INDUSTRIAL TRAINING

IN

Kirloskar Ferrous Industries Limited,

Solapur plant.


TRAINING REPORT


SUBMITTED BY:

Mr. Sikandar. J. Girgoukar


FROM

Department of Mechanical Engineering

Walchand Institute of Technology,

Solapur.

2012




~ 2 ~

ACKNOWLEDGEMENT


I am thankful and deeply indebted to the management of
KIRLOSKAR FERROUS INDUSTRIES SOLAPUR for allowing
me to undergo implant training during my Mechanical Course.

I am grateful to Mr. Pangaonkar and Mr. H Kulkarni granted
for the training. I am very much thankful to our Prof.Ekhande, who
made it possible and helped me and guided me for this training session.

I would like to express my sincere gratitude to our Principal Dr. S.
A. HALKUDE and Dr.K.H.JATKAR (Head of MECHANICAL
Engineering Department) for giving me the opportunity to widen our
knowledge and project Guide Prof. G.B.AGALAVE for giving much
of their valuable time, precious guidance and constructive criticism for
bringing out this report. Their moral support and kind co-operation
enabled us to bring out, this report successfully.

I am also thankful to all the operators and supervisors for all the
information given by them.




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INDEX


Serial
No.
TITLE Page
No.
1

Introduction
Plant Layout
4

2 Departments of KFIL 9
3 R&D Department 15
4 B Plant
Sand section
Core section
Moulding section
Melting and pouring section
Fettling section
20
21
24
28
29
32
5 Assembly Department
Kalpak
Pratik
Ekatma
33
34
35
36
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6 HPML 37
7 Learning Points 41
8 Conclusion 42

































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INTRODUCTION

COMPANY PROFILE :

KIRLOSKAR FERROUS INDUSTRIES LTD , Solapur plant (KFIL-S)
Shivashahi, Solapur formerly known as KIRLOSKAR OIL ENGINES LTD ,Casting Division
(KCD) erstwhile M/s Shivashahi Works Ltd(SWL), was founded in 1900 by Dr. Vasudarao
Kirloskar. During the initial years, SWL was engaged in the manufacturing of Iron ploughs,
vices and other Agricultural impartments from 1934,SWL started manufacturing of Gray
Iron Casting. SWL become a part of Kirloskar Group. In 1959, to expand its foundry
activities for manufacturing of priming pumps and vice.
~ 6 ~

SWL modernized its foundry facilities in 1969 with a semi mechanized mould
handling line iatrical induction furnaces. In 1979 SWT collaborated with M/s Kitchener
Manufacturing co. in USA in Investment Casting facilities in the plant.
SWL was severely affected during past decade due to unprecedented slowdown
in the Indian Economy and went into heavy losses. It has to restructure and downsize its
operations and workforce in 1997. It was then amalgamated with KOEL in PUNE. In 2000 it
was operating as its Casting Division I.E.-KCD. In the recent past KCD has been making
consistent progress is stabilizing its operation. Looking at the excellent growth potentials in
foundry industry in India, the group Chairman Mr. Atul Kirloskar in January 2007
envisioned Kirloskar group to become one of the leading foundry group in India and
accordingly planned the synergy of the two big foundries in K-Group, KFINL and KCD.
The two entities merged into one company in January 2007, with KFIL-Hospet
acquiring the interest of KCD and designating it as KFIL-Solapur plant, spread over 80acres
of land, KFIL-S has three manufacturing plants a pattern shop and a week equipped
metallurgical and physical testing lab.












~ 7 ~

VISION AND MISSION OF KFIL:
MISSION:
A family committed to Growth and Prosperity of the organization
through Leadership activities attributes and quality orientation of people and
process that continuously satisfy the ever changing needs.
a) The company is a family to growth and prosperity of the organization
through team work.
b) Family that is committed to growth prosperity Leadership is promoting
tool.
c) People and processes in place to satisfy customers and shareholder
through continuous improvements.
d) Committed to total quality through systems institutionalization.
e) Integration of people and processes to bring about rate of internal
changes faster than that of external change.
They are:
#Pumps
#Automobiles
#Engines and Compressors
#Others

The chemical composition of the product is the reason for production of
different kinds of products. Mainly products are differentiated on the basis of
silicon compensation. Company has got different kinds of customers varying
between with high or low range of silicon contents.










~ 8 ~


VISION:
To be a world class product leader through the state of art
Manufacturing technologies and processes.

VALUES:
To achieve the Mission and Vision, company derived following Value:
1) Customer Orientation
2) Vender Development
3) Development of HR
4) Process and product excellence.

AWARDS OF KFIL-S:

The following are certificates of awards given to the company,
# ISO 9000 Certification since in 1993.
# TS 16949 : 2002 In the month of October 2008.
# ISO 14001 : 2004 Certification in the month of September 2008


ORGANIZATION STRUCTURE OF KFIL-S:
It is a part for specialization and coordination. It comprises of the basis
organization of the company, its departments, reporting lines areas of expertise,
and responsibilities the way in which the parts of a things are arranged or
organized.
The main theme of the organization structure comprehends all the possible
dimensions of the organization structure as in developing the ability to these
dimensions which are currently important to the organization evaluations.

WORKING STAFFS OF KFIL-S:
MANAGERS : 85
STAFFS :5
TEAM MEMBERS :356
~ 9 ~

TOTAL EMOPLYEES :436
PRODUCTS OF KFIL

1 4R 1040 Cylinder Head 12 P2 Crank Case
2 3R 1040 Cylinder Head 13 RB-33 Crank Case
3 DM-14 Cylinder Head 14 P1 Crank Case
4 P1 Cylinder Head 15 Flywheel-03079
5 BEML-140 Cylinder Head 16 Flywheel-03050
6 NEF Cylinder Head 17 692 Drum
7 DM-10 Cylinder Head 18 Stiffener
8 RV3 Crank Case 19 TKAP Transmission Plate
9 HA2 Crank Case 20 Carrier
10 RB-22 Crank Case 21 Bearing Cap
11 4R & 3R Crank Case 22 692 Disc
Table no.- : Products of KFIL


CUSTOMER OF KFIL

1 K.O.E.L.
2 Mahindra & Mahindra
3 Tata
4 Toyota
5 Indian Railway
6 H.M.T. Tractor
7 Escorts
8 Swaraj Mazda
9 KBSA South Africa
10 DLW- Waranasi
11 Ashok Leyland
12 Bajaj Tempo, Pune
13 Kerala Agro Machinery
14 Bharat Earth Movers, Banglore
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Table no.- : Customers of KFIL












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O
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F

K
K
F
F
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DEPARTMENTS OF KFIL

A) Administrative Departments:

1) Personnel Department:

This department is meant for employees development. This
department organizes various activities like training, placement, recruitment
and skill development to enhance the skill of employees in the industry.

Functional Area:
Training, education and development of employee skills.
Maintaining adequate employee supply.
Maintaining satisfactory relations between employees and management.
Recruitment of new employees in case of vacation or expansion.


2) Finance Department:

Finance department is one of the most important departments as it is
all related to money or economic matters of concern. It provides finance to
industry and audits of all financial activities going around.
It is the responsibility of finance department to provide maximum
possible finance to the industry and when required.

Functional Area:
To raise adequate funds whenever required.
To prepare the balance sheet maintain profit and loss account
Keeping account.
To prepare an account report for distribution amongst the
management, shareholder and whoever related to industry.
To invest the part capital to gain profit for the industry.
To decide the wages or payment structure of employees and use part
profit to pay them and audit it.


~ 12 ~


3) Purchase Department:

Purchase is one of the major tasks during the commencement of the
business. Generally industry has to purchase almost everything from the
market such as raw materials, tools, machinery etc. It works 5R principal
i.e.
Right time.
Right quantity.
Right quality.
Right price.
Right source.
Properly following these principles puts industry in more efficient position
and also increase its profit.

Functional Area:
Acquire different specifications from departments and place them for
orders.
Check supplier reliability.
Plan the orders according to the requirements of production activity.
Follow the order.
Checking of goods as per order specifications.
Payment of invoices.


4) Marketing Department:
The marketing department is mainly focus on the activities of
marketing products, pricing and promotion of products. These are activities
collectively called as 4 Ps in marketing.
a) Products:
The company has following products in its products. They
are:
Basic grade pig iron.
Foundry grade pig iron.
Spherical grade pig iron.



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b) Pricing:
The name Kirloskar is the mark of quality for the customer.
The company has left the opinion of transporting Pig Iron to the
buyer. So one can buy the Pig Iron at the companys site or can order.
The company has come across different prices terminology.
They are:
List price
Discount
Allowance
Payment periods
Credit terms

People prefer this company Pig Iron because the following reasons:
High quality
Fixed chemical position
Test certificates are issued with every load.

c) Promotion :

The company has appointed number of dealers throughout
India for its marketing purpose. Each dealer will get Rs 100 PMT, as
commission for the pig iron is sells. Credit notes are given to these
dealers for their commission.

d) Distribution:
The company has got distribution network spread all over
India in from of dealership and also through companys employees, the
divided its market into 7 zones:
Zone A) Karnataka: Belgaum, Shimoga, Bangalore.
Zone B) Andhra Pradesh : Hyderabad, Vijay Wada
Zone C) Maharashtra: Kolhapur, Pune, Mumbai, Nagpur, Solapur
Zone D) Gujarat: Ahmadabad, Rajkot, Surat
Zone E) Rajsthan: Jaipur
Zone F) Delhi: Faridabad, Kohinoor, Agra
Zone G) Tamilnadu: Chennai, Coimbatore, Mtura



~ 14 ~


5) Security department :
It is one of the important department of the industry. This department
ensures security of available facility as well as of the goods in industry. A
special team of guards is hired by in industry and employed for security
purpose.

Functional area:
Through checking and maintaining the records of visitors and
employees entering or leaving in the industry.
Through checking and maintaining the record of the vehicles carrying
goods and empty vehicles entering or leaving in the industry.
Keeping records of visitors and ensuring that they have got the
permission for visit by querying to the respecting concern.
To guide who enter new person in the industry to certain department.


B) Manufacturing Departments

1) Research and Development Department:
This department is the most important department as far as efficient and
effective manufacturing is concerned. It performs iterative design process and
increase the productivity. The various activities like pattern design and
development, metal composition checking, copy milling.

Functional Area:
To develop the manufacturing processes for efficient and effective
working.
To check the properties of casting time to time.
To assist the marketing department in performing contract review for
technical aspects.
To design equipment such as jigs and fixtures necessary.

2) Production Department :
This department controls all the production activities carried out in
industry. It performs activities such as planning, controlling etc. This
department makes efficient plans for production process to satisfy the
~ 15 ~

customer requirement and delivery of product. The functions duties and all
the other details of this department.

3) Quality Control Department :
KFIL is an ISO 9001 certificate organization. To maintain this
status, industry people have to keep working for quality of products. This
department applies various check points and critical examination the process
to insure precise quality of product. The quality has to be maintained right
from the beginning to the end of the process I.C. from raw material to final
product. This department carries out vendor department program where it
trains the supplies to enhance their quality and improve their standard. The
material and finished goods products coming in and going out of industry
are thoroughly checked to ensure these are of required quality and as per the
specification.



4) Maintenance Department :
The department plays an important role to keep the industries
well functioning. Every process at its point only when it is properly maintained.
Thus department works continuously for seven days of week to ensure high
productivity.

















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Research and Development Department

Perfect casting requires accurate dimensions of pattern on which
moulds are made. The pattern designing with allowances is very important and
responsible task is done in R&D department.

Working Procedure of R&D Department-:
1) R&D department receive the drawing from customer through
marketing department.
2) Drawing studied in details & position of cores, core prints etc are
decided in drawing office.
3) Contact review, method cards are filled in drawing office and
submitted to marketing department, which are helpful in providing
costing information.
4) Pattern layout is made in the pattern development section.
5) Sample pattern is manufactured. Gating system of pattern is designed
in this department and sample casting is inspected.
6) Correlation if necessary is made in the sample pattern and the actual
production is started.


Sections of R & D :
A. Drawing Office
B. Pattern development & Maintenance
C. Pattern Machining
D. Spectrometer
E. Sand testing

A. Drawing office:
This is heart of R & D department. In this section, in details &
decision regarding the customer requirement & satisfaction are taken by
making contact review.
a. Contact Review: It is nothing but written
communication between the customer & company. All requirements of
the customer are written on one side & what SWL can provide in that
~ 18 ~

respect on other side. This also provides useful information in cost
calculation.
b. Method Card: It provides information about type
machine used, type of moulding box, sand, core etc. This card also
provide information about type of casting methods available, up to
what tolerance parts can be manufactured in the company or not.

B. Pattern Development :
In this section, after drawing received from drawing office, the pattern
layout is decided. While designing the layout, all the allowances such as
machining, draft, distortion & shrinkage are taken into consideration.

Selection of material for master pattern:
First of all, master pattern is prepared. Generally, material used for
pattern are thermo coal, wood & metal. Selection of material for finish
pattern equipment is done considering below mentioned factors.

Quality of casting to be manufactured.
Life of pattern equipment.
Production processes for which the equipment is made.
a. Teakwood- up to 500 casting
b. Aluminum- 50,000 to 75,000 casting
c. C.I.- 75,000 to 1,50,000 casting
d. Brasses/Gun metal- especially used for fine patterns & core boxes.
e. Resin-up to 5000 approx.
f. Thermo coal for only one casting.

The machines available in R & D Department for pattern making are,
1. Two Drilling machines
2. Two Milling machines
3. One Copy Milling machines
4. Three Lathe machines
5. Two Grinding machines
6. Engraving machine


C. Pattern Machining:

~ 19 ~

After deciding all the parameters marking is done on the metallic
block from which pattern is developed, then machining is done in
development stage using above mentioned machines. A sample pattern is
prepared & sample casting is poured. After the penetration of sample
casting, marking is done with height gauge. Check the casting. If the
dimensions are less than those required, then metal is removed by
machining.
In R&D department properties of castings which are considered
while designing are checked. Following apparatus is used for the testing.
1) Universal testing machine-: When metal is melted in induction
furnace, some metal is used to create a required for this machine.
It is used to determine the tensile strength.
2) Impact testing machine-: It test the impact or shock bearing
capacity of the casting.
3) Cutting machine-: In this machine, band saws are used to cut the
casting. By cutting the casting we can detect the internal faults in
casting such as cracks, blowholes etc.

D. Spectrometer:
Different kind of raw materials are involved in metal production.
Variations of their compositions & impurities are directly reflect on the
quality of metal alloys. Cores, raw materials as well as production
accessories like coal anodes, refractoriness, coal & limestone need to be
analyzed in advance to avoid any conflict on the process. The fast quality
control of the final metal alloy is the second important analytical t ask, X
ray tools are dedicated to serve in the best way.
Due the different kind of materials, which have to be analyzed, a
wide selection of element in changing concentration range need to be
determined & several types of sample preparation techniques are involved.
Wavelength dispersive X-ray spectrometer is the fast analytical method of
control element concentration in metal alloys & flexible serve all the
different analytical tasks beside routine.
The ferrous industry is producing cast iron as well as different
kinds of products like low & high alloys, stainless & tool steels. In process
control, the accurate and fast analysis of iron & steel is important, but the
process benefits as well from the reliable & fast determination of materials
like slag, ferro alloys, refractorys & sinters. In non-ferrous industries,
different kinds of elements are in the production of lead, cobalt, nickel or
copper based alloys. Finally in the production of precious metals or high
~ 20 ~

purity grades copper for highest conductivity fast and reliable trace analysis
becomes the major task in process control.



E:Sand Testing:
Green sand and core sand are test in laboratory. Sand testing is
done at micro level. Following apparatus and machines are used for
sand testing:
1. Universal strength machine : In this machine compressive, tensile,
shear strength are determined changing its apparatus.
2. Hot tensile strength machine: This test carried out only for the
resin coated sand.
3. Shell Transverse Strength Machine : This test is used for
HSLD( High Strength Low Deformation Resin coated sand)
4. Polishing machine: Sand polishing is test through various silicon
carbide papers. There are different grids Si carbide papers.
5. PH meter
6. Stick point apparatus
7. Clay washer
8. Muffle furnace : This furnace used to test specially the loss of
ignition ( LOI ). Maximum temperature is 920c.
9. Carbon and sulpher apparatus / Strohlein apparatus: This is
volumetric titration method for determining Carbon and Sulpher
content in cast iron and steel.
10. Sieve shaker : this is used for getting uniform grain structure.

All properties of sand and the composition is determined in sand
testing lab. The properties are checked after determined period


.




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B
B

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B PLANT

In B plant mainly castings of various products are carried out .
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It consists of following main sections -:
A) Sand section
B) Core section
C) Moulding section
D) Melting and pouring section
E) Fettling section

A) Sand section-:
Sand is a basic material used for making cores and
moulds. As the sand have a great property to sustain at high temperature
called refractoriness. Green sand is used for mould making while beach
sand is used for core making. Further this green sand is reused as a baking
sand .
a) Green sand -:
We cannot use normal sand as it is for mould making.
So to improve sand properties such as refractoriness, compressive, tensile, shear
strengths, bench life, permeability etc;
Some additives are added, as it has to face nearly 1420c temperature of
molten metal with hardness about 90-95. Mixing of additives takes place in
Pioneer Mixer for 2to3 minutes as follows proportion.

Sr
No
.
Job
Name
Retur
n
Sand
( Kg )
Coal
Powde
r
( Kg )
Lustro
n
Powde
r
( Kg )
Bentonit
e
Wood
Powde
r
( Kg )
Dextrin
e
( Kg )
Wate
r
( lit )





1
Pioneer
Mixer
unites
sand &
all m/c
mouldin
g sand


825
To
900


2
To
3


2
To
3


8
To
10



-



-


20
To
28

Green sand moulding composition.


The properties required for green sand moulding are given
in following table. These properties are necessary for sand to sustain at high
temperature.
~ 23 ~



Sr
No.
Sand Test Range Testing
Time
Testing Place
1. Green compressive
strength.
1300-1700 Every day Sand section
2. Permeability no 100-160 Every day Sand section
3. Compactibility (%) 38-45 Every day Sand section
4. Moisture (%) 3.1-3.6 Every day Sand section
5. Total clay (%) 11-14 Every week Laboratory
6. Active clay (%) 8-11 Every week Laboratory
7. Dead clay (%) 50 ( max ) Every week Laboratory
8. Loss of ignition (%) 4-5.5 Every week Laboratory
9. V.M. (%) 3.0-4.0 Every week Laboratory
10. AFS No ( % in
prepared sand )
45-55 Every week Laboratory
11. AFS NO ( % in return
sand )
48-55 Every week Laboratory
12. Ph 8-9 Every week Laboratory

Properties of green sand

The properties of sand tested in lab at the R & D department.

As the sand is reused, the flow path of sand which is return from
various processes as shown below.-









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Diagram: Flow path of sand.

b) Core sand-:
Basically core sand is ordered from Goa, Andhra Pradesh,
Arul. First core sand is separated from lumps, stones etc then sand gets dried
in sand dryer to reduce moisture percentage for getting free flow.
Afterwards sand is transferred to the bunker from where it goes to mixer. At
mixer 0.8% resin & 0.8% hardner get added with sand and mixed finely,
then sand is provide to core shooters.







Shake out
machine
Magnetic
separator
Sand storage
bunker
Control unit
Elevator
Sand muller
Belt
conveyor
Moulding
machine
~ 25 ~

Sand testing Range Testing time Sand testing
place
A) Oil sand property
1)Tensile strength
2) Gas content
Min-15kg/cm2
Max-20cc/gm
Every day one
sample
Laboratory
B) Three part resin
sand property
1) Compression
strength
2) Gas content

Min-15kg/cm2
Max-26cc/gm
Every day one
sample
Laboratory
C) Two part resin
property
1) Compression
strength
2) Gas content

Min-30kg/cm2
Max-26cc/gm
Every day one
sample
Laboratory
D) CO2 sand
property
1) Compression
Strength

Min-4kg/cm2
Every day one
sample
Laboratory
Properties of core sand.

B) Core section-:
Core is basically used for creating internal cavity in
casting. For core formation beach sand is used, since the core has to sustain
at high temperature and has to face molten metal pressure so it should be
hard . In KFIL different types of cores are produced , as number of casting
products are manufactured . To increase the productivity core shooter are used
.
In KFIL two types of processes are used for core making -
1) Cold box process ( using Amine gas )
2) Shell core making

1)Cold box process-:
Machines used for cold box process are,
Compax 1
Compax 2
Compax 3
K20C core shooter
K40C ( NEW )core shooter
~ 26 ~

K40C ( OLD ) core shooter
SUSHA core shooter
Small to medium size cores are produced with the help of COMPAX-
1, COMPAX-2, COMPAX-3 and SUSHA such as cores of Carriers, Dip case,
cylinder heads. For making heavy cores up to 80 kg, K20C, K40C (OLD),
K40C ( NEW) core shooters are used. All core shooters have same working
principle and procedure.

Core shooters-
It is automatic core making machine. It is operated hydro-
pneumatically. The core shooter consists following parts,
1. Hopper ( 100 Kg )
2. Air cylinder
3. Amine shooting head / gassing chamber
4. Sand chamber
5. Core boxes
6. Upgrading mandrel

Process -:
Operator gives signal to the trolley( 100 Kg ) for sand demand . As
soon as trolley gets this input signal it goes to its home position
from where it collects the mixed sand . Then trolley moves to the
hopper of machine from where it got input signal and transfers sand
to it.
Air cylinder is used for maintaining required air pressure .
The two boxes are closed by hydro-pneumatic force without any
clearance.
Sand mixture is filled in the core boxes with 5-8 Kg/ cm2 pressure
from the sand chamber.
Liquid Amine is vaporize at 70c to 90c and pass to the gassing
chamber. This Amine gas 1
st
pass with LPP ( Low pressure purge)
about 2-2.5 Kg/cm2 pressure , then it pass with HPP ( High pressure
purge ) about 4-4.5 Kg/cm2 pressure . Due to LPP starting part of core
gets hard to make next HPP operation easy. Amine purging time is
about 15 sec.
In this process resin polymerize and hold sand particles together with
greater dry strength.
~ 27 ~

The core boxes detaches and core is withdrawn on upgrading mandrel
, and further carefully taken out. In one shoot 2 cores are taken out at
a time.
After each shoot, core boxes are cleaned using pressurized air. Also
sometimes Garglene and Benzene Polish are used for cleaning any
machine part.

K20C means suitable capacity of core shooter is 20 kg.
Similarly K40C has 40 kg suitable capacity. Maximum 80 kg core can be
withdrawn.

Controlling parameters-:

1) LPP = 40 sec
2) HPP = 50 sec
3) Amine passing time = 10 to 15 sec
4) Purging time = 40 sec
5) Frequency = 50 Hz

Electrical information:-
All core shooter machines are connected to the
Regulator power supply ( RPS ) Unit of 24 V , 5 A .
This RPS has Central Processing Unit ( CPU ) .
CPU consists EPROM which stores all programming of machine with input
pins of 8.25 DC and bus system of 5 V supply .
CPU has 3.6 V battery .
Two types of sensor are used in the machines :
1. Inductive sensor - It gives signal when metallic material passes
or comes in front of it . At the side of core boxes this sensors are used for
getting idea about the sand shooting and gassing process .
2. Capacitive sensor - It gives signal when any liquid , metal or
any plastic material passes or comes in front of it . At the resin and hardner
pipes this sensors are used for getting correct proportion of them .
These sensors require 24 V supply .
Advantages of core shooter -:
1) Higher productivity
2) Energy saving
3) Good dimensional accuracy
4) Superior surface finish
5) Excellent break down property
~ 28 ~

6) Low gas evolution

Cores are assembled in some cases such as, 4 pieces of cylinder and
crank case casing are assembled using nut and bolt.
The ready cores or core assembly are dipped into an arcopal 6172XLM tank
for 14-16 sec. Arcopal is used for getting maximum refractoriness and to get
good surface finish to the casting. Cores are then loaded to the baking
chamber. At the core baking chamber cores are heated for 15 minutes under
controlled condition and then unloaded . Then further the cores are shifted to
core storage section.



2) Shell core making -:
In this shell core making process resin coated sand
is used named as HSLD ( High strength low deformation ). The resin coated
sand when under goes high pressure and temperature , the core formation
takes place .
The temperature at which resin holds sand particles together known as
curing temperature.
Machines used for shell core making process is
(2424) SUSHA. Core capacity varies from 3.1 gm to 8 kg. All operations of
machine are done by hydro-pneumatically.
Core boxes ( top and bottom sides ) are heated up to the curing
temperature about hour known as preheating process. The core boxes are
closed without any clearance. The sand is transferred to the core box with
pressure . The air pressure required is 5-6 Kg . The process requires curing
temperature is about 230-250c. The core setting requires some time to get
core properties called as curing time. Generally, curing time is up to 3 min.
Graphite spray is used to get better finish & improve the refractoriness.
Cores are made in two types
1) Single piece core -: Sealing is not requires as it is a complete core.

2) Two piece core -: Sealing is requires for joining of 2 piece of cores.
Porshako sealer powder is used for sealing purpose. Further the cores are
kept in induction heating furnace to get well sealed cores.
Thermo coals are used to control the temperature.


~ 29 ~

Core assembly -:
After core making different types of cores get assembled
to form core of single casting such as water jacket cores, cores used to get
inlet and outlet holes and other small cores are assembled for 4R 1040
cylinder head casting & for critical cores. For joining purpose polyethylene (
PVC ) material is used.


C) Moulding Section -:
There are three moulding lines according to their
capacity. Each line has a push-off type machine which is used to get
forward motion of the moulding boxes. These are operated hydro-
pneumatically.


Sr
No.
Type of line Capacity
( max Wt per box in Kg )
1. ARPA 900 132
2. SM3 48
3. BQ3 32
Push off type machine capacity

Moulds are made on the simultaneous squeeze jolt pin lift
moulding machine . There are two moulding machines for each line one for
the drag part and another for cope part of mould boxes .
In KFIL metallic patterns are used generally made up of Aluminum.
Pattern is made from R&D department considering all allowances such as
contraction , drag , machining , shrinkage etc and clearances .
Process-
The green sand is collected in the hopper of moulding machine and
transferred in the mould box keeping around the pattern.
The moulding boxes are kept on the machine with reference to moulding
pins.
The talcum powder spread around pattern.
Some of facing sand spread around the pattern , then remaining space of
moulding box is filled with baking sand ( from hopper ).
First jolting operation is performed by high pressure air. Due to static and
dynamic forces act on sand which the green sand packed around the
pattern.
~ 30 ~

After the simultaneous squeeze jolt operation performed by pneumatic
process where the sand in the moulding box holds all around the inner
surface of moulding box as well as the loose sand from upper side get
compressed.
Now the moulding box is ready.
At last the moulding box get lifted by four cornered lifting pins slowly
where hydro-pneumatic pressure is used.
The heavy drag parts are inverted and transferred to the moulding line
which moves forward using Push off machine.
Then cores are kept at the proper position in drag part . Also the ceramic
filter ( 10010022 ) inserted at the end of the down sprue .
Cope parts are formed similar to that of the drag part. But the cope part
consists gating system and riser with it . venting is done manually
Further the cope part is kept on the drag part and are closed using three
lockers inside it.

2 min&20 sec are required to get ready for one mould boxes.


D) Melting & pouring section -:
In KFIL two types of materials castings are manufactured
1) FGI ( Flake Graphite Iron ) - Flakes of graphite are of plain
type
2) SGI ( Spheroidal Graphite Iron ) Flakes of graphite are of
spheroidal type.

In KFIL Induction furnace is used for melting purpose .Total there are three
induction furnace, two of them are of 1 tone capacity and last one is of 3 tone
capacity.

Induction furnace specification
Medium frequency induction furnace
Frequency - 300 Hz
Capacity - 1-3 tone
Power - 450 KW

Charging of furnace-:
Cast Iron is basic material used for melting.
To get required chemical composition different materials are added.
~ 31 ~


Sr no. Charge mix Material ( % )
1. CRCA Scrap 30-60
2. TKAP Returns 10-30
3. Pig Iron 15-30
4. CPC ( Calcinised Petroleum Coke ) 3-4
5. Ferro Silicon 1-2
6. Silicon Carbide 0.5-1
7. Ferro Manganese 0.8-1
Charging specifications

If TKAP scrap is not available the CRCA scrap and also CSIC scrap is used
.

Chemical compositions of molten metal in terms of elements such as C , Si
, Mn , Cr , Sb , Cu , Sn , S , p should be checked before pouring. Sample of
molten metal in form of coin is checked in the spectrometer ( R&D
department ) to get the detailed chemical composition .

Construction of the furnace -:
The induction furnace consist following
parts,
Supporting yokes
Water tubing copper coil
Refractory cement
Asbestos sheets
Silica ramming mass

The copper coils are supported with the help of supporting yokes.
Since the water tubing copper coils are used water is circulated inside
the coil for the cooling purpose.
Refractory cement ( ALE Company ) named as Whytheat cement is used
on copper coil upto certain thickness.
Asbestos sheets are kept after the cement.
Now the silica ramming mass is plastered on sheets as refractory lining.
It sustains at temperature around 1600c.



~ 32 ~

Working of furnace -:
1
st
former of consumable type is kept inside the furnace and starting
block is added to it.
Supply of 11 KV is further step down to the required voltage and
frequency is set .
Current flowing through the copper winding produce magnetic field .
The block cuts the magnetic flux which causes tremendous heat evolution
and hence block starts to melt .
Slowly former also get melted as it is a consumable type . It cup shape
to the furnace .
Further charge is added. It starts to melt causing the same principle.
The temperature of molten is measured with the help of Deep Type
Pyrometer which has a thermo tip use to sense the temperature .
The metal has temperature about 1600c . It is not suitable for pouring
hence to reduce the temperature sintering agent .Boric Acid is used as
sintering agent .
Slag coagulant powder is spread on the molten metal to bound the slag
particles together .
Inoculants are added in the molten metal for the following purpose -
To improve the microstructure
To reduce the chill
To avoid white iron structure
To improve the machinability
Wedge test : It is carried out for checking Inoculation % or
effectiveness.

Induction furnace uses hydraulic mechanism for its tilting operation at
the time of unloading of furnace.
The specifications of Hydraulic Unit
Motor - 12.5 HP , 1440 RPM
Tank - 2001 Capacity
Oil - ENKLO 68
Pouring station -:
After unloading of induction furnace, molten metal is collected
into the ladle of 1 tone capacity . This ladle is handled with the help of
over hanging cross crane of capacity 5 tone . Silica ramming mass and
Whytheat cement materials are used as refractory material for ladle .
Before pouring of molten metal the coagulants are added to easy removal
of slag from the ladle . Again the temperature of metal in ladle is checked
~ 33 ~

using Deep Type Pyrometer . The ladle is closed during pouring with
ceramic wool as it is heat resistive material and helps to maintain the
temperature inside the ladle . Now the ladle is passed through the another
crane which moves parallel to the moulding line . The ladle is tilted using
hand-wheel at required angle .The molten metal is carefully poured into the
basin of moulding boxes .

These mould boxes after pouring , are allowed to cool for 2 hours .


E) Fettling section -:
In fettling following operations are carried out

1) Shake out - This operation consists separation of casting along with
getting system from mould box, with the help of crane.
Further the getting system is separated from casting .

2) Knocking - The separated castings are knocked out so that castings
get cleaned from moulding sand .

3) Short blasting - In short blasting casting surface gets polished using
Nickel shots. In shot blasting machine, nickel shots are
bombarded on casting for 15 min. Shot blasting
machines are provided with bucket elevator. This
bucket elevator is used to collect the nickel shots
for the further use, after the shot blasting process.

4) Muffle furnace - This operation is known as heat treatment process.
In muffle furnace castings are heated at particular
temperature to reduce the stresses occurred during
process and to improve the strength of it .


After these operations , pneumatic grinding , cheeping and other
finishing operations are carried out on casting . Further castings are painted
and transferred to the machine shop after rough milling process.




~ 34 ~











A
A
S
S
S
S
E
E
M
M
B
B
L
L
Y
Y


D
D
E
E
P
P
A
A
R
R
T
T
M
M
E
E
N
N
T
T




















~ 35 ~

ASSEMBLY DEPARTMENT

The castings from B plant are sent to the subcontractor for rough
milling process . After rough milling , castings are transferred to the assembly
department for further machining operation . The machining operation is done
to get the accurate dimensions and good surface finish .
Assembly department is divided in three parts -

1. Kalpak
2. Ekatma
3. Pratik
4. Suyash

1. Kalpak
Kalpak consists single VMC and five HMC CNC machines with
a single Booth cleaning machines.
Machine specifications
a) VMC CHAKRA BMV 60 TC 20
Power supply 810 Watt
Running current 2.8 Amp
Voltage 230 Volt
Single phase
Ambient temperature 20c ( min ) to 45c ( max )
Input air pressure required is 6 bar
20 tool case .

b) HMC MAXPRO H440E
Frequency 50 Hz
3 Phase
Supply voltage 41.5 V AC
Rated current 50 A
Total controlled load 36 KVA
Temperature range 20c - 50c
40 tool case





~ 36 ~

Booth cleaning machine:
The castings after machining are transferred for the
booth cleaning process. For booth cleaning , mixture of SUPRA cleaning oil
and water is used . In this process casting is cleaned externally and
internally. The borings trapped in the internal cavity of the castings are
cleaned during this process. The time required to clean the casting is known
as dunking time. It varies between 1 sec (min.) to 1 hour (max.).
After booth cleaning casting passed for the water cleaning
process. Further castings are cleaned using high pressure air and are sent to
the dispatch line.


2. Pratik
This is another important machining line in the assembly
department. Pratik consist two VMC , single HMC , two drilling machines.
VMC specification : ( BMV 60 TC 20 )
Voltage supply 415 V AC
Power 15.5 HP
Current 24.5 A
Frequency 50 Hz
Auxiliary voltage 24 V AC
20 tool collector
HMC machines are of same specification .
The top side drilling , reaming , spot facing operations are done using
drilling machines .

All VMC and HMC machines consist -
- Two pallets named A and B
- Tool pockets
- Servo controlled voltage stabilizer ( max 480 V , current- 48 A )
- Trout Coolant Tank of 100 LPM capacity with pressure and
frequency , 20 bar and 50 Hz respectively. Also an excess
coolant tank is connected to this
- A filter bag which separates the metal chips from coolant
corresponds reuse of coolant .
- A chip conveyor which collects the chips coming from filter
bag.
- Colored signals:
Green signal indicates cycle start
~ 37 ~

Orange signal indicates pallet change enable
Red signal indicates emergency stop

The different types of tools are set into the tool pockets to which the
specified M Code are given . The program consists this M Codes
corresponding to the different operations . Also the time required for
particular operation is set already in the program . After this particular time
Pneumatic hand is used to change the tools as per the given signal for the
next operation .


3.Ekatma
In this line castings are checked and get ready for dispatching.
The castings are cleaned from all sides using water and high pressure air.
Further closing of the unwanted holes using studs , finishing of the tapings of
the holes such operations are done. Afterwards leakage testing is carried out
on the castings.
Leakage Testing :
Casting is checked under 74-77 PSI air pressure .
All the holes of different sizes such as oil holes , inlet exhaust holes etc
in case of oil engines are checked . But the holes of 5mm size are tested
separately . The process requires 4-5 minutes .
After testing the OK castings are sprayed by the MICRODROPS to
avoid rusting. Further the castings are packed and ready to dispatch.
















~ 38 ~















H
H
P
P
M
M
L
L




















~ 39 ~

HPML PLANT

- HPML High Pressure Moulding Line.
- This HPML plant was planted in 29 August 2008 by Atul Kirloskar.
- The plant consist totally mechanized casting process, means reduced
manual work.
- The main purpose of HPML plant is best quality castings with high
productivity.

Sand section & Core Making:
1. Sand section of HPML is similar to that of the B plant but all
process are mechanized. All required additives are automatically
added. Now this sand is transferred to the core making machines.
2. Core making is done machine. Cores are made by the cold box
process. At a time 6 cores are prepared on this machine.
3. Two robots are used for the further processing. The operation
performed on these robots are as follows.

1
st
ROBOT: It collects the 4 cores from 2-side index table
and make them assembled. The rod inserted manually and nut
fitted automatically to this core assembly. The core assembly
is transferred to the next robot.
2
nd
ROBOT: It picks the assembly of cores and deep into
ARCOPAL tank to increase the refractoriness and good
surface finish. Further it is transferred for the baking to the
heating furnace. Before picking next core assembly it washes
its hand with water.

As the robots are electronic machines, it is operated
by program controlling. Perfect programming tends to efficient
working of robot.

~ 40 ~

4. All OK cores are send to the quality gate for checking of dimensions
& defects.


Moulding Line :
For moulding purpose RUNKEL WAGNER moulding machine.
On this machine both Cope & Drag parts of mould box are created
simultaneously.
They are prepared by changing the pattern position automatically &
simultaneously.
The assembled cores are kept in a drag part manually and cope part
are kept over drag part with the help of ZL flask closing device.
Then this mould boxes are transferred to the pouring station.


Melting Section or Pouring Section :
Induction furnace is used for melting purpose.
Induction furnace with inoculation hopper as inoculation increases
metal fluidity.
Pouring time is 10 min.


Fettling Section:
Shake Out : The crane named as Andromat is used for shake out
process of moulding boxes. Which helps to cut out the getting system
in some extent.
Shot Blasting : The machine named as DISA is used. For shot blasting
MS shots are used.



~ 41 ~

Advantages :
As all process are automatic , productivity is increases.
It consumes less time for whole casting.
The requirement of skilled labour as compared to B plant is very low.
The robot can perform their operation non-stop.
Robots are used to improve and to increase productivity.
The Turnover of the company has increased in large amount.
There are more chances of development at minute level.
The casting have good surface finish .
As labour work is reduced , cost of product is also reduced.



























~ 42 ~

LEARNING POINTS

1) What company culture is & how a team in company works.
2) Various departments in KFIL & their working.
3) Role of an engineer in company. Various responsibilities of
engineers in various departments.
4) Discipline in regards with timing, dress code, punctuality, work
culture.
5) Various casting process in details like mould making, sand
making, melting, fettling, machine shop etc.
6) Relevance of our theoretical knowledge with practical things.
7) Quality norms, safety standards, charts, various cards formats on
shopfloor, dispatching method.
8) Studied sales invoice, purchase invoice, internal memo, shift
records, rejection records, SPC charts.
9) Responsibilities of supervisor, purchase engineer, marketing
engineer, R&D engineer.
10) History, various products, customer of KFIL.
11) Dependability of all departments on each other in company.
12) To get a small success huge team has to work together.

















~ 43 ~

C CO ON NC CL LU US SI IO ON N

1) To get success in market , a good and healthy company
culture is needed.
2) Team work is most important in any achievement.
3) To get a success disciplined, systematic approach is
must.
4) Contribution from all departments is necessary to
achieve success.
5) Engineer has to perform various duties in company.
6) To get success in market quality & standard is must.