mechanical - charu gupta
TRANSCRIPT
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PREFACE
Training in an industry is a dynamic tool to get feeling of practical aspect
of whatever has been learnt by us in the books. It greatly enhances knowledge
with the practical experience. Training in such great and well-managed company
is a great opportunity for the trainer as apart from the basic training. Also we get
a change to be familiar with certain other aspects of industry relations etc.
Our main objective of undergoing industrial training is to acquire
practical knowledge. Training enables us to get a clear-cut view of the subject
that we have read. Both theory and practical are essential. Hence we can say,
“The theory is blind without practical and practical without theory”. In fact, both
are complementary to each other.
As a part of three years of Degree with Industrial Engineering , I have
undergone for two month Industrial Training after the sixth Semester. I am
proud of receiving my Industrial Training in Tool Room at “INDIAN SUGAR &
GENERAL ENGINEERING CORPORATION (ISGEC)” Yamunanagar, Haryana
that is one of the top heaviest engineering industries of the country.
ACKNOWLEDGEMENT
During my training of two months as ISGEC ,whatever I learnt is going
to be of great practical importance in my future. For this I would like to express
my gratitude to Mr.Shiv Charan Sharma(Assistant Superivisor) so that under
his guidance I successfully completed my training.
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I would also like to thanks the whole staff of Tool Room who’s friendly
and cooperative behaviour help me lot in learning various techniques and gave
me a never before experience in such reputed firm.
I would like to thanks to Mr. Mohinder Saini who gave me a chance to do
my training at ISGEC and to Mr.Shiv Charan Sharma for guiding me about my
training.
I convey my heartiest thanks to all those officers and employees of
ISGEC who have given me their full co-operation and devoted their valuable
time for rendering me their needy services, guidelines during the course of imparting me practical training and with whose sincere and precious helps, I
have been able to complete my practical training successfully.
ISGEC PROFILE
THE COMPANY
1. ISGEC the heavy engineering unit of Saraswati industrial ltd. was
established in 1946 and is located at yamunangar, Haryana about 200kms
from New Delhi.
2. The annual turnover of ISGEC is US $ 50 million and group turnover of the
Saraswati Industial Syndicate ltd.
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APPROVALS
• ISGEC has been approved by Lloyds Register
Asia (LRA) of quality assurance as an ISO-9001: 2000 company.• The American Society of Mechanical Engineers
(ASME) approves ISGEC for the use of ASME ‘U’, ‘U2’, R & S code
stamps.
• Lloyds Register Asia as class-I Manufacturing of
Fusion welded pressure vessels approves ISGEC up to 200 mm
thickness.• Engineers India Ltd. (EIL) approves ISGEC for Manufacture of
vessels and columns in carbon and alloy steels up to 155mm thickness
and in clad steel up to 130mm thickness.
• Engineers India Ltd. approves ISGEC for
Manufacture of Heat Exchangers up to maximum tube sheet thickness of
300mm.
• China Safety Quality License
INFRASTUCTURE
1. ISGEC has a sprawling works covering an area of about 25 hectares
including covered production area of around 35,000 square meters.
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2. It has the capacity to handle jobs weighing upto 100 tonnes (single
piece).
3. Extensive facilities for hot & cold rolling, machining, welding, heat
treatment and stringent quality controls to ensure strict compliance to
international standards.
4. More than 125 sophisticated machines and machine tools are installed in
various production bays. Apart from these, more than 100 welding
machines ( for various processes including SMAW, SAW, MIG, TIG
and flash butt welding and under operation).
5. ISGEC has own captive power generation of 3650 Kv through DG sets.
CORPORATE PROFILE
The Saraswati Industrial Syndicate Limited grew from the sugar mill
and the general Engineering group. The engineering group was launched in 1946with the establishment of the Indian Sugar And General Engineering
Corporation now it is famous as ISGEC. Today, ISGEC is ISO 9001:2000.
Company concentrates its production activities at Yamunanagar, Haryana about
200 km. North of Delhi, manufactures a variety of heavy Engineering
equipments such as Chlorine Containers, Boilers, Sugar Machineries, Cement
Machinery, Pressure Vessels, Mechanical and Hydraulic Presses, Plate Bending
Rolls and Iron Castings.
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This flagship unit of group also maintains the process division at New
Delhi; responsible for the design, sales, contracting, and erection and
commissioning of turn key plants besides equipment for sugar and cement
industries.
In 1960 ISGEC collaborated with John Thompson, UK (now known as
NEI International Combustion Limited, UK). Located at New Delhi, ISGEC
John Thompson (IJT) designs, sales, erect a range of boilers and associated
equipments.
UP Steels was acquired in 1981 and latter merged with the parent
company. Established as a foundry in 1966 with the technical know how from
Japans Kobe steels, UP Steels, an ISO 9002 company at Muzaffar Nagar, UP
about 100 km. North of Delhi, manufactures sophisticated alloy steels and steel
casting, both hand and machine molded – as well as alloy iron castings steel
ingots.
Saraswati Sugar Mill (SSM) located at Yamuna Nagar, Haryana is
having crushing capacity of 9600 tones per day and has recorded best overall
recovering in India.
ISGEC COLLABORATIONS
Working continuously towards further excellence in technology, ISGEC entered
into technical collaborations with international well known companies.
To mention a few:-
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1955 A.F. Cariag & Co. U.K. Sugar Machinery
1960 John Thompson, U.K. Industrial Boilers
1963 Kawasaki, Japan Cement Machinery
1964 Farrels, U.S.A. Sugar Mills
1966 John Shaw & Sons Hydraulic Presses
1968 Bronx, U.K. Plate Bending &
Leveling machine.
1979 NEI International Pulverized Fuel
Combustion, U.K. Boilers.
1980 Rovetta, Italy Mechanical Press.
PRODUCT RANGE
Diversity of ISGEC products range enables us to serve industry from
Automobile and ship building to oil & natural gas, defense, aeronautics and
nuclear power.
The group’s product range includes for:-
1. Hydraulic Presses, Mechanical Presses & Press brake. ISGEC has
successfully commissioned around 100 presses built include a 3700 tonnes
hydraulic presses for defense and a 2500 tonnes mechanical press.
2. Process plant equipments (pressure vessels, heat exchangers, columns,
storage and transport vessels, reactors etc.) from fertilizer refinery,
petrochemical and other industries.
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3. Industrial & power boilers (including pulverized fuel boilers upto 60
MW size bubbling as well as circulating fluidized bed boilers up 200
TPH size).
4. Custom made equipments for India’s nuclear establishments. ISGEC has
supplied equipment during last 15 years to Bhabha Atomic Research
Center, Nuclear power corporation, center of advanced technology.
5. Chlorine, Ammonia and other gases containers. ISGEC are the largest
manufactures of chlorine in the world.
DIVISION OF ISGEC
ISGEC has been divided into three divisions as follows:-
1. PRESSURE VESSEL DIVISION (PVD)
Pressure vessel division is the oldest of ISGEC and it manufactures pressure
vessels such as boilers, heat exchangers etc. It is sub-divided into following
shops:-
a) PVD-I
b) PVD-II
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c) PVD-III
d) PVD-IV
2. MACHINE BUILDING DIVISION (MBD)
Machine building division is very important division of ISGEC and it
manufactures sugar mill machinery. Press components and other Steel plant
machinery. It is sub-divided into following shops:-
a) FABRICATION SHOP-I,II
b) MACHINE SHOP-I,II
c) ASSEMBLY SHOP
d) QUALITY SHOP
3. FOUNDRY GROUP (FG)
Foundry group is the third important group of ISGEC and it is
responsible for casting of large castings for the big industries.
4.TUBE SHOP
Tube shop deals with tube manipulation and fabrication of tubing system
used in economizers and super-heaters.
5.CONTAINER SHOP
Container shop manufactures chlorine, ammonia and other gases
containers.
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FABRICATION SHOP
Fabrication shop is one of the constituents of the machine-building department.
Almost all sort of fabrication work are done here. In this shop thick sheets of
mild steel are cut, welded and bent according to the required design. For the
cutting of plates and sheets CNC gas cutting techniques are made use of. Then
different cut parts are joined together with the help of welding.
Some of the welding techniques adopted in ISGEC are:-
• Gas Metal Arc Welding (GMAW)
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• Submerged Arc Welding (SAW)
• Shielded Metal Arc Welding(SMAW)
• Semi Saw
• Plasma Arc Welding
Brief description of these welding techniques is given in the following pages.
The bending of sheets is preferred in hydraulic presses. For bending, a specific
type and size of the die is kept under the plate to be bent and then hydraulic
pressure is applied above the plate. Extent of bending depends upon the radiusof curvature of arc formed by bend plate. Gauging is used for cutting sheets.
WELDING TECHNIQUES
1. Shielding Metal Arc Welding (SMAW)
Principle:-
It is arc welding process in which coalescence if the metal is produced by
heat from an electric arc. That is maintained between tip of a covered electrode
and surface of base metal in joint being welded. The principal function of
covering on electrode is to provide arc stability and to shield molten metal from
oxidation with gases created as coating down from heat of the arc. For
generating arc there should be some difference between electrode and work-
piece. For better results length of the arc should be as small as possible.
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Advantage:-
Auxiliary gas shielding or granular flux is not required any more.
Limitation:-
Due to high temperature are characteristics may change.
2. Submerged Arc Welding(SAW)
It produces the coalescence of metal by hating them with arc between
base metal electrode and work-piece. The arc and molten metal are
submerged in a blanket of granular fusible flux. The main role of the flux is
to control the chemical and mechanical properties of final weld. In the
welding end of a continuous bare wire electrode is inserted into the mould of
flux that covers area to be welded. An arc is initiated using one of the arc
initiation methods. A “wire feeding mechanism” begins to feed electrodewire. Additional flux is fed along with electrode. Heat evolved by electric
arc melts some of flux creating a pool of molten metal beneath layer of
molten slag. The flux blanket on the top surface of weld pool prevents the
atmospheric gases to mix.
Factors that usually effect SAW:-
• Chemical composition and final deposits of weld.
• Type of metal to be welded.
• Position in which weld is to be made.
• Volume of welding to be performed.
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3. Gas Tungsten Arc Welding (GTAW)
It is technique that uses an arc between a tungsten electrode and weld
pool. The process is adopted with/without shielding gas. Shielding gas is fed
through torch to protect electrode, molten weld metal and shielding weld metal
from oxidation. The arc is produced by the passage of current through
conducting gas. The arc is established between the tip of electrode and work.
Heat generated by arc melts the joining surfaces. Filler wire is added to leading
edge to fill the joint.
4. Co2 Gas Welding/Metal Active Gas Welding (MGAW)
MGAW is so called because Co2 is an active gas. MS wire electrode is
fed automatically in the welding torch and Co2 gas is allowed to pass through
the torch pipes. It acts as a shielding gas because it protects the weld pool from
oxidation by atmospheric gases. If instead of Co2 we use helium/argon welding
technique is called MIG.
5. Plasma Arc Welding (PAW)
It is an arc welding process that produces coalescence of metals by
heating with a constricted arc between electrodes and constricted nozzle. It uses
a non consumable electrode. PAW torch has a nozzle that creates a gas in the
chamber surrounding the electrode. The arc heats the gas fed into chamber to a
particular temperature. It becomes ionized and conducts electricity. The ionized
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gas is called ‘plasma’. It raises the gas temperature up to 30,000 degree F. It is
very expensive technique.
Principle:-
The gas is directed through the torch to surround the electrode. It bears
ionized un arc to form plasma. For most operations auxiliary shielding gas is
used. The arc construction nozzle is specified by nozzle diameter and throat
length.
Disadvantage:-
Major disadvantage of PAW is the relatively high expenses of equipment. Also
there are more control variables, more complex and expensive operator training.
ASSEMBLY SHOP
Study of liftable ladel turret assembly ;
A ladle rotating turret arrangement to be used in a continuous casting
plant. The central column can also be designed as a bushing and can serve for
accommodating a liftable and lowerable ladle support. A ladle turret has two
liftale forks, usually 180° apart. It has capacity of 300ton.
It is used in steel plant industry where molten material at high
temperature has to transfer from one place to other, where final shape has to be
given to the molten material. Firstly, this molten material is collected in
container and placed over the one end of the cradle for its movement.
Main parts of this assembly ;
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Ladle turret rotation unit
Portal
Basement
Central body
Arms
Lever
Cradle
Hydrulaic cylinders
Bearings
Manuplating isulators
Manifold
Motor
Construction
In this assembly the main part is the basement. In the basement so
much type of piping is done. However, this piping is done to provide the
required force at different positions in the assembly. As in central part
hyduralic cylinders are provided, so for their movement required force
comes from piping of basement.
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On the basement ladle turret unit is placed. There are no of bearings
system is also attached in between the central part and the basement.
Motor is also provided to give the motion to rotary unit (pinon). Bearing
gives the relative motion to central body.
In central body there is attachement of hydrulaic cylinders,which
gives the motion to cradle. There are two arms provided on the either side
of portal. On these arms cradles are attached. The motion of cradle is
controlled by the cylinders via levers. Portal is the vertical part, where all
these parts are assembled.
Surfaces of the cradles are tapered. It is because the containers
which has molten material in it has to place on this tapered part. In the
cradle pins and load cells are attached, which acts as shock absorber
during the movement of cradle. Around the load cells manifold pipe is
provided.
It is because when there is dissipation of heat during movement of
cradle, this pipe give cool air there.There are no. of holes on the manifold
for removal of cool air. Isulating plate is attached on the outer part of
cradle to maintain the temperature inside the assembly.
WORKING
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As the simple working definition of this assembly is that the
transfer of molten material from one place to other where final shape has
to given to this molten material.
But each part in this assembly has its own and important role for carrying
out this process and the important parts are basement, central body,
arms and cradle;
• BASEMENT
It is the main part of the assembly. In this hydraulic and
pneumatic piping is done as per the require force in different
sections of the assembly. It is made up of such strong material so
that it can bear the whole load of the upper part and can absorb the
any type of shock observed during movement.
• CENTRAL BODY
In this part hydraulic cylinders are attached. The main
function of these cylinders is to control the motion of the cradles
via levers. To move these cylinders, we also require some force
which comes from the basement piping. The motion of the
cylinders with respect to cradle is opposite or relative i.e. when
cylinders move upward cradle moves downward and vice versa.
This central body also rotates relative to the basement due to
motion of rotary unit. Relative motion to the central body is
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provided by bearing and motor attached in between the central
body and basement.
• ARMS
On the either side of portal arms are attached to give support
to the cradles. Cradles are attached to the bushes of arms, which
are self lubricating. It is because when cradle move up and down or
rotates then friction and wear tear losses will be there. So to
remove these effects lubrication is provided to bushes.
• CRADLE
This part of assembly attached to the arms. It has tapered
surface on which molten material carrier is placed. Its motion is
controlled by hydraulic cylinders. Levers of this cradle give it
require motion for movement. Pins are attached in this cradle
which acts as shock absorber. Load cells are also attached in this
cradle for the same function. However, these load cells have
springs to resist.
During the motion of cradle heat is generated, which is
controlled by manifold piping. It has so many holes for the exit of
cool air and is attached around the load cells in the cradle. This
cool air balances the temperature inside the cradle assembly.
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Xeramic fiber insulator plate is attached on the outer
surface of the cradle. Once all the inner parts of cradle are well
assembled, then this plate is attached. This is placed like
plate/insulator/plate. As explained earlier function of inner plate to
control the inner temprature and function of outer plate is to resist
the outer temperature to come in contact with inside.
♦ This process of transfer is so rapid. It is because when one partof cradle takes the molten material, it moves to other position
and 2nd part of cradle comes nearer to the furnace of molten
material to move it away.
Now if this process of take and transfer is slow, then the
molten material will cool down. That’s why this process is so
rapid to keep the material hot. Because of this rapid process
there is attachment of load cells to absorb the shocks. Because
of this process every component plays an important role on
their specified positions. For e.g.
• Insulating plate
• Hydraulic cylinders
• Pins
• Bearings
• Motor
• Rotary unit
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SOME OTHER COMPONENTS USED IN THIS ASSEBLY
• Washer
• Hex bolt phosphatized L40
• External serrated washer
• Pin
• Hex bolt L60
• Hex bolt L20
• Cover
• Plate
• SML pipe
• “U” bolt complete with nuts/washers
• MF UNION taper seat ZIN COAT
• Chain
• Door
• Mounting
• Latch housing
• Cam
• Bed plate
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• Weld on number
• MAT.PER RETI DI TERRA #.45MT
• HEX SOCKET HEADCAP SCREW
• Slotted counters
So, these are also some helpful components used in this assembly to
support the large parts.
PLANNING AND SELECTION OF ASSEBLY
Now in any organisation basically there are three levels of management
Top level
Middle level
Bottom level
So in the top level of management managers and higher authorities set up
a project in an organisation. After discussion there is selection of best
method for achievement of the goal.
So it is set up for the next level of the organisation.
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Now in the next level, executive engineers and other staff members
read this method properly and after removing any difficulties, it is
implemented.
So workers of organisation work as per scheduling and requirement of
the project. For this so many supervisors are provided to workers to ask
any difficult during working or carrying out the project.
Now selection of any assembly is done by BOM (bill of
material). In BOM specification of every part is given. With this
diagram of each component is also sent by that industry which
gives the order of assemblies to such companies.
By the study of BOM, it become easy to make decisions that
which kind of assembly shop is available or kind of assembly can
be done and what parts has to be purchased for the require
product.
After proper studying of BOM decisions are made for the
required assembly.
A layout of assembly;
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Fabrication
Machining
Assembly
Quality
Dispatch
Firstly some parts which required welding etc send to
fabrication shop as per requirement. Then machining is done of some
parts to remove the sharp edges. After that finally machined parts
assembled to required positions. Quality is checked by the comparing
the final product with standard and then dispatched to the industry.
During assembly of pins in the cradle, chemphering is done. It can
be done by two ways by filler and grinder. By grinder it can be donefaster than the filler. It is done to make the radius of pin equal to that part
where it is going to attach. Because if there is any tolerance left, it may
make the assembly loose. That’s why proper oiling is done of the pins
and bolts are clamped tightly. It is done by so many workers so work rate
of each worker is checked out. Incentives are given as per there working
hours. By this time study we can also calculate the time taken by each
assembly and no of workers also.
•CONCLUSION
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Hence it is a modern approach to carry out a process in short time to
keeping the material nearly at the same temperature at which we are
taking from the furnace. It is very rapid process by the help of which
productivity can be increased and also the efficiency of product.
MACHINE SHOP
Machine shop is the main work station of the organization. Here various
machining operations are carried out to produce different parts of hydraulic andmechanical presses.
There are two division of machine shop
a) Machine shop-I :- Heavy Work Division
b) Machine shop-II:- Light Word Division
Various Machine Employed at Machine Shop-I
1. SACEM CNC Horizontal Boring Machine. HB-9
2. WELDRICH COBURG plano-miller P-4
3. SWIFT LATHE L-14
4.H.M.T Radial Drilling Machine RD-4
5. SKODA Horizontal Boring Machine HB-1
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6. HAURISTI Horizontal boring machine HB-8
7. WMW UNION Horizontal boring machine HB-5
8. SKODA Horizontal boring machine HB-3
PROCEDURE OF WORK:-
Every department or every work station works under planning department
of ISGEC. So the Machine-I planning Department prepare the design of the
press and any other job, to be manufactured. It prepares the drawing and route
card, which are directly obtained through the computers installed at shop floor
directly linked with the planning department. Route card is document at which
the whole process to be carried out and is printed in sequence i.e. operations to
be performed on the machine tool and after completion of work on job on one
machine then at which machine tool to be transferred and sequence of job on
one machine to be performed on that machine tool and operation observed.
FOUNDRY SHOP
Foundry shop is the main work station of the organization. Here various types
of difficult castings are to be cast, as required by the client. There is only one
division of casting in the ISGEC, rest of the work of casting is done at the U.P.
Steel plant of ISGEC group.
Pattern:- Pattern is the same or the original shape of the substance which we
have to cast.
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Mould:- Whereas mould is the replica of the pattern which is used for giving
the proper shape to the casting as required and these moulds are made from the
sand.
Types of Sand used:-
There are two types of sand used in ISGEC for casting.
1. Cement Sand
2. Phenolic Sand
1. Cement Sand:- Cement sand contains two or three things i.e river Sand,
cement and molasses. These three things are mixed in fixed proportion
so that sand does not loose its adhesive nature. In Cement Sand there is
85% to 90% is river sand, 8% molasses and 4% cement. In this mixture
molasses act as binder, which binds the sand properly and its adhesive
nature. Cement sand is used only for filling the vacant area around the
mould. After the proper ramming of the cement, sand baked so that it
does not fatal by gaining moisture.
2. Phenolic Sand:- Phenolic sand is also the mixture of three things i.e
silica sand, resin and catalyst. The composition of Phenolic Sand is 90%
to 93% Silica Sand and 2% to 3% Catalyst. Here resin acts as chemical
which increases the properties of the sand and catalyst is used as binder
or hardener which helps in setting the sand. Silica sand is coarse sand, so
there is no need of baking it. After mixing all the things for making the
mixture of Phenolic sand, it is taken to the patterns where it is properly
rammed. After that it would be left for some time so that it becomes as
hard as stone.
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Types of Materials Used for Making Patterns
1. Mostly the patterns used in ISGEC are made from thermocol sheets.
These thermocol sheets are cut in the shapes as per drawing given to
pattern making man. Pattern making man cut the big blocks of
thermocol in the pieces as per dimensions given in the drawing with the
help of cutters and element wire ( Element wire is that wire which is
used in heaters. This wire becomes hot and cuts the thermocol sheets
very smoothly without damaging the material).
2. Wooden patterns are also used for making the moulds .Wooden patterns
are used when more finishing is required.
3. Metal patterns are also used in castings. These patterns are used only for
taking the prints on the mould.
Direction for Moulding Work
⇒ On getting the patterns and moulding, understand the shape of
casting clearly.
⇒ Discuss the position of risers and setting clearly with the
supervisor.
⇒ Check the mixture poured from the mill.
⇒ Never use the set moulding and coarse sand.
⇒ Ram the sand in the moulds very well.
⇒ Always repair the moulds with the same sand, fix the repairing
portion with nails.
⇒ It is necessary to paint mould. Never use thinner for oily sand and
never use water paint for silicate sand.
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⇒ Dry the core or mould of oil paint in the core oven or with the help
of burner.
⇒ Decide the thickness of mould and core assembly according to the
drawing.
⇒ Before closing the moulds provide passage for the release of the
gases.
⇒ Release the gases of core and moulds separately.
⇒ Clean the mould with air and brush before closing it.
⇒ Use thin sealing between mould boxes or between the cores before
closing it.
⇒ Place weight on the moulding boxes or tight them with the help of
bolts.
Procedure for Making a Mould
∗ Check clearly that the pattern is not wet from anywhere and it is not
damaged from anywhere.
∗ Always place the pattern on the plain surface.
∗ The handles used on the patterns should not be loose and always be
straight.
∗ Ramming in the pockets and contours should be properly done.
∗ After facing sand provide proper vents in the cement sand.
∗ Always check there is no alignment in the mould and the ramming of
upper box should be properly done.
∗ The height of the upper box should not less than 10” or it should be
according to pouring basin.
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STUDY OF TIME CONSUMPTION
Types of time consumption:-
1. Manual Time
2. Machining Time
1. Manual Time:- Manual time is the time which is consumed during the
manual activity. Manual time is classified as:-
•Loading and Unloading
• Preparation Time study
• Setting Time Study
a. Loading and Unloading
This is the time which gets consumed during the loading and unloading
of the job from the machine. This involves operator involvement but it is
beyond limits to get it under control unless and until whose system is
computerized.
b. Preparation Time Study
Preparation time study is the study of all activities, which starts just after
unloading the finished job and halts before setting of the job in parallel and
perpendicular with the machine. Activities include in PTS are:-
1. Loading of the job
2. Clamping of the job
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3. Search for the clamps
4. Instructions from supervisor
5. Getting route card
6. Setting tool on machine
7. Getting tool from tool room
c. Setting Time Study
Setting time study is carried out to record the time consumed during setting
of the job in parallel and perpendicular with bed and tool of the machine,
concentric with the chuck of the lathe and checking for circular run out on
lathe. As the machining operation involve lease operator interventions and it
has to work with the pace fed/set by the operator so to snatch time from this
part is difficult rather impossible. Now we are left only manual activities.