Velkast Foundries Internship Report
Velkast Foundries Internship Report
Velkast Foundries Internship Report
Chapter No.
1
Introduction
2
Functional Departments
3
Foundry Design and Technology
4
Casting Defects
5
Conclusion, Recommendations & Learnings
References
INTRODUCTION
In September 2013, Velkast Foundry was founded under the technical direction of Mr. M.R.
Satyanarayana, the founder of Sri Laxmi Foundry Harihar. Making shell moulding castings of
exceptional quality and efficiency for the automotive and non-automotive industries is the primary
goal of VKF (Velkast Foundries). Mr. M.R. Satyanarayana, who has more than 45 years of solid
experience in the foundry industry, played a key role in establishing this unit to serve new potential
clients. Mr. S. Pradeep is in charge of the plant's operations and advertisements. Since then, VKF has
expanded its specialization to include the production of a full line of FOUNDRY CAST PRODUCTS.
M/S VELKAST FOUNDRIES is a modern, mechanized foundry tha built with the latest technology
to produce and provide cast iron items and cylinder liners that meet ional and international standard
grades. The foundry is situated geographically in the lovely, industria Harihar's lovely, industrially
advanced city from the state capital of Bangalore, Karnataka.
Harihar Heads: CI cylinder heads in-direct exports. 100 tons per month have an additional
capacity of 50 tons per month
Pradeep Enterprises: Cylinder Liner and Air-cooled blocks (Machined). At this stage, 150
tons per month and upon specific requirement capacity can be generated.
In case of any additional capacity is required these units will be used and customer demand is met.
All above units are ISO certified.
Velkast is ISO 9001:2015 certified foundry for manufacturing CI & SG shell molding castings.
Exceeding the expectations of customers, by competitive Cost in the industry, highest Quality, and
on-time delivery of castings Strive continually to improve our casting process flow with the best of
our foundry knowledge.
To make Velkast Foundry a well-recognized leader in automotive and non-automotive shell mould
machined castings.
QUALITY POLICY
By improving customer satisfaction, managing waste, involving all of their employees, and relying
on their valued suppliers, the VELKAST foundries are dedicated to organizational growth. They
provide precision quality engineering casting components. They also strive for excellence by meeting
all applicable requirements and continuously improving their quality management system.
INDUSTRIES SERVED
PRODUCT PROFILE
BRACKET MOTOR
SG IRON PARTS
Single-speed port
DELPHI TVS Housing casting 34C
PRODUCTION DEPARTMENT
Pattern making
Sand preparation
Mould and core making
Melting of metals
Metal treatment
Cooling and separation of casting
Quality testing and dispatch
PATTERN MAKING
The patterns are prepared as per the engineering drawings to meet the required shape and dimensions
of casting. The patterns are prepared in accordance with the customer’s needs.
SAND PREPARATION
Sand moulds are prepared under GREEN SAND MOULDING PROCESS. In green sand process, the
required quality of washed, dried and graded sand procured from outside is mixed with bentonite
(clay), which acts as a binding material and water and thoroughly mixed in Intensive Mixer. Certain
other additives like pitch powder is added to get the right condition of sand.
Sand properties of mixed sand tested before moulding and maintained to get quality castings
without sand defects like sand drops, blow holes etc. Proper metal to sand ratios will be adopted and
the requisite quantity of fresh sand will be added as required. Similarly the unwanted sand in each
cycle will be discarded also.
Fully automatic moulding line with a High-pressure dynamitic moulding machine, with an average
production rate of about 280 moulds/hrs., the moulds are moved to the pouring zone by an automatic
mould conveyor, where the metal from Auto pour is poured into moulds. In the case of casting that
requires cores, the cores are placed in the moulds before the two portions of the moulds are closed.
MELTING OF METAL
The requisite charge composition of Pig iron, controlled scrap, foundry returns in the form of runners,
risers and rejected castings are charged into the Medium frequency Induction Furnace and melted to
molten state by including electric current. The requisite other element like Carbon, Silicon, etc are
added during the melting stage to get the required chemical composition.
In the case of Grey Iron, there is no treatment of metal involved. How, ever in the case of SG iron,
the molten metal with the right composition of other elements has to be treated with an alloy having
magnesium of the required percentage. This alloy reacts with the molten metal which when solidified
gives properties of steel in physical strength and the properties of cast iron are retained. The treated
molten metal is then pinto into ladles for pouring into moulds.
POURING
After pouring the molten metal into the sand moulds it is allowed to cool for 1 to 12 hr. After
cooling the casting is removed from the moulds in the knockout section. After the knockout, the
runner and riser will be removed and returned to the melting section.
After the removal of the runner and raiser, the casting will be sent to the engineering division for shot
blasting and fettling. Shot blasting is the most efficient and mechanical method of removing unwanted
particles. Casting is hung from hooks in a moving conveyor inside a chamber. The particles of shot
or grit are thrown at the casting by means of centrifugal force and steel balls are placed through the
conveyor bucket on the rotating vanes and blasted into the chamber and hanged castings are cleaned.
This method has a peening effect on the surface and it makes the surface bright and shiny.
Grinding is usually performed using portable or stationary pedestal grinders. After the shot blast,
the excess materials and joint chips are removed by grinding then the castings are sent for further
process.
All the castings are tested for strength, dimension, visual, physical test and other required properties.
Good casting is sent to the warehouse for dispatch. Off-spec castings are returned to the melting
section of remelting.
INSPECTION TOOLS DEFECT PRODUCT
MARKETING DEPARTMENT
Marketing department is consisting of Marketing Manager, Sales Officer and sales representatives
etc… Marketing is a consumer-oriented activity, and also it is a social process by which individuals
and groups obtain what they need and want through creating, offering & freely exchanging products
and services of value with others.
Marketing Department activities involves planning, organizing, directing and controlling the
activities relating to the marketing of goods and services to safety the needs of customers. Marketing
research and product planning are integral part of the marketing department. The department
determines the appropriate marketing mix of the firm, i.e., product design, its promotion, its pricing
and its distribution.
MARKETING FUNCTIONS
The marketing and sales department functions of Velkast Foundry is vast, a few of which is mentioned
below:
1. Monitoring of sales in the area
2. Monitoring of prices and terms of company products compared to competitors
3. Processing credit proposals for dealers and institutions
4. Processing proposals for special arrangements / sales terms with bulk buyers / commodity
5. Motivating marketing staff through internal and external training programmes
6. Monitoring overdue and outstanding of area or credit management
7. Co-ordination of sales promotion and market development activities
8. Monitoring the marketing communications.
Procurement of Funds
The funds are collected for the smooth and efficient running of the company. The company collects
funds from the following sources:
1. Loans and advances: Loans can be taken from banks and other financial institutions in the form of
Bank OD, cash credits, bank loans etc.
2. Funds from sales: The funds emerging from sales are in the form of cash or credit. In the case of
cash sales, the cash is directly received by the department, and in the case of credit sale, cash is
collected from the debtors within a certain period.
Allocation of Funds
It is of great significance for the finance department to channelize the fund in a strategic manner for
the existence and operation of the business. The funds would be allocated to the following:
1. Procurement of raw materials
2. Employee wages and office salary
3. Office expenses
4. Taxes and other legal expenses
5. Maintenance expenses
6. Carriage and Transportation
7. Petty expenses
FOUNDRY TECHNOLOGY
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into
a liquid, pouring the metal into a mould, and removing the mould material after the metal has
solidified as it cools. The most common metals processed are aluminium and cast iron. However,
other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in
foundries. In this process, parts of desired shapes and sizes can be formed.
TYPES OF FOUNDRIES
Foundry processes can be divided into two types: ferrous foundries and non-ferrous
foundries. Depending upon the type of end users, the wide variety of moulding or the casting process
can be basically divided into- Commercial foundry and hobby foundry.
COMMERCIAL FOUNDRIES:
Here the production activity is on a large scale and in abidance to the international standards of
manufacturing practice. This type of foundry offers semi-finished or fully finished products like
Railroad Equipment, Machine Tools, Farm Machinery, Mining Machine, etc. Major types of casting
employed in commercial foundries are sand casting, die casting, investment casting and lost foam
casting. According the type of foundry activity that the foundries are involved in, commercial
foundries are known as:
TYPES OF COMMERCIAL FOUNDRIES
» Captive foundry: These foundries are part of a manufacturing company which uses the
casted products to meet the companies own production need.
» Jobbing foundry: These are fully equipped foundry which does not have its own
individual casting business, but undertake contractual casting for other companies.
Mostly, production is taken up for small quantity only.
» Production foundry: In such foundries casting operations are done in bulk for one types
of casting. The advantage in this method is that this fully equipped foundry unit can
deliver flawless products at the most economical rates.
» Semi production shop: It is the kind of operations where the company operations follow
both the jobbing and the production casting.
Hobby Foundries:
These are small but fully equipped foundry unit’s setup inside a house or in the backyards. Such
foundries are set up by amateurs who love to create casting products
according to one’s desire. The home foundries also serves other purpose like mending the worn our
metal items and for casting special part or component that are not available in the market.
Many factors are taken into account while setting up a foundry operation. The basic settings are done
in consultation with experts and by taking suggestions from potential customer who are the ultimate
beneficiaries of the foundry operations. Some of the basic concerns are:
» Environmental: The environmental study is done to ensure that the foundry operation does not
affect the natural surroundings. It is essential for the foundries to follow the standard guidelines
for setting up the industry, so that the residential areas near the foundry are not affected in any
way. While setting up a foundry care must be taken also to protect the flora and fauna, and the
water bodies in the surrounding areas.
» Economical: The economic capacity of the foundry owners and the end-users is an important
aspect while selecting the equipment and machines for the foundry operations. Cost effective and
premium quality castings can be manufactured by selecting the appropriate metallurgical designs
and making optimum use of alloys. Foundry operations can also be made cost-effective and
convenient by avoiding patterns which are difficult to draw or molds. In addition, coring can
either be eliminated or reduced for economic reasons.
RUBBER DEFECT
When standard feed metal is not available to account for shrinkage when the thick metal solidifies,
shrinkage problems may develop. Defects from shrinkage will seem jagged or linear. In the cope
or drag region of the casting, shrinkage faults are most common. Open shrinkage faults and closed
shrinkage defects are the two categories under which shrinkage defects fall. Since open shrinkage
faults are exposed to the environment, air balances off shrinkage as the cavity forms. Pipes and
surfaces that have caved in are two different kinds of open-air faults. While collapsed surfaces are
shallow cavities that form across the surface of the casting, pipes form at the casting's surface and
burrow into the casting.
Within the casting, closed shrinkage flaws also referred to as shrinkage porosity, develop. Hot
spots are small, isolated pools of liquid that occur inside the hardened metal. Typically, the hot
patches' tops are where the shrinkage problem develops. Impurities and dissolved gas can cause
closed shrinkage flaws since they need a nucleation spot. Microporosity (also known as micro
shrinkage) and microporosity are two types of flaws that can both be seen with the unaided eye,
but not the other.
POROSITY OF GAS
The creation of bubbles inside the casting after it has cooled is known as gas porosity. Due to the
fact that most liquid materials can store a lot of dissolved gas but not in their solid-state, the gas
condenses inside the substance as it cools. Gas porosity may appear as porosity on the casting's
surface or the pore may be confined inside the metal, which weakens the area around it. In
instances of gas porosity, nitrogen, oxygen, and hydrogen are the most often encountered gases.
Only hydrogen dissolves in a large amount in aluminum castings, which can lead to porosity. The
holes for castings weighing a few kilos are typically 0.01 to 0.5 mm (0.00039 to 0.01969 in) in
size. They can have a diameter of up to a millimeter (0.040 in) in larger castings.
In order to prevent gas porosity, the material can be melted in a vacuum, with low-solubility
gases like argon or carbon dioxide, or with a flux that protects it from the air. To lessen gas
solubility, the superheat temperatures can be kept low. Turbulence created when liquid metal is
poured into a mould has the potential to introduce gases; for this reason, moulds are commonly
streamlined. Other methods include precipitation, gas flushing, and vacuum degassing. In the
course of precipitation, the gas reacts with another substance to produce a mixture that causes
dross to float to the surface. To remove oxygen from copper, for instance, add phosphorus; to
remove oxygen from steel, add silicon or aluminum. A third source is the result of the molten
metal reacting with grease or other leftovers in the mold.
When metal reacts with humidity or lingering moisture in a mold, hydrogen is created. This
source of hydrogen production can be removed by drying the mold.
Because micro shrinkage cavities can also contain gases, it can occasionally be challenging to
tell the difference between gas porosity and micro shrinkage. Micro porosities will typically
develop if the casting is improperly risered or if a material with a broad range of solidification is
cast. If neither of these apply, the porosity is presumably the result of gas production.
BLOW HOLE DEFECT IN CAST IRON PART
Porosities are small gas bubbles; blowholes or blisters are larger gas bubbles. Air entrapped in
the melt, steam or smoke from the casting sand, or other gasses from the melt or mold can all
result in such flaws. (Blowholes is another name for vacuum holes created by metal shrinkage;
see above.) These flaws can be avoided by using proper foundry procedures, such as melt
preparation and mould design. Blowholes may be challenging to find as they are frequently
covered in a skin of sound metal, necessitating harmonic, ultrasonic, magnetic, or X-ray (i.e.,
industrial CT scanning) investigation.
Misruns, cold shuts, and inclusions are among the pouring metal flaws. A misrun happens when
the liquid metal leaves a piece of the mould cavity unfilled and does not entirely fill the cavity.
When two fronts of liquid metal fail to fuse together effectively in the cavity of the mold, a weak
area results in cold shuts. Both are brought on by either insufficient fluidity in the molten metal
or too constrained cross-sections. By altering the metal's chemical makeup or raising the pouring
temperature, the fluidity can be made more fluid. Back pressure from inadequately vented mold
cavities is another potential factor.
Both misruns and cold closes entail the material freezing before it completely fills the mold
chamber, and they are closely linked. Because the area immediately surrounding the defect is
substantially weaker than anticipated, these kinds of flaws are serious. With these issues, the
material's castability and viscosity may be crucial elements. The smallest section thickness that
can be cast, the maximum length of thin sections, the fineness of cast details that can be made,
and the precision of filling mould extremities are all influenced by fluidity. There are several
methods for determining a substance's fluidity, but they all often require utilizing a common mold
shape and counting the distance the material flows. The composition of the substance, the
freezing temperature or range, the surface tension of oxide coatings, and—most significantly—
the pouring temperature all have an impact on fluidity. The greater the pouring temperature, the
more fluid the substance will be; nevertheless, high temperatures can be harmful, causing a
reaction between the substance and the mold; in casting procedures that employ a porous mould
material, the substance may potentially enter the mould material. The coherency point is the
location beyond which the substance becomes immobile. Because the point depends on the solid
fraction, the structure of the solidified particles, and the local shear strain rate of the fluid, it is
challenging to forecast in mould design. This number typically falls between 0.4 and 0.8. A metal
inclusion is a contaminant made up of liquid or solid slag or dross. These typically include
contaminants from the mold, material that has been eroded from the furnace or ladle linings, or
impurities in the metal being poured (most commonly oxides, but less frequently nitrides,
carbides, or sulfides). In the particular situation of aluminum alloys, it's critical to regulate the
inclusion concentration by monitoring it in the liquid metal and taking steps to maintain the
required amount.
The amount of inclusions can be decreased in a variety of ways. The metal can be melted using
a flux, in a vacuum, or in an inert atmosphere to lessen oxide production. Before the metal is
poured into the mold, other materials can be added to the mixture to make the dross float to the
top where it can be skimmed off. A special ladle that pours metal from the bottom can be used if
this is not practical. Installing ceramic filters in the gating system is an additional choice. The
lighter inclusions will be forced to the center and kept out of the casting if swirl gates are not
built instead, which will swirl the liquid metal as it is poured in. An entrainment fault results
when dross or slag is folded into the liquid metal.
METALLOGRAPHIC ERRORS
Hot spots and hot tears are the two flaws that fall under this group. Hot tears often referred to as
hot cracking, are casting failures that happen when the casting cools. This occurs because metal
is fragile when it is hot, and as the metal cools, residual tensions in the material can lead to casting
failure. This kind of fault is avoided by using proper mold design.
Hot spots are areas of casting that have cooled down more slowly than the material around them
because they have a higher volume. In this area, there is anomalous shrinkage that might result
in porosity and fissures. By using suitable cooling techniques or by altering the chemical makeup
of the metal, this type of flaw can be prevented.
DIE CASTING
The most frequent flaws in die casting are misruns and cold shuts. These flaws may be brought
on by cold dies, cool metal, filthy metal, inadequate ventilation, or an excess of lubricant. Gas
porosity, shrinkage porosity, hot rips, and flow markings are further potential flaws. Due to
improper gating, sharp edges, or excessive lubricant, flow markings are left on the casting's
surface.
PERIODICAL CASTING
A particular kind of flaw known as a longitudinal face fracture only happens during continuous
casting operations. This flaw, which results from uneven cooling during both primary and
secondary cooling, affects the chemical composition, cleanliness, and homogeneity of the molten
steel as well as other aspects.
SLEEVE CASTING
The failure of the mold can result in a number of issues with sand casting. The mould typically
fails for one of two reasons: either the incorrect material is utilized, or it is rammed incorrectly.
The first kind is called mould erosion, and it is the process by which the mold erodes as liquid
metal fills it. Due to the generally more durable moulds used in other casting methods, this kind
of flaw typically only arises in sand castings. The cast iron has extra material and rough areas.
The ductility, fatigue strength, and fracture toughness of the casting are reduced as a result of the
moulding sand's incorporation into the casting metal. This can be brought on by sand that isn't
strong enough or by pouring too quickly. By modifying the gating system to use larger runners
or more gates, the pouring velocity can be decreased. Drops, in which a portion of the moulding
sand from the coping drops into the casting while it is still a liquid, are a related source of faults.
Additionally, this happens if the mold is not correctly pushed. Metal penetration, the second
kind of flaw, happens when liquid metal seeps into the molding sand. A rough surface finish
results from this. Too-coarse sand particles, a lack of mold wash, or excessive pouring
temperatures are the causes of this. Sand cracking results in veining, an alternative method of
metal penetration into the mold.
Sand can fuse to the casting if the pouring temperature is too high or if a low melting point sand
is utilized. When this occurs, the casting's surface has a glassy, brittle aspect.
A run out happens when a mold or flask is defective and the liquid metal escapes out of the mold.
A thin coating of metal called a "scab" protrudes from a casting. They are simple to take off,
always exposing a buckle underneath that is a divot in the casting's surface. Rattails are ridged
indentations that resemble buckles, but they are not connected to scabs. Pulldowns, which are
buckles that develop in the coping of sand castings, are another comparable flaw. There is no
need to discard the work item due to any of these cosmetic flaws. Overly high pouring
temperatures or a lack of carbonaceous material are the root causes of these flaws.
A swell is brought on by an inadequately rammed mold and happens when the mold wall gives
way across the entire face.
Metallic oxides and silica sand impurities interact to cause burn-on. Sand fragments end up
imbedded in the surface of the finished casting as a result. By lowering the temperature of the
liquid metal, employing a mould wash, and incorporating other additives into the sand mixture,
this fault can be prevented.
LEARNING EXPERIENCE
Organisational Structure Training was very helpful and knowledgeable to me. Through OST
project I have gained a lot of practical knowledge about manufacturing activities and production
process of Velkast Foundry I have learnt about the company profile, products, proper utilization
of machineries, management of raw materials, packaging system and functions of various
departments.
Aditionally, The internship was very helpful, I learned many new things from this project they
are as follows:
CONCLUSION
In conclusion, I would like to say that according to the findings of this investigation,
theoretical knowledge is useless without a practical approach. The two facets of the same
coin are theoretical and practical knowledge. I had the chance to learn about an organization's
working environment, which made this experience worthwhile for me.
REFERENCE