total foundry solutions - welcome to hmt machine … foundries at hmt follows no-bake process that...

Total Foundry Solutions

2

� Commissioned in 1961 as a Meehanite License holder to meet

captive requirements of high quality castings needed for

machine tools.

� Caters to the requirement of jobbing orders

� Five foundries – each attached to manufacturing units at

Bangalore, Pinjore, Kalamassery, Hyderabad, & Ajmer.

� The Foundry supplies from simple to critical castings to

machine tools, printing machine, press, foundry machinery,

earthmoving machinery, compressors, etc.

Foundry Capabilities

3

The Infrastructure - Capacity

� Total Capacity 6000 MT per annum

� Weight Range Gray Iron Up to 12 MT

SG Iron Up to 5 MT

4

The Infrastructure – Products & Grades

� Gray Iron – FG20, FG25, FG30, FG35, FG40

(IS 210)

� Flame hardening

� Heat and wear resistant

� Pressure type

� SG 400/12, SG 500/7, SG 600/3

(IS 1865)

5

The Infrastructure – Pattern Shop

� Has all the adequate facilities for manufacture of

complicated patterns and has expertise in the manufacture

of metal, wooden and polystyrene patterns.

6

The Infrastructure - Moulding

� The Foundries at HMT follows No-Bake process that

guarantees dimensional accuracy.

� In one of the foundries (Machine Tool Division, Kalamassery)

continuous mixer with reclamation unit is installed that

adopts Furan/Phenolic Binder system that has flexible core

setting and pouring operations to provide versatility to

handle varying size, intricacy and volume requirements.

7

The Infrastructure - Melting

� The Foundries in each Unit have 2-3 main frequency

induction furnaces of different capacities ranging from

1.5 MT to 5 MT. The melting process undergoes strict

quality control of composition with spectrometer.

� All critical parameters like physical properties of metal

analysed using state-of-the-art testing equipment

8

The Infrastructure - Melting

9

The Infrastructure - Fettling

� The Foundries in each Unit have following facilities.

� Pneumatic equipment for fettling operations including

chamber type shot blasting unit and heat treatment and

painting facilities for customised finishing requirement.

� Outsourcing whenever required.

10

The Infrastructure – Testing Facilities

� Each foundry is equipped with

� Raw materials

� Sand properties for green / dry / no-bake

� Core / mould hardness

� Chemical analysis (direct readout vacuum emission

spectrometer)

� Temperature

� Metallographic

� Hardness

� Elongation

� Non-destructive test like magnaflux, ultrasonic, etc.

11

Castings for Varied Applications

� Machine Tool Applications

� Power Generation Plants

� Automotive Applications

� Compressor Castings

� Locomotives

� Space Applications

� Printing Machinery

12

Castings for Machine Tool Applications

� Column – Machining Center

(Gray Iron, 6 MT)

� Multispindle Automat MSA Bed

(AS 67), 5 MT

13

Castings for Machine Tool Applications

� Heavy Duty Lathe Bed (5800 mm x 900 mm x 850 mm), 4 MT

14

Castings for Machine Tool Applications

� Drill Head � Machine Tool Bed

(6000 mm x 2800 mm x 600 mm) – 12 MT

15

Castings for Foundry Applications

� Frame Casting of Foundry

Machinery (DISA)

� Bell Casting for Blast Furnace Charging – 2.2 MT, SG Iron

( φφφφ1800 mm, height : 1200 mm)

16

Castings for Foundry Applications

� Basin Casting of Charging

System Blast Furnace – 3.8 MT,

SG Iron

( φφφφ3000 mm, height : 1400 mm)

17

Castings for Earthmoving Applications

� Transmission Case D80 – 140 kg

18

Castings for Compressor Applications

� 4-Throw Compressor Housing – 7 MT

(2400 mm x 2200 mm x 600 mm)

19

Castings for Printing Machinery Applications

� Printing Machine Cylinder

20

Castings for Presses

� Drive Ring � Clutch Cylinder