

ABOUT THE ORGANISATION

2.1 INTRODUCTION

JEMCO is a division of INDIAN STEEL AND WIRE PRODUCTS LTD (IWPL).

So firstly I would like to give Introduction about ISWPL.

ISWP stands for Indian Steel and Wire Products Limited. The ISWP manufactures
products like wire rods, cast iron and steel based rolls and has its plant in Telco
colony, Jamshedpur. After being shut for nearly 6 years, the company struck a deal
with Tata Steel on December 20, 2003. It closed down in 1998 after its losses
accumulated to several crores. It was then referred to the Board for Industrial and
Financial Reconstruction or BFIR. At the time of takeover, the company had
incurred losses to the tune of INR 78 crore.

The Indian Steel & Wire Products Ltd saw the light of the day in the year 1920. In
the year 1935 it was incorporated as a company under the Companies Act, 1913.
A primary manufacturer of wire rods, TMT rebar’s and wires, welding products,
fasteners, rolls and castings; ISWP strictly adheres to the highest standards of
quality and services. 

There are many firsts with ISWPL! It established the first Wire Drawing Plant in
Asia & is a pioneer in the Rolls industry of India. Pre-independence it also
established the privately owned fasteners plant and supported industrial
development. This is how ISWPL emerged as a major manufacturing centre during
the 20th Century thereby giving a boost to the nation building and industrial
growth.

With its wealth of experience and expertise in the welding consumable and
fastening industry, ISWP, markets its Welding and Fasteners products under the
brand name, “SPARK”. The Company has a state-of-the-art Welding Technology
Centre, efficient Fasteners manufacturing equipment imported from Germany and
an all-India distribution channel for all its facilities.  Pioneer in the Rolls industry,
ISWPL’s Rolls and Casting products are sold under the brand “JEMCO” across
International market.  

ISWPL is subsidiary of TATA STEEL. So there is a small overview of TATA

STEEL GROUP

TATA GROUP PROFILE

Founded by Jamshedji Tata in 1868, the Tata group is a global enterprise,

headquartered in India, comprising over 100 independent operating companies.
The group operates in more than 100 countries across six continents, with a
mission “To improve the quality of life of the communities we serve globally,
through long-term stakeholder value creation based on Leadership with Trust”.

Tata Sons is the principal investment holding company and promoter of Tata
companies. Sixty-six percent of the equity share capital of Tata Sons is held by
philanthropic trusts, which support education, health, livelihood generation and art
and culture. In 2014-15, the revenue of Tata companies, taken together, was
$108.78 billion. These companies collectively employ over 600,000 people.

Tata companies with significant scale include Tata Steel, Tata Motors, Tata
Consultancy Services, Tata Power, Tata Chemicals, Tata Global Beverages, Tata
Teleservices, Titan, Tata Communications and Indian Hotels.

Many Tata companies have achieved global leadership in their businesses. For
instance, Tata Communications is number 1 international wholesale voice provider
and Tata Motors is among the top ten commercial vehicle manufacturers in the
world. Tata Steel is among the top fifteen best steelmakers and TCS is the second
largest IT services company in the world by market cap and profit. Tata Global
Beverages is the second-largest tea company in the world and Tata Chemicals is
the world’s second-largest manufacturer of soda ash. Employing a diverse
workforce in their operations, Tata companies have made significant local
investments in different geographies.

With its pioneering and entrepreneurial spirit, the Tata group has spawned several
industries of national importance in India: steel, hydro-power, hospitality and
airlines. The same spirit, coupled with innovativeness, has been displayed by
entities such as TCS, India’s first software company, and Tata Motors, which made
India’s first indigenously developed car, the Tata Indica and the smart city car, the
Tata Nano. Pursuit of excellence has similarly been manifested in recent
innovations like the Silent Track technology developed by Tata Steel Europe and
the next-generation Terrain Response, including infrared laser scanning to predict
terrain, and Wade Aid to predict water depth, by Jaguar Land Rover.

The Tata trusts, majority shareholders of Tata Sons, have endowed institutions for
science and technology, medical research, social studies and the performing arts.
The trusts also provide aid and assistance to non-government organisations
working in the areas of education, health care and livelihoods. Tata companies
themselves undertake a wide range of social welfare activities, especially at the
locations of their operations, as also deploy sustainable business practices. Going
forward, Tata companies are building multinational businesses that seek to
differentiate themselves through customer-centricity, innovation, entrepreneurship,
trustworthiness and values-driven business operations, while balancing the
interests of diverse stakeholders including shareholders, employees and civil
society.
ABOUT JEMCO.

JEMCO is manufacturer and provider of Cast iron & Cast Steel rolls and

Engineering Castings. With continual improvement and technological up-
gradation, it’s achieved the market leadership in domestic marketplace for Non-
metallurgical (Hollow) Rolls in Indian. JEMCO additionally provides rolls for
Long and flat product phase of steel rolling, and has additionally established
itself within the producing and provide of engineering castings for Power sector
and Rolling Mills.
JEMCO Works & Office is situated at Jamshedpur, it is only 5 KM from
Tatanagar railway station and it is spread over 97acres.It is equipped
with appropriate Melting furnaces, trendy factory subtle shop and a well equipped
laboratory having all up thus far testing facilities. The
Plant nowadays has associate put in capability of 4500 MT for Rolls and
Engineering Castings. authorized with "ISO-9001.2008 Certification", JEMCO
is within the path of continuous improvement like implementation of TPM to
travel on the far side client and different stake holders’ expectation and
satisfaction.

JEMCO has ability and capability to undertake manufacture of customized design

products. JEMCO rolls are designed to roll steel ingots, blooms, billets, angles,
channels, rods, tubes, strips, sheets and other section products. Within the non-
metallurgical area, JEMCO rolls notice wide unfold application & appreciation in
rubber, paper, textiles, asbestos jointing and poly film industries. JEMCO's special
engineering castings are acknowledge for steel industries, off road castings, mines
& collieries, power plants, cement industries, defence, railways etc. different range
of products is as under.

CI Grade & SG Upto

Grade Ø280-1250 mm 16MT
ROLLS
Upto10
STEEL Grade Ø300-950 mm
MT
   
CI Grade & SG
Upto 20
Grade
    MT
ENGINEERING
Upto10
CASTING STEEL GRADE
    MT
Special Alloy 25Kigs-
Steel     12MT
ABOUT FOUNDRY & MELTING PLANT

JEMCO has well equipped Foundry & Melting shop with following Equipments
detail:

 Two Arc Furnaces – 3.5 MT & 7.5 MT capacity

 Two Induction Furnaces

 Main frequency 8 MT capacity

 Dual Track Medium Frequency – 0.75 MT & 1.5

MT capacity

 Ladles of various sizes both of Lip pouring &

Bottom pouring types.

 Weighing Facility for Charge

 In-house refractory repair facilities

 24 MT of liquid metal is possible to have at a time

 Can prepare all types of Metals like Cast Iron &

Steel

 Development of New production line for Special

castings

 Availability of different sizes of chillers and moulds to cater to custom

design

 Availability of Pattern Making facility

ESTABLISHMENT OF INDUSTRIAL ENGINEERING DEPARTMENT IN
TATA STEEL

It was only after 1947 that the Management of Tata Steel and the Tata workers
Union (TWU) appreciated the need for industrial engineering as a useful activity
and decided that a systematic appraisal of all industrial activities should be
undertaken in TISCO, as was being done in other industrially advanced countries
at that time. Thus came into being a pioneering Industrial Engineering Department
in TISCO in 1948 through M/s International Business Consultants (IBCON) USA.
IED undertook various studies to assess the production capacities of various
production units as well as work load of workers, which took 5 years to complete.
Subsequently, incentive bonus schemes were designed and implemented for all
production departments and later on other departments were covered. Thereafter
Mr. PC Lewis became IBCON manager from 1951 to 1955. After completion of
IBCON assignment, in 1955, Mr. VS Vernekar took over as the first Chief
Industrial Engineer.

In the fifties, Tata Steel embarked upon the expansion plan to increase steel output
from 1 MT to 2 MT per annum. With the findings of Industrial Engineering work
studies, it was decided to produce the additional 1 MT capacity without any
increase in the manpower by improving the labor productivity. The issue was
discussed with the Tata Workers Union and in January 1956, an historic agreement
was made between the company and the Union. After discussions with the
departments for rationalization of labor force based on work load studies a
‗Revised Standard Force was established for all the departments. Finally, a total
workforce of approximately 28000 employees were provided for operating 2
MTPA plant compared the erstwhile workforce of approximately 33000 employees
for operating 1 MTPA plant.
ROLES AND FUNCTION OF PRODUCTIVITY SERVICES
DEPARTMENT

ABOUT THIS PROJECT

INTRODUCTION

In today’s modern industry, machine and equipment are very important to any
organization along with skilled employ. It is very challenging for any firm to exit
in market. So, Yield of the product manufactured by firm and equipment
effectiveness plays very vital role in this modern manufacturing world, to achieve
the firm’s goal. However, with the development of special and sophisticated
machines and equipment’s cost a lot and therefore their downtime of idleness
becomes very much expensive. Machine breakdown, low plant availability and
increased in overtime are the main reasons to increase the costs of an industry.
Cost is the main key of any organization, for this it is important that the plant
product should have better Yield and machines should be properly work and well
maintained. TPM is the methodology to increase the availability of the already
existing equipment hence it reduces the further capital investment.

Lesser the metal will be wasted during casting, higher will be the Yield of
the product and higher will be the benefit of the firm.

2.2 ORGANIZATION STRUCTURE

2.3 FUNCTIONING AND PROCESS

JEMCO is manufacturer and provider of Cast iron & Cast Steel rolls and

Engineering Castings. With continual improvement and technological up-
gradation, it’s achieved the market leadership in domestic marketplace for Non-
metallurgical (Hollow) Rolls in Indian. JEMCO additionally provides rolls for
Long and flat product phase of steel rolling, and has additionally established
itself within the producing and provide of engineering castings for Power sector
and Rolling Mills.

VISION 2020

To emerge as a prominent and leading downstream steel long products company

through:

Products: Be the preferred supplier of innovative and high quality rods, wires,
wire products and rolls & castings.

People: Become an employer of choice in the Tata Steel group

Planet: Be a benchmark in safety, health & environmental stewardship within the

Tata Steel group
Profit: Double the profits and revenue to achieve a minimum ROIC (Return On
Investment Capital) of 22% by 2020

ISWPL VALUES

Tata group companies have always been values-driven. In line with the Group
value, ISWPL has also adopted four core values to direct the growth and business
of the companies. The four core ISWPL values underpinning the way we do
business are:

Respect for Individual: We must be caring, show respect, compassion and

humanity for our colleagues and customers around the world, and always work for
the benefit of the communities we serve.

Integrity: We must conduct our business fairly, with honesty and transparency.
Everything we do must stand the test of public scrutiny.

Credibility: We must execute all operation and activities with competency.

Excellence: We must constantly strive to achieve the highest possible standards in

our day-to-day work and in the quality of the goods and services we provide.

ISWPL is a subsidiary of TATA STEEL Ltd. It is a profit making organization

with a positive net worth. It has its registered office at Kolkata, West Bengal.

2.3.1 DESCRIPTION ABOUT JEMCO PLANTS:

JEMCO is in the business of Rolls, Engineering Castings, and Zinc Dross

Refining, with an approximate annual capacity of 5000MT. it is the industry leader
in the Domestic Hollow Roll segment, and also exports its products primarily to
Middle East and Turkey.
JEMCO has the simplest and the best combination of melting furnaces to
manufacture totally different grades and different kind of custom-made product
like rolls and engineering castings. JEMCO has two Arc Furnaces of 7.5 MT
and 3.5 MT both are used to manufacture high strength cast iron, high quality of
SG iron and steel rolls. The 8 MT main frequencies Coreless Induction furnace is
use to medium and small size of cast iron, Steel and SG Rolls. These
furnaces are used for producing of varied grades of engineering casting. the
twin Track Induction furnace of 0.75 MT and 1.5 MT is employed for
prime alloyed low weight castings and rolls. These furnaces
additionally offer extremely alloyed shell metal for static forged rolls. The wide
range of Furnaces supply full flexibility in production of rolls and engineering
casting of various sizes and weights. Melting is carried out using
segregated scrap, pig iron and ferrous alloys to achieve the required composition.

2.3.1.1 RESEARCH AND DEVELOPMENT

JEMCO has a small research & development center to cater following purposes:

 Improvement in already existing like sleeve

 Development of new product and plan
 How to increase the plant efficiency

It has also access to advance research facilities of National Metallurgical

Laboratory (NML) and TATA STEEL for its bigger projects.

2.3.1.2 QUALITY ASSURANCE

  Team of metallurgist available to have a control on the process. All of them
have a background of metallurgy as their primary subject in the curriculum.
It is emphasized that people should know why they are doing something,
rather than how it’s being done.

 Quality Plan and SOP formulation is the key process of QA. After
standardization its being circulated to the concerned departments.

 Regular audits under Quality Management System and Environment

Management System are being done to assess the compliance of the SOP.

 Entire process, from selection of raw material (both incoming and in

process) to dispatch of finished product goes through series of quality
control checks.

 Well-equipped QA Laboratory available – Spectrometer, Image Analyzer,

C-Si-S Analyzer, Tensile Testing Machine, Electronic Weighing Scale etc.

 Computer controlled emission spectrometer analysis for bath sample

 Surface Hardness testing done by conventional hardness testing equipment

 Metallographic & mechanical tests are carried out to keep a constant check
on the desired structural constituents, strength & homogeneity of the product

 Ultrasound Testing conducted to ensure the internal soundness of the

product

 Hydraulic testing for hollow roll is a unique process at JEMCO

Each product is dispatched along with the valid test certification.

2.3.1.3 HEAT TREATMENT PLANT

  It has electrically controlled Heat treatment furnace to ensure good control
and least pollution generation.
 Annealing and Stress Relieving process programmed as per the product.
 The Best thing of this Heat treatment plant that none of the domestic
competitors have Electrical Heat Treatment Furnace
 To ensure the control of fluctuation in temperature variation by <30 degree
used Microprocessor based control system
 Mist cooling System for Graphite Steel

2.3.1.4 MACHINING PLANT

This Plant has Robust machine shop with following which can take care of all
machining processes required for the manufacturing of a roll. For each roll there is
quality plan for machining.

 Duplex Milling machines

 Drilling Machines
 Rough Turning Machines
 Hand Finishing Section
 CNC Finishing Machines
 Conventional Grinding Machines
  Flute Cutting Machines

The range of the Roll that can be Machined in this plant is from 280 mm to
1400 mm (gross diameter)

2.3.1.5IT FACILITIES SUITABLE FOR ERP SYSTEM

 Licensed AutoCAD software availability for translating Customer drawing

to internal standard

 Capability of designing the CNC program as per drawing.

 Communication through Lotus Notes

 ERP through Microsoft Business Solution Navision 0.4

 Easy access to internet for knowledge sharing

 There is a plan in future to connect all suppliers and customers through ERP.

2.3.2 TYPES OF FURNACE USES FOR MELTING

NAME
CAPACITY

1. ARC FURNACE 1 7.5 MT

(INSTALL)

2. ARC FURNACE 2 3.5 MT

(INSTALL)

3. INDUCTION FURNACE 8 MT

4. DUAL TRACK INDUCTION FURNACE 1.5 MT

& 0.75 MT
Pic of Induction Furnace

Pic of Dual Track Induction Furnace

Pic of Arc Furnace and Graphite Used in It

Ladle
 Ladle is made up of mild steel which can’t sustain tapping
temperature so, ladle lining is done of bricks.

Fig:- ladle lining

 2 layer is lined up in ladle.
 1st lining is called 70 % high alumina bricks and 2 nd lining is safety
bricks or magnesite bricks.
 The gap between both lined up brick is 15mm and it is filled up
with weight ramming mass material.
 After lining, ladle is preheated for 24hrs up to 1200 0C by ladle
preheater machine.
 After preheating the ladle brought forward side of the Electric arc
furnace for TAPPING OF MOLTEN METAL.
 Pic of ladle preheater pic of Tapping of molten
metal

2.3.3 PROCESS FLOW CHART OF FOUNDRY AND MELTING

PLANT
1. RAW MATERIAL
Working with companies with the best quality and with the most
reliable companies in the purchase of raw materials with the philosophy that good
roll production would be possible with the supply of raw material with “Trusty
and Quality”.

All ferrous alloys, metallic materials melting and in making alloys and sand, resin,
feeder lining and the mold dyes that are used in molding are being supplied from
those companies that are the leaders in their own areas and not any sacrifice is
definitely being granted from this subject for the continuance of its quality.

The chemical analysis of the steel scraps that come to scrap site is made in
laboratories with optical emission spectrometer and their analyses being within
the values required in their quality aspects are controlled. All controls that are
carried out on the scrap sample are being reported.

Whereas the ferrous alloys, metallic materials and the raw materials that are used
in molding are accepted after carrying out the certificate controls.

Pic. Of Raw Material

2.TOOLS AND EQUIPMENT ARRANGEMENT

 Arrangement & selection of tools & tackles plays very important role in
production of adamite rolls. Since proper selection of tackle is very important
because it effects rolls production deeply. Selection of tackles completely
depend upon method which is used in adamite roll making. Method play must
important role in adamite roll production & selection of all tackles depend
upon method. With the help of method we select correct chill, drag box, top
boxes & pouring basin.

CHILL

DRAG BOX
TOP BOX

Pic of CHILL, TOP BOX, DRAG BOX

2. PRODUCTION

Molding: - molding is the primary process of any roll making. Here we made the
mold as per the method & size of the roll. In molding we prepare drag as per the
requirement, select chill as per the method & prepare it. We also prepare top boxes
as per the method. After preparation of mold we use different type of coating
which is normally contains bentonite & zirconium base paint. Graphite base paint
is also use in roll making. Selection of coating depend upon the requirement of
mold. These coatings have different sp. Gravity. After coating we pre heat the
mold before assembly. Assembly process is last process before pouring of liquid
metals.

The roll bodies are being molded into metal molds that have been clad with special
cladding materials that contains zirconium, silicate and graphite that provides the
fast cooling of the molten metal for the roll bodies to have the wear strength as
especially expected by our customers, whereas the necks are molded into sand
molds that provides the slow cooling of the molten metal for the necks to have the
high mechanical properties to be exhibited.

Gate system that conveys the molten metal into the mold void provides inclusions
that may create segregation to propagate by remaining in the center of the mold
void in collective manner by providing the formation of vortex at maximum rate
while the molten metal is propagating along the mold and thus provides the
disposal of the inclusions from the mold at the end of the casting process.

All these mold components are being installed inside the casting pits for the
provision of casting safety and then casting is proceeded with.

Pic. Of Mould Assembly

Melting:- Melting of scrap started before few hours of pouring. In melting process,
we normally charge scarps (raw material) in required furnaces & started melt down
it. In melting we have started our work from selection of raw materials, ladle
which is used for pouring, additive alloys for addition in liquid metals to obtained
required composition. Once metal melt we have done so many processes for slag
of & then after we go for addition of alloys. After addition of alloying element we
took sample for analyzing the present composition & then after when we got
required composition we go for tapping of liquid metals. In during melting of
liquid metal we preheat ladle at certain temperature.

The chemical analysis controls of the molten metal are being carried out along all
the phases of melting and the being compliant of the amounts of the alloy elements
within the molten metal to our qualities are being provided with high precision.

Control is being provided at each moment of melting and the homogeneity of the
alloy elements are being guaranteed, thanks to the advanced technology that our
induction furnaces have, our charging systems and our melting practices.

The molten metal is being taken into the casting pot following the spherodization,
seeding, de-oxidation and grain thinning processes are realized in accordance with
the type of the molten metal inside the pots that have been specially made for this
job. The affectivity of the spherodizers, seeders and the grain thinners are being
increased, since these processes are carried out in a certain sequence.

Pic. Of Melting Shop

Pouring: -This process is completely related with molding . Here we can say that
molding is an internal customer of melt shop. In this pouring process we pour the
liquid metal of assembled mold.
The molten metal temperature is being measured with dipping type of temperature
thermocouples and casting is being started just at the temperatures that have been
determined for each of our analyses and right at that moment. The discontinuities
that may occur in the bodies and in the trunnions are eliminated by affecting the
casting process from the bottom or from the top depending on the roll type, thanks
to making the metal to overflow

The molten metal temperature is being measured with dipping type of temperature
thermocouples and casting is being started just at the temperatures that have been
determined for each of our analyses and right at that moment. The discontinuities
that may occur in the bodies and in the trunnions are eliminated by affecting the
casting process from the bottom or from the top depending on the roll type, thanks
to making the metal to overflow.

Pic. Of Pouring in to Mould

Shake out:-It is the process where roll comes out from mold. Here we use crane &
wire rope for roll shake out. This process has done after limited time depending
upon size of roll & metal weight. Every ton metal increases the shakeout time. So
we have a standard time chart with respect to size, grade & weight of metal.
Fettling:-In fettling process we remove sand which normally comes out with roll
surface. It is the process where all sand removes.

Fettling

Rough turning:-This is process where machining of roll starts. Here first step of
machining has done. In this process we just remove as cast surface of roll. During
this process we get a smooth surface. This process has done with help lathe
machines. Selection of lathe machine depending upon size or roll & capacity of
lathe. Different size of lathe used for different types of rolls.
 Rough turning

Heat Treatment:-In this process we heated roll in electrical heat treatment furnace
& then after cool it. The cooling process of roll is different. Selection of cooling
process depends upon the hardness & property in roll to be achieved. Some time
we cool rolls inside the furnace that process is called annelean. Some time it cools
outside the furnace with help of fans called air quenching or normalizing.
Sometime having different temperature for cooling. Selection of heating & cooling
temp. varies upon the property what was achieved.

Heat treatment

Machining:- Machine all kinds of details of the rolls that the iron and steel sector
is in need of in a precise and complete correctness with our machine tools that are
present in our machine tool workshop. We are closely following the tool and the
machine tool technologies that develop, by maintaining our works in this direction
by never forgetting the reality as that machining in Faster – in More
Precise – More Economic manner is possible at all times.

Machining and finishing department comprises of 6 parts:

 Rough Lathe Machining

 Length Completion

 Finishing Lathe Machining

  Milling

 Cylindrical Grinding

 Vertical Lathe Machining

Finish turning

Inspection:-It is final stage before packing. Here we have done die penetrate
testing to find out any type of surface crack or defect, dimensional checking as per
the customer need & ultrasonic testing to find out any type of internal crack. After
completion of all type of test roll is going for packing stage which is last stage of
dispatch.

Packing & dispatch: - Each one product for which production and controls have
been completed is homogenously clad with preventive oil of high viscosity by
spraying after numbering and marking. Different types of packaging are made in
accordance with the product form, the country of destination and the distance for
the purpose of the products not to be physically damaged and not to be subjected to
corrosion during the dispatch of these to the users. Recyclable materials are being
used in all of our packaging, inclusive of the palettes due to the importance that we
pay for the environment.

2.3.4 Process Flow Chart of Melting Plant

2.3.5 CSR POLICY (CSR VISION STATEMENT & OBJECTIVE)
 The Tata Steel Group focus in the area of corporate sustainability which includes
Social Sustainability; Environmental Sustainability; Social Welfare; Sports; and
Inclusive Growth. This ensures that the Group’s success is shared by all its
constituents and stakeholders.

In alignment with vision of the company, ISWPL believes in Triple Bottom Line
(People, Planet and Profit) approach. Through its CSR initiatives, it strives to
enhance value creation in the society and community, in fulfillment of its role as a
Socially Responsible Corporate.

The objective of the ISWP CSR policy is to “improve the quality of life of the
communities we serve through long term value creation for all the stakeholders”,
which is in line with that of the Tata Group.

The company shall allocate at least 2% of its average net profits before taxes of
the preceding three years, towards CSR activities to sustain and improve a healthy
and prosperous environment and to improve the quality of life of the communities
it serves. The company may also utilize its products and services as suitable for its
CSR activities. Any surplus arising out of CSR projects or programmes or
activities shall be re-deployed back into CSR activities and will form a part of the
business profits of the company.

PURPOSE OF CSR POLICY

 Depicts the Company’s approach towards the society.

 Identifies the project areas specified by the statute.
 Indicates the activities to be undertaken by the company under CSR
category.
 It is a guiding document to implement, monitor and review the CSR
activities.
 Explains the manner of CSR expenditure and treatment of surpluses arising
out of CSR activities.
 POLICY STATEMENT

ISWPL CSR policy is based on sustainable development and inclusive growth.

The CSR policy focuses on people, planet and profit. The CSR activities of ISWPL
emphasizes on enhancing societal sustainability. Equitable development of society
is a key area of focus as per company policy.

2.4 BUSINESS ENVIROMENT

2.4.1 MILESTONES OF JEMCO

2003-Tata Steel Takeover of ISWP and JEMCO

2004-ISO 9001 Certification for JEMCO

2005-ISO 9001 certification for ISWP

2007-New Business venture: Zinc Refinement at JEMCO

2009-New Business venture with Nail and Electrode

 Product basket enhancement: TMT Rolling & TMT Straightening

2010-Galvanizing Operation in Wire Mill

 Effluent Treatment Plant

 TPM Kick Off

2011-NTM Recycling System

 ISO 14001 certification for ISWP

 Weld – o – vation
 Safety Excellence Journey started
2012- TBEM Assessment

 Sports Complex inaugurated

 New Innovation Center created

2013- Barbed wire production

 ISO 14001 and OHSAS 18001 Certification for JEMCO

 Re-started the Fastener Unit

2014-Cleared TPM Health by TPM Club India (CII)

 Applied for JIPM Awards

 Adopted Kasturba Gandhi Ballika Vidyalaya, Potka, a school for under
privileged girl students and started training centers for Archery, Mushroom
farming, organic farming and stiching.
 Cleared the 1st Stage Assessment for TPM Excellence Award by Japan
Institute of Plant Maintenance (JIPM)
 Undergone second TAAP Assessment and was put under the band of 30-40

2015- Awarded for TPM Excellence (Category A) by Japan Institute of Plant

Maintenance (JIPM)

 Undergone TAAP Assessment and was placed under the band of 375 – 400

2016-IMS certification for JEMCO for the standards ISO 9001.2008, ISO
14001.2004 and OHSAS 18001.2007
 CHAPTER-3

3.1 OBJECTIVE OF PROJECT

Yield in casting is defined as the ratio of net wt. to the gross wt. of
casting. It is mathematically, given as

Where, YIELD= (NET Wt./GROSS Wt.)

*100
Net wt.- is the wt. of finished casting product.
Gross wt.- is the total wt. including casting + molten metal in riser,
runner, ingate, sprue.
The profit of a foundry is greatly influenced by yield in
casting. So, it is vital to put essential steps in consideration at the
time of design itself. The yield improvements also contribute a lot
directly towards energy consumption. Also it helps in saving
labour cost, raw materials and so cost saving. Therefore, every
foundries takes leading steps in yield improvement.
The yield of casting can be improved by following ways:
 YIELD IMPROVEMENT PROCESSES
1.The shape, size and location of risers.
SIZE: - Riser size is determined by meeting two different
requirements i.e., those of freezing time and feed volume to
obtain directional solidification and thus a sound casting.
(a) considering the freezing time criteria, the riser must be large
enough to freeze after the casting. Riser dimension can be
estimated from the consideration that

Volume Volume
( Area ) riser¿(
Area )casting
 Since higher V/A associates with it increase time to freeze.

(b) Riser size can also be estimated by using Caine’s method was based
on an experimentally determined hyperbolic relationship between
relative volumes and relative solidification rates of riser and casting to
produce shrinkage free casting.

(c) The relationship was

a
X = y−b + c
{ Area Area
Where, X is freezing ratio =[ Volume }casting÷{ Volume }riser ]
riser volume
Y is casting volume = Volume ratio
a is freezing characteristics constant.
b is liquid - solid solidification contraction.
c is relative freezing rate of riser and casting.
A typical value of a, b, and c is 0.10, 0.03, and 0.8 respectively.
(d) when plotted provides the theoretical locus of point which
separate solid sound casting (right) and shrink unsound casting
(left).
The Caine’s formula and curve is given below.
SHAPE: - Risers are of two shapes.ie. cylindrical and spherical. But
cylindrical is recommended for most of the casting because it
easier to cast and its volume is smaller than sphere even if the
thickness of the two shapes are same.

CYLINDRICAL

LOCATION: - when there is more than one riser in casting then

their location must be well placed using Modulus of casting.

MODULUS= VOLUME/ COOLING SURFACE AREA

 In other words, Modulus deals with solidification process of
casting of different geometry and determining melt volume and
cooling surface.

2.No. of risers: - In addition to its adequate size, a riser must be

properly located to obtain a sound casting.
A riser should have adequate metallostatic head and must
maintain positive pressure of liquid metal on all portion of the
solidifying casting, it is required to feed.
Riser location depends upon
 The design and complexity of casting.
 Type of cast metal.
 Number of riser.
 Size and number of heavy (casting) sections.
 Ease of molding.
 Ease of riser removal after the casting has solidified.
 Chances of directional solidification, etc.
 Risers Can be located on the top of the casting or in the side of
the same. Should be placed on a flat rather than the contoured
surfaces because a riser on the flat surface avoids the need of
sculpture in the fettling shop.

3.Types of riser :- .
i.The use of top riser:- In vertical molding system, it is relatively
simple to locate the top risers. But in horizontal molding system
the situation is more complicated. The application of these kinds
of risers in both cases allows the handling of appropriate feeding
volume (based on the difference between the risers and the cope
height) with smaller risers contributing to increase yield.
ii.The use of blind riser:- Blind riser is smaller than a comparable
open riser.so less molten metal is used to compensate the
shrinkage. Also, it is easier to place.

4.Gating system and its type :- The gating system is the passage
through which molten metal passes to the mold cavity. It
comprises of pouring cup and basin, sprue, runner, gates, risers.
The use of proper pouring basin or cup maintains the rate of liquid
metal flow, reduces turbulence, helps in separating dross, slag etc.
The use of tapered sprue to minimizes turbulency and the of round
sprue as it has minimum surface exposed to cooling and offers the
lowest resistance to flow of metal.
The use of trapezoidal gates cross section, minimize the turbulent
flow.
The size, location and no. of gates connecting the runner and
casting.
Type of gating system:- Based on the ratio of sprue, runner and
gates, the gating system is classified in two types.
i.Pressuried G.S :- In this type of G.S back pressure is maintained
and is used generally with the molten metal which solidify fastly.
ii.Unpressurised G.S :- In this type of G.S no pressure is applied
and is used for molten metal whose solidification time is more.

5.Increasing directional solidification:-The basic behind

increasing the directional solidification is to get sound casting. The
directional Solidification is achieved by increasing the solidification
rate of casting than the risers.
It is increased by insulating raisers, padding, using chill. The
average solidification relation of casting and riser is

1.25tcasting=triser
6.Optimizing pouring time, pouring sequence :- With decrease in
pouring time shrinkage increases.

7.Otimum gatting /runner to control temp.loss :-The modulii of

gating channel must be kept in mind since, high values ( runner
and ingates) decreases yield.

8.Minimum machining allowances :- Lower the machining

allowances given, higher will be the yield.

3.2 GENESIS OF PROBLEM

JEMCO manufactures different types of castings like power plant
casting (Ni-Hard ring & hollow spherical balls), rolls and other
engineering casting (roll mill stand, steel drum, choke, sliding shoe
etc.). And infect JEMCO is one of the largest and oldest
manufacturer of these casting. But other companies are giving
tough competition to JEMCO. As a result, price of the product is
decreasing. So, it is becoming miserable for extracting at least the
manufacturing cost of the products. Therefore, it is necessary to
find out alternate way to short out the issue.
YIELD IMPROVEMENT is one of it. The details of Yield
improvement of Engineering casting are discussed below.

3.3 YIELD IMPROVEMENT OF POWERPLANT

#. NI-HARD RING AND HOLLOW STEEL BALLS
Ni-hard is the generic name for a family of white cast iron alloyed
with nickel and chromium to give high hardness and outstanding
resistance to abrasion.
The Ni-hard ring is the ring used for pulverization or
grinding of coal for combustion in steam generating furnace of
fossil fuel power plants.

SUPPLY OF NI-HARD RING AND BALLS

The NI-HARD RING manufactured in JEMCO is of very high quality
and is highly demanded.
1.BOKARO STEEL PLANT
2.ROURKELA STEEL PLANT
3.DURGAPUR STEEL PLANT
 YIELD CALCULATION OF POWERPLANT CASTING

CASTING FINISHED Wt. GROSS Wt. YIELD %

1.NI-HAARD 5.80 Mt. 9.00 Mt. 64.44
RING
2.H.S BALL 1.10 Mt. 1.30 Mt. 84.615

3.3.1 YIELD IMPROVEMENT OF THE NI-HARD RING

1.Aqurate size of risers: The size of risers should be such that it

should compensate the shrinkage properly. If it would be larger
than that it would decrease yield. As for example, the size of riser
presently used gives better yield compared to previous one.

 Previously used risers: 14’’

volume of cylinder¿ π r 2h
14’’=35.56cm
21’’=53.34cm 21’’
So, its volume = (3.14*17.78*53.34)
=52947.587cm3
Since, the density of Ni-Hard alloy is 8.0gm/cc
Mass=Volume*Density
=423580.696gm
=423.58 kg
 So, total volume of metal in all 12 riser
= 12*423.58cm3 =5082.96 Kg
 Presently used risers:
14’’=35.56cm
9’’=22.86cm
7’’=17.78cm
6’’=15.24cm
Volume of this riser 14’’
= volume of ( cylinder + frustum)
π
2 ∗h
=πr h + 3 *(D2 +d2 +Dd ) 9’’
4
=3.14*(17.78)2*22.86
+ (3.14/3) *17.78*{(17.78)2 + (7.62) 2 +(17.78*7.62)}
=22691.823cm3 +9484.56cm3 7’’
=32176.3911cm3 6’’
Since, the density of Ni-Hard alloy is 8.0gm/cc.
So, mass=volume*density
= 257411.12gm
=257.411 Kg
Now, the mass of 12 risers = 12*257.411
=3088.932 Kg
Hence, the difference between the molten metal occupied by all
12 risers using previous to the modern risers is
= 5082.96-3088.932Kg=1994.028Kg
So, Gross wt.=9000+1994.028kg
Finished wt.=5080kg
Hence, the yield % when previous shaped riser were used was
Yield%= (5800/10944.028) *100
=52.99%

hence, by using modern riser size, the yield increases to 64.44 %

3. Proper Location of Risers to compensate volumetric

shrinkage: - The ring is made up of 12 segment pattern each
having a riser in it. The radial angle is of 30 degrees each. So,
the distance between each riser is

O. D=3255mm
I.D=1800
MEAN OD-I. D /2=1455
SO, Riser will be on circle of dia=1800+(1455mm/2) =2527.5mm
NOW, CIRCUMFERENCE OF CIRCLE¿ 2 πr
= [2*3.14*2527.5)/2 mm=7936.664mm
Since, no. of riser is 12 & its width is 14’’
=(25.4*14mm) = 355.6mm
So, width of 12 risers = 12*355.6 = 4267.2mm
Then, empty space =7936.664-4267.2mm =3669.464mm
Since, the risers are equally placed at
(3669.464/12) mm= 305.788mm
I.e. 305.464/25.4= 12.038’’=12.04’’
Hence, the distance between the two risers is almost equal to the
dia of riser i.e.. ‘d’.

3.PRESSURISED GATING SYSTEM: -The gating system of NI-hard

ring is pressurized, since the solidification rate is high. The ratio of
cross sectional area of sprue, runner, ingates is 1.39 : 2.5 :1.
Calculation of gating ratio -
Sprue
Dia=3.5’’=88.9mm
Hence, area=πr2=6204.019mm2
Runner
H=80mm, W=70mm
since, the poured metal from sprue moves in two directions by
runner.
Area=(H*W) *2=11200mm2
Ingate
H=8mm, W=70mm
Since, there is 8 ingates in the complete mould box.
Area=(H*W) *8=4480mm2
So, gating ratio=ar. Of sprue : ar. of runner : ar. Of gates
1.39: 2.50 : 1

4.Minimum machining allowances:- In NI-hard ring the machining

allowances is very less. Generally, NI-Hard Metal is given 3mm to
%mm machining allowances. Only the riser containing part need
to be machined here.
 3.3.2 YIELD IMPROVEMENT OF H.S. BALL
The hollow steel ball used in carbonization of coal in thermal plant
along with the set of NI-HARD RING is made up of cast steel. Its
yield can be increased by

1.Aquarate size of riser: - The size of risers should be such that it

should compensate the shrinkage properly. If it would be larger
than that it would decrease yield. As for example, the size of riser
presently used gives better yield compared to previous one.
 Previously used risers:
Volume of riser= π r 2 h 12’’
12’’=30.48cm
18’’=45.72 18’’
= 3.14*15.242*45.72
= 33357.6726 cm3
Since, the density of steel is 7.85gm/cc.
So, mass=volume*density
=261.857Kg
 Presently used Riser:
12=30.48cm
9’’=22.86cm
7’’=17.78cm
6’’=15.24

Volume of riser 12’’

=volume of cylinder + volume of frustum 9’’

π
∗h
2
¿πr h ++ 3 *(D2 +d2 Dr)
4

=3.14*(15.24)2*22.86 7’’
+(3.14/3)*(17.78/4)*(30.48)2+(22.86)2+{(30.48+15.24)} 6’’
=16671.54+7563.1750 cm3
=24234.71cm3
Since, the density of steel is 7.85gm/cc.
So, mass=volume*density
=190 Kg
since, the difference between the molten metal occupied by the
riser using previous to the modern risers is =71.85Kg
So, Gross wt.=1300 + 71.85kg
Finished wt.=1371.85kg
Hence, the yield % when previous shaped riser were used was
Yield%= (1110/2016) *100
=80.18 %
And hence by using modern riser size, the yield increases to
84.615%

2.Proper Location of riser: Since, ball has only one riser. So,
it should be Geometrically placed at such position that it can

compensate the volumetric shrinkage.

3.Unpressurised gating system: The gating system of Hollow

steel ball is unpressurised because the solidification rate is not
so fast. The gating of ball is 1: 1.7.

Calculation of gating ratio-

Sprue
Dia=3’’=76.2mm
Area=πr2=4558.05mm2
Ingate
H=35mm, w=76.2mm
Since the metal poured from sprue goes to mould box by two
gates.
So, area=2*(H*W) =5334mm2
Gating ratio = ar. Of sprue: ar. Of gates
1 : 1.17

4.Minimum machining allowances: In H.W Steel Ball the

machining allowances is less. Generally, steel is given 10mm to
12mm machining allowances. only the riser containing part need
to be machined here.
3.4 YIELD IMROVMENT OF ENGINEERING CASTING
YIELD CALCULATION OF ENGINEERING CASTING
CASTING FINISHED Wt. GROSS Wt. YIELD%
ROLL MILL 4.40 Mt. 7.00 Mt. 62.85
STAND
CHOKE 0.425 Mt. 0.7008Mt. 60.65
SLIDING 0.790 Mt. 1.50 Mt. 52.67
SHOE
STEEL 1.00 Mt. 2.00 Mt. 5.00
DRUM

The yield of these can be increased by above measures given in

section 3.1

CONCLUSION

The yield of different casting manufactured in JEMCO is as follows.

CASTING FINISHED GROSS YIELD %

Wt. Wt.
(IN MT.) (IN MT.)
NI-HARD 5.80 9.00 64.44
RING
H.S.BALL 1.10 1.30 84.615

ROLLING 4.40 7.00 62.8571

MILL
STAND
CHOKE 0.425 0.7008 60.65
SLIDING 0.790 1.50 52.67
SHOE
STEEL 1.00 2.00 50.00
 DRUM

SUGGESTIONS
1.Use of procast simulation software for methoding which will
provide exact riser location and riser size and hence will improve
Yield of casting.
2.Use of Graphite mould for highly accurate and better surface
finish and hence decreases machining allowances.
3.Reduce machining in bore of choke casting.
4.Use of thermoxo steel in place of APC (anti piping compound) in
all steel compounds.

REFERENCES

 Principle of foundry technology by Prakash.Lall.Jain

 Foundry Technology by O.P.Khanna
 Yield improvement pdf by Ramon D.Duque and Sudesh Kannan
 http://jemco.co.in/home/
 http://www.iproject.com
 http://www.iswp.co.in
 http://www.tatasteel.com
 Tata.com
 Wikipedia, the free encyclopedia