TATA Metaliks DI Pipes Hot Zone Project
TATA Metaliks DI Pipes
Hot Zone Project (Summer Internship)
for
Maulana Abul Kalam Azad University of Technology
Future Institute of Engineering and Management
by
Shayan Nandy
MAKAUT Roll No:- 14800715049
shayan96nandy@gmail.com
Topic: -
Sayontan Chandra
MAKAUT Roll No:- 14800715048
sayontan1234@gmail.com
Reducing Casting Rejections
ACKNOWLEDGEMENT
We,
Nandy
Shayan
and
Sayontan
Chandra
underwent
a
training at TATA
Metaliks DI pipes, in the hot zone, under the
supervision of H.O.D Mr. Mohit Kale, and trainer Mr.
Hari Krishna. This project was given to us by our trainer.
We thank everyone at TATA Metaliks for giving us this
exciting opportunity.
1. AbstractAt TATA Metaliks DI Pipes Division, the process of making ductile
iron (DI) pipes has been divided into two zones:
Hot Zone
Cold Zone
The two zones have very different nature of work. While in the hot
zone the raw molten metals are given the shape of a pipe, in the cold
zone the newly casted pipes are given the finishing it requires for
longevity, durability and better properties for greater range of
applications. Foundry industries suffer from poor quality and
productivity due to involvement of a number of process parameters.
Even in completely controlled process, defect in casting are observed
and hence casting process is also known as process of uncertainty
which challenges explanation about the cause of casting defects. In
order to identify the casting defect and problem related to casting,
the study is aimed in the research work. This will be beneficial in
enhancing the yield of casting. Beside this, standardization
(optimization) of process parameter for entire cycle of manufacturing
of the critical part is intended in the proposed work. This study aims
to finding different defects in casting, analysis of defect and providing
their remedies with their causes. In this paper an attempt has been
made to list different types of casting defects and their root causes of
occurrence. This paper also aims to provide correct guideline to
quality control department to find casting defects and will help them
to analyse defects which are not desired.
2. Introduction:
Casting is a process which contains risk of failure occurrence during
all the process of accomplishments of the finished products. Hence
necessary action should be taken while manufacturing of cast
products so that defect free parts are obtained. Mostly casting
defects are concerned with process parameters. Hence one has to
control the process parameter to achieve zero defect parts. For
controlling process parameters one must have knowledge about
effect of process parameter on casting and their influence on defects.
To obtain this all knowledge about casting defect, their causes, and
defect remedies one has to be analyse casting defects. Casting defect
analysis is the process of finding root causes of occurrence of defects
in the rejection of casting and taking necessary step to reduce the
defects and to improve the casting yield. In this review project an
attempt has been made to provide all casting related defect with
their causes and remedies often seen in the DI pipes industry.
During the process of casting there is always a chance that defect will
occur. Minor defects may be adjusted easily, but high rejected rates
could lead to significant change at high cost. Therefore, it is essential
for the die caster to have knowledge on the type of defect and be
able to identify the exact root cause and their remedies.
3. Processes in the hot zone
The Pig Iron is received at the DI Pipes plant in the molten form.
This pig iron now has to be chemically converted to ductile iron. Here
the first step is the mini blast furnace(MBF).
3.1.
MBF:
The molten pig iron received is first put in the mini blast
furnace to boost up the temperature to 1500˚C, as the
temperature of the molten metal reduces during the transfer.
From here a small sample is taken to the Quality Control of a
quality check. The compositions of a few samples are as:
Batch
C
Si
Mn
P
S
Mg
Ti
Cr
MBF-02(A1.8
0.11 0.02
Hot Zone Project (Summer Internship)
for
Maulana Abul Kalam Azad University of Technology
Future Institute of Engineering and Management
by
Shayan Nandy
MAKAUT Roll No:- 14800715049
shayan96nandy@gmail.com
Topic: -
Sayontan Chandra
MAKAUT Roll No:- 14800715048
sayontan1234@gmail.com
Reducing Casting Rejections
ACKNOWLEDGEMENT
We,
Nandy
Shayan
and
Sayontan
Chandra
underwent
a
training at TATA
Metaliks DI pipes, in the hot zone, under the
supervision of H.O.D Mr. Mohit Kale, and trainer Mr.
Hari Krishna. This project was given to us by our trainer.
We thank everyone at TATA Metaliks for giving us this
exciting opportunity.
1. AbstractAt TATA Metaliks DI Pipes Division, the process of making ductile
iron (DI) pipes has been divided into two zones:
Hot Zone
Cold Zone
The two zones have very different nature of work. While in the hot
zone the raw molten metals are given the shape of a pipe, in the cold
zone the newly casted pipes are given the finishing it requires for
longevity, durability and better properties for greater range of
applications. Foundry industries suffer from poor quality and
productivity due to involvement of a number of process parameters.
Even in completely controlled process, defect in casting are observed
and hence casting process is also known as process of uncertainty
which challenges explanation about the cause of casting defects. In
order to identify the casting defect and problem related to casting,
the study is aimed in the research work. This will be beneficial in
enhancing the yield of casting. Beside this, standardization
(optimization) of process parameter for entire cycle of manufacturing
of the critical part is intended in the proposed work. This study aims
to finding different defects in casting, analysis of defect and providing
their remedies with their causes. In this paper an attempt has been
made to list different types of casting defects and their root causes of
occurrence. This paper also aims to provide correct guideline to
quality control department to find casting defects and will help them
to analyse defects which are not desired.
2. Introduction:
Casting is a process which contains risk of failure occurrence during
all the process of accomplishments of the finished products. Hence
necessary action should be taken while manufacturing of cast
products so that defect free parts are obtained. Mostly casting
defects are concerned with process parameters. Hence one has to
control the process parameter to achieve zero defect parts. For
controlling process parameters one must have knowledge about
effect of process parameter on casting and their influence on defects.
To obtain this all knowledge about casting defect, their causes, and
defect remedies one has to be analyse casting defects. Casting defect
analysis is the process of finding root causes of occurrence of defects
in the rejection of casting and taking necessary step to reduce the
defects and to improve the casting yield. In this review project an
attempt has been made to provide all casting related defect with
their causes and remedies often seen in the DI pipes industry.
During the process of casting there is always a chance that defect will
occur. Minor defects may be adjusted easily, but high rejected rates
could lead to significant change at high cost. Therefore, it is essential
for the die caster to have knowledge on the type of defect and be
able to identify the exact root cause and their remedies.
3. Processes in the hot zone
The Pig Iron is received at the DI Pipes plant in the molten form.
This pig iron now has to be chemically converted to ductile iron. Here
the first step is the mini blast furnace(MBF).
3.1.
MBF:
The molten pig iron received is first put in the mini blast
furnace to boost up the temperature to 1500˚C, as the
temperature of the molten metal reduces during the transfer.
From here a small sample is taken to the Quality Control of a
quality check. The compositions of a few samples are as:
Batch
C
Si
Mn
P
S
Mg
Ti
Cr
MBF-02(A1.8
0.11 0.02