MOLDING LINE FLOW

Moulding machine
Sand Cutter,
type,,EFA - SD 6 "
Roll - over for forward automatically
with turntable and Cope and Drag setting
turning of moulding adjustable in two
multi - ram pressing down
boxes - drum roll-over steps,placed
device with different
underneath
squeezing fields

Roll-over for backward Whistler piercing Transfer truck with

Sprue Cup Drilling
turning of copes -Drum device,pneumatic (1 roller conveyor and
device
roll- over needle) track section

Cope setting - down and Moulding box clamping

Pouring Line Cooling Line
closing unit device

Moulding box punch -

out upwards with cod
push-off ,movable
 UNIT SAND - SYSTEM JOURNEY OF THE RETURNED SAND

OBMS

CASTING
BUCKET
SHAKE OUT VIBROFEEDER BELT CONVEYOR
SAND ELEVATOR

BELT HOPPER BELOW POLYGON

COOLER
CONVEYOR POLYGON SCREEN SCREEN

CORE LUMPS
BUCKET RETURNED SAND WITHDRAWL BELT
ELECATOR STORAGE HOPPERS CONVEYORS

CONTROL SYSTEM

MIXER PREPARED SAND BELT CONVEYOR

COAL DUST MOULDING

BENTONITE WATER
SUBSTITUTE MACHINE HOPPER
Sr.no. Elements Range
1 LOI 8 -10%
2. SiO2 48 – 54%
3. Al2O3 14 – 17%
4. Fe2O3 12 – 17%
5. CaO 1- 3%
6. MgO 2 – 3%
7. Na2O 1.5 – 2.4%
8. K2O <1%
9. SO4 <0.5%
10. Cu <20 ppm
11. Pb <15 ppm
12. Cr <10 ppm
13. Zn <10 ppm
14. TiO2 <2%
15. P2O5 <1%
MATERIAL NAME: BENTONITE

Sampling Plan/
Sr. Control
Properties Specification Test Frequency/
No Limits*
Retention period
1. Moisture % 12% Max. 9 - 12 Collect approximately
2. Swelling capacity in 150 gm sample from five
ml. (2g/100 ml of 30ml Min. 30 – 33 ml different bags of the same
water) consignment and by mixing
3. pH at 6 % slurry. 09 – 10.5 9.5 – 10.5 all samples, a
4. Swelling Index 32-38 32 - 38 representative
5. Gelling Time in Sec. Instant Instant sample to be prepared for
6. Green compression conducting test no1 to 7 for
strength in Kg/cm2( 0.50-1.0 0.55-0.95 every consignment.
Note : 1) For rejected consignment
7. Sieve analysis % Retained % Retained keep the sample after
ASTM Sieve No ≤ 10.0 ≤ 10.0 proper identification for
100 ≤ 15.0 ≤ 15.0 one months.
140 ≤20.0 ≤20.0
200 Balance Balance.
Pan

Note : 1) For GCS test

a)use dry silica sand of moisture ≤0.3%, AFS Clay ≤ 0.3%, AFS No.=52-62
b)7% Bentonite Addition
c)3% water Addition &
d)After 5 Minutes of wet mulling.
2) Each consignment should be accompanied with a test certificate indicating Conformance to
the properties mentioned at point no. 1 to 7.
MATERIAL NAME : PIG IRON

Sampling Plan/
Sr.
Properties Specification Control Limits* Test Frequency/
No
Retention period
1. Carbon 3.6 – 4.2 % 3.6 – 4.2 % One number of pig
2. Silicon. 1.8 – 2.5 % 1.8 – 2.5 % iron sample
3. Manganese 0.4 – 0.8 % 0.4 – 0.8 % collected from every
4. Phosphorus 0.04 - 0.10 % 0.04 - 0.10 % consignment to be
5. Sulphur 0.03 – 0.10 % 0.03 – 0.10 % analysed for the
property no. 1 - 5.
Store the sample
after testing with
proper
identification.
Sample retention
period:
i) Accepted
Material: One
working day.
ii) Rejected /
Accepted under
deviation material:
15 working days.
MATERIAL NAME : PIG IRON (S.G.IRON GRADE)

Sampling Plan/
Sr.
Properties Specification Control Limits* Test Frequency/
No
Retention period

1. Carbon 3.6 – 4.2 % 3.6 – 4.2 % One number of pig iron

2. Silicon. 1.8 – 2.5 % 1.8 – 2.5 % sample collected from
3. Manganese 0.10 -0.30 % 0.10 -0.30 % every consignment to
4. Phosphorus 0.04 - 0.08 % 0.04 - 0.08 % be analysed for the
5. Sulphur 0.005 - 0.03 % 0.005 - 0.03 % property no. 1 - 5.
Store the sample after
testing with proper
identification. Sample
retention period:
i) Accepted Material:
One Working day.
ii) Rejected / Accepted
under deviation
material: 15 working
days.
MATERIAL NAME : STEEL SCRAP

Sampling Plan/
Sr. Control
Properties Specification Test Frequency/
No Limits*
Retention period
1. Carbon 1.5 % Max. 1.5 % Max. Minimum two no
2. Silicon 1.5 % Max. 1.5 % Max. of sample pieces
3. Manganese 2.0 % Max. 2.0 % Max. from every
4. Sulphur 0.12% Max. 0.12% Max. consignment & to
5. Phosphorus 0.12% Max. 0.12% Max. conduct the test by
6. Chromium 0.20 % Max. 0.20 % Max. spectrometer or
wet analysis for all
properties.
Store the sample
after testing with
proper
identification.
Sample retention
period:
i). Accepted
Material: One
Working day.
ii) Rejected /
Accepted under
deviation material:
15 working days.
MATERIAL NAME : CRCA STEEL SCRAP

Sampling Plan/
Sr. Control
Properties Specification Test Frequency/
No Limits*
Retention period
1. Carbon 0.50 % Max. 0.50 % Max. Minimum two no
2. Silicon 0.50 % Max. 0.50 % Max. of. sample pieces
3. Manganese 0.7 % Max. 0.7 % Max. from every
4. Sulphur 0.03 % Max 0.03 % Max consignment & to
5. Phosphorus 0.05 % Max. 0.05 % Max. conduct the test by
6. Chromium 0.08% Max. 0.08% Max. spectrometer or wet
analysis for all
properties.
Store the sample
after testing with
proper
identification for.
Sample retention
period:
i) Accepted
Material: One
Working day.
ii) Rejected /
Accepted under
deviation material:
15 working days.
MATERIAL NAME: FERRO MANGANESE
Sampling Plan/
Sr. Control
Properties Specification Test Frequency/
No Limits*
Retention period
1. Carbon 05 – 09 % 06 – 08 % Collect two lumps from
2. Manganese 70 – 75 % 72 – 75 % each consignment and
3. Size 25 - 150 mm 25 - 150 mm crush to make 50 g.
representative samples to
conduct test for the
property no.1-2 For
property no.3, size of
material shall be checked
in at least 2 bags of each
consignment.
Store the sample after
testing with proper
identification.
Sample retention period:
i) Accepted Material: One
working day.
ii) Rejected / Accepted
under deviation material:
15 working days.
MATERIAL NAME : FERRO CHROMIUM

Sampling Plan/
Sr. Control
Properties Specification Test Frequency/ Retention
No Limits*
period
1. Carbon 05 – 09 % 06 – 08 % Collect two lumps from
2. Chromium 60 – 67 % 62 – 65 % each consignment and
3. Size 25 - 150 mm 25 - 150 mm crush to make 50 g.
representative sample to
conduct test for the
property no.1 and 2. For
property no.3, size of
material shall be checked in
at least 2 bags of each
consignment.
Store the sample after
testing with proper
identification.
Sample retention period:
i) Accepted Material: One
working day.
ii) Rejected / Accepted
under deviation material:
15 working days.
MATERIAL NAME : M. S. SCRAP ( FROM FORGING PLANT)

Sampling Plan/
Sr.
Properties Specification Control Limits* Test Frequency/
No
Retention period

1. Carbon 1.20 % Max 1.00 % Max. Minimum two no of

2. Silicon 1.00 % Max. 0.8 % Max. sample pieces from
3. Manganese 2.00 % Max. 1.80 % Max. every consignment &
4. Sulphur 0.08 % Max. 0.06 % Max. to conduct the test by
5. Phosphorus 0.08 % Max. 0.06 % Max. spectrometer or wet
analysis for all
properties
Store the sample after
testing with proper
identification. Sample
retention period:
i) Accepted Material:
One working day.
ii) Rejected / Accepted
under deviation
material: 15 working
days.
MATERIAL NAME : STEEL SHOTS

Sampling Plan/
Sr. Control
Properties Specification Test Frequency/
No Limits*
Retention period
1. Carbon % 0.8 – 1.2 % -Do- Approximately
2. Density 7 g/ml (should not contain > 10 % -Do- 50 gm sample from five
3. Sieve analysis hollows) Min. -Do- different bags of the same
ASTM % Retained -Do- consignment and by
Sieve No ( in mm.) S 550 S 460 S 390 -Do- mixing all samples, a
10 (2.00) -Do- representative
12 (1.70) All pass All pass -- -Do- sample to be prepared for
14 (1.40) -Do- conducting test no.1, 2,
16 (1.18) -- 05.0 Max. All pass and 3 for every
18 (1.00) consignment .
20 (0.85) 85.0 Min. -- 05.0 Max Store the sample after
testing with proper
97.0 Min. 85.0 Min. -- identification.
-- 96.0 Min. 85.0 Min. Sample retention period:
-- -- 96.0 Min. i) Accepted Material: One
working day.
ii) Rejected / Accepted
under deviation material:
15 working days.
MATERIAL NAME : FERRO SILICON MAGNESIUM

Sampling Plan/
Sr.
Properties Specification Control Limits* Test Frequency/
No
Retention period
1. Magnesium 5–7% Material will be accepted on the Approximately
2. Silicon 44 – 48 % basis of supplier test report. 10 kg sample from five
3. Calcium 1.5 – 2.0 % Residual magnesium content different bags of the same
4. Total Rare Earths 1.5 – 2.0 % checked by spectrometer analysis consignment and by mixing all
5. Aluminum 1.00 % Max. should be 0.035 % minimum by samples, a representative
6. Iron Balance using 1.1 % FeSiMg (of liquid sample to be prepared for
7. Size 15 -25 mm metal) in sandwich process after conducting floor trial for every
5 minutes of treatment. consignment as follows.
Treatment temperature 1450- Floor trial to be conducted by
1490 ° C using 1.1 % FeSiMg (of liquid
15 -25 mm metal) in sandwich process.
One spcetro sample to be drawn
from the pouring ladle after
treatment and inoculation.
Residual magnesium content to
be checked by spectrometer.
Store the sample after testing
with proper identification.
Sample retention period:
i) Accepted Material: One
Working day.
ii) Rejected / Accepted under
deviation material: 15 working
days.
MATERIAL NAME: CALCINED PETROLIUM COKE

Sampling Plan/
Sr.
Properties Specification Control Limits* Test Frequency/ Retention
No
period
1. Ash % 0.5 -2.0 1.0-1.5 Approximately
2. Fix Carbon % 96 - 99 97 - 98 100 gm sample from five
3. Volatile Matter % 0.5 – 2.5 1.0 – 2.0 different bags of the same
4 Lump Size % 95 -99 96 -98 consignment and by mixing
> 4.75 mm % by wt. 1-5 2-4 all samples, a representative
< 4.75 mm % by wt. sample to be prepared for
conducting test no.1,2,3, for
every consignment. For
property no.4, size of
material shall be checked in
at least 2 bags of each
consignment. Store the
sample after testing with
proper identification.
Sample retention period:
i) Accepted Material: One
Working day.
ii) Rejected / Accepted
under deviation material: 15
working days.
MATERIAL NAME : COAL DUST SUBSTITUTE GRADE-I
Sampling Plan/
Sr.
Properties Specification Control Limits* Test Frequency/
No
Retention period

1. Ash % 3.0 – 4.5 3.5 -4.0 Approximately

2. Volatile matter % 65 -72 100 gm sample from
3. Sieve analysis 63 - 75 % Retained five different bags of
ASTM Sieve No % Retained 32 - 38 the same consignment
70 30 -40 52 - 58 and by mixing all
100 50 - 60 Balance samples, a
Pan Balance representative
sample to be prepared
for conducting test
no.1,2 &3 for every
consignment.
Store the sample after
testing with proper
identification.
Sample retention
period:
i) Accepted Material:
One working day.
ii) Rejected / Accepted
under deviation
material: 15 working
days.
MATERIAL NAME : COAL DUST SUBSTITUTE GRADE-II

Sampling Plan/
Sr.
No
Properties Specification Control Limits* Test Frequency/
Retention period

1. Moisture (%) 10 % Max. 8% Max. Collect approximately

2. Volatile matter (%) 45 – 51 48±2 150 gm sample from five
3. Ash (%) 7% Max. 6.0% Max. different bags of the same
4. Sieve analysis % Retained % Retained consignment and by
ASTM Sieve No 2.0% Max 1.0% Max mixing all samples, a
20 (850 µm) Balance Balance representative
sample to be prepared for
Pan conduct the properties
no.1,2 ,3&4.
Testing to be done for
every consignment.
Store the sample after
testing with proper
identification.
Sample retention period:
i) Accepted Material: One
Working day.
ii) Rejected / Accepted
under deviation material:
15 working days.
GFD –MOULD LINE: 24/09/2011

Calculation of pressure on mould:

Standards for Calculation:
Hydraulic Piston cross-sectional area: 0.785*16.5 = 213.716 cm2 --- (P)
Hydraulic Pressure at pump: 320 kg/cm2 ---- (A)
Pressure setting as per Production; 90% of (A) is: 288 kg/cm2 --- (B)
Load on Squeeze pad is ---: B*P = 213.716*288 = 61,550 kgf -----(x)
Squeeze pad area is --- = 88.6*68.6 = 6077.96 cm2 ---- (y)
Pressure on Mould is --= x/y = 61550/6077.96 = 10.126 kg/cm2

For various pressures:

Formula:

Mould pressure = ((320*Y)*213.716)/6077.96 = 11.251Y

Where “Y” is = % of Hydraulic Pressure setting by Production on (A)
Example: If y = 80% , then,
Mould Pressure is = 11.251*0.8 = 9.0 kg/cm2
 HWS MOULDING LINE PRESSURE SETTING

Calculation:

Hydraulic squeeze cylinder piston cross section area = (3.14/4)*6.3*6.3

= 31.15 cm2
Squeeze feet area (13.7 * 13.7) = 187.69 cm2
Hydraulic pressure setting in Outer Ring = 95 kg/cm2
Inner Ring = 90 kg/cm2
Center Ring = 90 kg/cm2

Pressure on Mould = Load on Squeeze feet / Squeeze feet area

Load on Squeeze feet = Hydraulic Pressure*Area of piston

= 31.15*95 = 2959.8 kgf

= 2959.8/187.69 = 15.77 kg/cm2

 HWS MOULDING LINE PRESSURE SETTING

If we want to make mould with various pressure on the mould,

the Hydraulic pressure settings are as follows:

Pressure Area of Load on Area of Pressure

on mould- squeeze squeeze Piston cm2 on mould-
kg/cm2 feet-cm2 feet-kgf kg/cm2
A B A*B C (A*B)/C
7 187.69 1313 31.15 42
8 187.69 1501 31.15 48
9 187.69 1689 31.15 54

From the above table we can understand that if we need mould

pressure as 7kg/cm2, the Hydraulic pressure setting should be 42
kg/cm2
 HWS Moulding Line Cope/Drag Pressure Settings
Pressure
Sl. No. Item Outer Center Inner
Drag 90 90 90
1 Mul F8D
Cope 90 85 85
Drag 95 90 90
2 Mul F8B
Cope 95 85 85
Drag 95 90 90
3 Mul F10D
Cope 95 85 85
Drag 95 90 90
4 Mul VA/VE
Cope 95 85 85
Drag 95 90 90
5 Mul Cylinder Block YE3
Cope 95 85 85
Drag 95 95 95
6 Tata Fiat Block
Cope 95 90 90
Drag 95 90 90
7 Spil Diesel Block
Cope 85 85 85
Drag 95 90 90
8 Eicher Block
Cope 85 80 80
Drag 95 90 90
9 Epsilon Block
Cope 95 85 85
Drag 100 90 90
10 Cummins Block
Cope 100 85 85
Drag 100 90 90
11 Tata Fire Block
Cope 100 85 85
Drag 95 90 90
12 Simpson S-3 Block
Cope 95 85 85
Drag 100 90 90
13 Forceman Cylinder Block
Cope 100 85 85
Drag 100 90 90
14 Simpson S-2 Block
Cope 100 85 85
Drag 95 90 90
15 Mazda Cylinder Block
Cope 95 85 85
Drag 90 90 90
16 JCB Bed Plate
Cope 90 85 85
Drag 95 90 90
17 Avtek Cylinder Block Petrol
Cope 95 85 85
Drag 95 90 90
18 Avtek Cylinder Block Diesel
Cope 95 85 85
Drag 100 90 90
19 ITL Crank Case
Cope 100 85 85
Drag 95 90 90
20 Standard Crank Case
Cope 95 85 85
Drag 95 85 85
21 J D Cylinder Head
Cope 90 85 85
Drag 95 90 90
22 J D Cylinder Head Trem 3A
Cope 90 85 85
Drag 95 90 90
23 Eicher Head
Cope 80 80 80
 HWS Moulding Line Cope/Drag Pressure Settings(Contd.)
Drag 95 90 90
24 Simpson S3 Cylinder Head
Cope 95 80 80
Drag 95 90 90
25 CNH GB Hsg.
Cope 90 85 85
Drag 95 90 90
26 ITL Diff. Hsg.
Cope 95 90 85
Drag 95 95 95
27 ITL Bell Hsg.
Cope 95 80 80
Drag 90 85 85
28 Eicher GB Rear 242
Cope 85 80 80
Drag 95 95 95
29 Eicher GB Front
Cope 90 80 80
Drag 95 90 90
30 Eicher GB Deluxe
Cope 90 85 85
Drag 95 90 90
31 Eicher GB Rear 241
Cope 90 85 85
Drag 90 85 85
32 Ashok Fly Wheel Hsg. 6 Bore
Cope 90 80 80
Drag 90 85 85
33 Ashok Fly Wheel Hsg. 4 Bore
Cope 90 80 80
Drag 90 85 85
34 JCB Fly Wheel Hsg.W300
Cope 90 80 80
Drag
35 JCB Case Rear
Cope
Drag 95 90 90
36 JCB Case Front
Cope 90 85 85
Drag 90 85 85
37 JCB Drive Head 322
Cope 90 80 80
Drag 95 90 90
38 JCB Case Front Midi
Cope 90 85 85
Drag 95 85 85
39 NH Axle Casing 84263743
Cope 90 80 80
Drag 90 85 85
40 CNH FDC 951
Cope 90 80 80
Drag 90 90 90
41 NH Trumpet 75 HP LH/RH
Cope 90 85 85
Drag 90 85 85
42 NH NDL Trumpet LH/RH
Cope 90 80 80
Drag 90 85 85
43 Escort Axle Hsg. LH/RH
Cope 90 80 80
Drag 95 85 85
44 NH PTO 253
Cope 95 80 80
Drag 90 80 80
45 JCB C/W Bearing
Cope 80 70 70
Drag 90 85 85
46 JCB Brake Piston
Cope 80 80 70
Drag 95 90 90
47 CNH FAS 7715
Cope 95 85 85
 HWS Moulding Line Cope/Drag Pressure Settings(Contd.)
Drag 95 90 90
48 NH FAS 6467
Cope 95 85 85
Drag 95 90 90
49 NH FAS 6460
Cope 95 85 85
Drag 90 85 85
50 NH FAS 7714
Cope 90 80 80
Drag 95 85 85
51 NH FAS 7716
Cope 95 80 80
Drag 95 90 90
52 NH FAS 7713
Cope 85 85 85
Drag 95 90 90
53 NH FAS 7715
Cope 90 90 90
Drag 95 90 90
54 NH FAS 50 HP
Cope 95 85 85
Drag 90 85 85
55 NH FAS x D508
Cope 85 80 80
Drag 90 85 85
56 NH FAS 47 HP
Cope 85 80 80
Drag 95 90 90
57 NH MCH SC 87725690
Cope 95 85 85
Drag 95 90 90
58 NH MCH DC 87664477
Cope 95 85 85
Drag 95 85 85
59 NH MCH 5081
Cope 90 80 80
Drag 90 85 85
60 NH Axle Casing 2910
Cope 85 80 80
Drag 90 85 85
61 NH Trumpet Hsg.55 HP
Cope 90 80 80
Drag 90 85 85
62 Carraro Central Body
Cope 90 80 80
Drag 90 85 85
63 Carraro Brake Housing -012787
Cope 90 80 80
Drag 90 85 85
64 Carraro Brake Housing -2
Cope 90 80 80
Drag 95 85 85
65 Eicher Transmission Case
Cope 90 80 80
Drag 90 85 85
66 Escort Central Hsg.
Cope 90 80 80
Drag 95 85 85
67 JCB Fly Wheel (vision)
Cope 90 80 80
Drag 95 85 85
68 GM Fly Wheel
Cope 95 80 80
 MOULDING SAND TESTS

 GCS
 GSS
 PERMEABILITY
 MOISTURE
 AFS CLAY
 MB CLAY
 LOI
 VM
 pH
 SIEVE ANALYSIS
 S H E L L C O R E S H O O T E R M A C H IN E
M O D E L N O . 3034 - H P A

SPECIFICATIONS:
Shell Core Shooter Model : 3034 HPA (Horizontal Parting)

Heater Plate size MM : 750 x 850

Core Box thickness (Max.) MM : 350

(Min) MM : 150

Core Blowing capacity KG : 40

Sand Hopper capacity(sand feed) KG : 150

Blow Area (inside) MM : 700 x 750

Blow plate : Part of core box.

Core ejection : Core ejection by top pushdown,

Drag ejection to be with hydraulic cylinder
and Guide Rods.

Heating arrangement : Part of tooling – Susha will

provided 3 plug/socket of
24+24+12 KW rating for top,
bottom & pullout.

Core Box mounting arrangement : The top core box to be mounted on

picture frame type arrangement. The bolster
to go inside along with drag & cope core box,
blow plate and top ejector plate placed on top
of each other.

Auto ./Manual : Through PLC Control- Messung

Temperature sensor & controller : Two nos. (for top side and bottom
Side).

Silicon rubber “O” rings : Two sets to be provided as

Spares.
 SHELL CORE SHOOTER MACHINE
MODEL NO. 3034 – HPA (Contind.)

Dry cycle time : 30 sec. without unloader.

Plug & socket. : Industrial Metal clad – CH

Sand feeding arrangement : Auto sand feed.

Additional equipment : a) Core unloader-(Motor gear

Box type.)

b) Blow Plate Exchange device

c) Core Box changing rail.

d) Pneumatic sand convey to

top hopper.

Other features (As per minutes of meeting with your Mr. Vijay Gandhi held on 6.2.07)

1. Necessary modification to be made in the machine to avoid fouling of ejection plate

during mounting of core box.
2. Hydraulic equalizer to be provided for ejection cylinder for smooth movement.
3. Operator’s panel consisting of operating switches, MMI and temperature controller to be
provided. This panel with swivelling arrangement should be fixed on machine.
4. Electrical panel should be mounted on the rear side of the machine where existing
pneumatic panel is fixed.
5. The un-loader to be shifted in forward direction to reduce space.
 COLD BOX PROCESS
SUB: AIR PASSAGE THROUGH VENTS
A. SLOTTED VENTS (3.0 mm slots)
VENT DIAMETER (mm) AIR FLOW AREA (mm² )

6.00 6.20
8.00 10.60
10.00 16.00
12.00 22.70
14.00 30.40
16.00 38.80
18.00 48.40
20.00 59.60
22.00 65.40

B. MESH VENTS (0.4 /0.2 mm )

VENT DIAMETER (mm) AIR FLOW AREA (mm² )

6.00 10.00
8.00 20.00
10.00 20.00
12.00 34.00
14.00 52.00
16.00 75.00
18.00 93.00
20.00 128.00
2
 1/2
Cold Box Core making Machine ,SPAN,CBHP 800

S.NO. SPECIFICATIONS SIZE

1. Maximum size of core box 900mm x 700 mm
Thickness of core box 400mm Max.
200mm Min.
2. Top casting window size 820mm x 620mm
3. Bolster size 900mm x 700mm (height 300mm)
4. Closing Travel 700mm
5. Distance between top of Tooling to top 900mm
of Bolster
6. Clamping force of closing Cylinder 4” Hydraulic Cylinder (8 ton closing
force at 100 bar)
7. Shoot head size overall 800mm x 600mm
8. Blow plate overall size 800mm x 600mm
9. Effective blowing size 700mm x 500mm
10. Up-down travel of sand magazine with 125mm Max.
shoot head 4” Hydraulic Cylinder
11. Side ways travel of sand magazine To suit
12. Sand Magazine Capacity 90 Kgs
13. Maximum Core Weight 50 Kgs
14. Sand valve opening Shutter valve with pneumatic
cylinder.
15. Sand hopper storage capacity 200 Kgs
16. Blow tank capacity 150 Ltrs.
17. Blow Valve 50 N.B. Cylinder Operated
18. Quick exhaust 25mm  Cylinder Operated
19. Top gassing cum ejection assembly 800mm x 600mm
overall size
20. Top ejection plate overall size 720mm x 520mm
 2/2

21. Guide for top ejection Four guide bars with separate
ejection cylinder
22. Top ejection plate up-down travel 150 mm (200mm bore x 150mm
stroke pneumatic cylinder).
23. Top ejection plate side ways travel To suit
24. Bottom ejection plate travel 250mm (63mm bore x 250mm stroke
Hydraulic cylinder – 2 nos.)
25. Unloader travel forward & reverse 1200mm
26. Unloader adjustment 200mm Up & Down(Screw & Nut)
27. Quick change of Bolster with bottom Pin & Rollers guide
tooling
28. Blow plate will have quick clamping arrangement for mounting (Pneumatic
cylinder operated)
2/2

29. Dry cycle time 30 seconds

30. The electrical control panel will have PLC Control with proximity switches. An
auto manual selector switch will be provided. The manual control will also
work through PLC. A 24 V DC Stabilized power supply will be provided.
31. Blow plate unloader Cylinder operated blow plate
unloader will be provided.
32. The hydraulic power pack will have a tandem gear pump with 12.5 HP motor.
One no. oil/water heat exchanger will be provided. The hydraulic oil tank will
be 400 Ltrs capacity. Necessary solenoid valves flow control valves, non
return valves, breather filters unloader valves etc. will be provided.
33. Quick Clamping arrangement for bolster.
34. Special arrangement for low sand spillage by new design sand valve.
35. Improved blow valve / blow up for higher sand compaction.
36. The blow cup seal arrangement to be as per the attached drawing.
 Cold Box Core making Machine ,SPAN ,CBVP 800

TECHNICAL SPECIFICATIONS

1. SIZE OF CORE BOX MOUNTING : 850MM X 750MM (VERTICAL)

PLATE.

2. DIMENSIONS OF CORE BOX : 850MM X 750MM X 400MM

MAXIMUM (200MM + 200MM)

3. WEIGHT OF CORE BOX : 800 KGS. MAXIMUM

4. OPENING BETWEEN CORE BOX

MOUNTING PLATE (DAY LIGHT) : 900MM

4A. CORE BOX CLOSING CYLINDER : 125MM BORE X 600MM STROKE

HYDRAULIC CYLINDER (CLAMPING
PRESSURE – 10 TONS MINIMUM.

5. SAND MAGAZINE CAPACITY. : 60 LITERS.

MAXIMUM CORE WEIGHT 60 KGS.

6. SHOOT HEAD DIMENSION
OVERALL : 800MM X 300MM

7. SHOOT HEAD OPENING : 700MM X 200MM INSIDE.

8. SAND MAGAZINE TRAVEL

UPDOWN : 75MM
63 BORE HYDRAULIC CYLINDER.

8-A. SAND MAGAZINE TRAVEL : 600MM (PNEUMATIC CYLINDER

SIDE WAY 125MM BORE X 600MM STROKE)
WITH SHOCK ABSORBER AND SPEED
CONTROL VALVE.

9. SAND STORAGE HOPPER : 200 KGS.

CAPACITY.

9-A. VIBRATORY FEEDER MOTOR : 0.5 H.P. 1440 R.P.M.

FOR SAND HOPPER

10. SWING OF R.H. PLATE : 90 DEGREES,SWING DOWN.

10-A. SWING DOWN CYLINDER : 75MM BORE X 700MM STROKE

HYDRAULIC CYLINDER,

11. EJECTION ON R.H. SWING : HYDRAULIC CYLINDER

PLATE. 75MM BORE X 25MM STROKE WITH
4 NOS. GUIDE RODS.
12. TRANSFER EJECTION ON : PNEUMATIC CYLINDER
L.H. SIDE 150 0 BORE X 25MMTRANSFER EJECTION

13. GASSING PLATE : OVERALL SIZE 800MM X 300MM

OPENING SIZE 700MM X 200MM

13-A GASSING PLATE TRAVEL : 600MM

SIDE WAYS (COUPLED TO MAGAZINE)

14. BLOW TANK : 200 LITERS WITH AUTO WATER DRAIN

VALVE.

15. SWING PLATE WILL BE FITTED

WITH BALL BEARINGS. :

16. MAXIMUM LENGTH OF LOWER

MANDREL : 600MM

17. STROKE OF HYDRAULIC : 63MM BORE X 600MM HYDRAULIC

CYLINDER FOR MANDREL CYLINDER.
OPERATION

18. A CORE CARRIER WITH 100MM LIFT & 1200 MM TRAVEL WILL BE PROVIDED.
EJECTED CORES MUST COME ON THE CENTER OF CARRIER PLATE TO AVOID DAMAGE
OF GUIDE RODS.

19. ONE NO. DIRECT AIR INJECTION TYPE AMINE GAS GENERATOR USING DRY AIR
AS CARRIER WILL BE PROVIDED. THE GAS GENERATOR WILL BE PROVIDED WITH
AMINE METERING PUMP, VAPORIZER AND AIR HEATER WITH DIFFERENT PRESSURE
LINE AND REGULATOR.

20.HYDRAULIC SYSTEM

THE HYDRAULIC POWER PACK WILL HAVE TANDEM VANE PUMP OPERATED BY 15 HP
MOTOR

PUMP – VICKERS VANE PUMP

MOTOR - SIEMENS/ BHARAT BIJLEE.

OIL TANK CAPACITY – 400 LITRES WITH OIL COOLER.

THE DIRECTION CONTROL VALVES WILL BE MOUNTED ON MANIFOLDS THE DIRECTION

CONTROL VALVES WILL BE VICKERS/REXROTH MAKE. UNLOADER VALVES, PRESSURE
GAUGE , BREATHER, PRESSURE RELIEF VALVE, FLOW CONTROL VALVE AND PILOT
CHECK VALVES WILL BE PROVIDED. OIL LEVEL GAUGE WITH TEMP INDICATOR WILL
BE PROVIDED .

ADDITIONALLY ONE SEPARATE HYDRAULIC PUMP 50 LPM FLOW WITH 1.5 H.P. MOTOR
WILL BE PROVIDED FOR OIL FILTRATION & COOLING. ONE NUMBER OIL/ WATER
HEAT EXCHANGER WILL BE PROVIDED.

MAX OPERATING PRESSURE – 100 KG/SQ.CM

3/3
 SHELL CORE MACHINE – MODEL NO.1828 – VTS

S.No. Description Specifications

1. Core Box size 450 height x 700 length
2. Core Box thickness 375 mm – max.
100 mm – min.
3. Core Blowing capacity 15 Ltrs
4. Sand hopper capacity 200 kgs on machine
5. Blow area 125 x 600
6. Core Box weight 300 kgs – max. on ram side and door side
7. Blow Head Water cooled
8. Heating arrangement Part of core box
9. Operation All pneumatic
10. Core Ejection Pneumatic cyl. with four guide rods on
door side. Electro Pneumatic.
11. Core Box mounting arrangement Mechanical with four guide rods on Sq.
Bar which can be adjusted by two pitches
at 400x400 center line.
12. Auto / Manual Through PLC control, Messung
13. Temp sensor and controller One each for fixed side and moving side,
Radix
14. Sand feed arrangement to machine By skip hoist of 200 kg capacity
hopper
15. Dry cycle time 30 sec.
16. Ejection attachment Magnetic holder – 15 nos
17. Ejector plate guide bush Gun metal
18. Core box mounting distance pin EN-8
19. Plug and socket Industrial Metal (C & H make)
20. FRL Unit / Regulator SHEVO NORGEN
 Shell Core Production
Core - Maruti F8D block , water jacket core upper and lower
Machine - Vertical Core making Machine
Types of sand- Grade- A
Curing Time - 40 - 50 sec
Core box Temperature - Bush half - 220 - 250°C
Pin Half - 230 - 260°C
Blow Pressure - 3- 5 Kg/cm²
Blow Time 3- 5- sec
 Cold Box Core Production
Core - Slab core of Escorts cylinder Head
Machine - Horizontly parted machines
Sand Feed Time - 5- 10 sec
Blow Pressure - 3- 5 Kg/cm²
Blow Time 4- 8 sec
TEA Pump Time 20 - 30 sec
Gassing Time 80 - 110 sec
 FOMET POURING FURNACE (Model- PR 7.8/250 )
Total Furnace Capacity KG 8000
Useful Pressure pouring capacity KG 6000
Installed Power KVA 300
Inductor Rating KW 250
Holding Power to maintain 1400 °C (Full Furnace at Reset) KW 80
Super Heating Rate for 50°C t/H 13
Super Heating Rate full Furnace at Full Power(250 Kw) °C/H 100
Consumtion for Superheating Operation for 50°C kWH/t 19
Rated Voltage 3 - Phase V 415
Frequency Hz 50
Command Voltage V 110
Auxillary Voltage 3- Phase V 415
Electric Power Factor Cos phi 1
Inductor Air cooling Motor Power KW 3
Oil- Hydraulic Motor Power Pump KW 5.5
Furnace Positioning Movements
Parallel to Moulding Line mm 2700
Orthogonal to Moulding line mm 625 + 175
 Inoculation of Grey iron
Late addition to the melt which alters structure of metal on solidification.

Addition of Inoculation facilitates the promotion of nucleation sites and

formation of graphite as Flakes (or nodules).It creates an equilibrium state
between casting time and temperature .By this Equilibrium state following
is achieved.

1. Control of Graphite Structure

2. Elimination or Reduction of Iron Carbide formation(Chill)
3. Reduction of Casting section Sensitivity
4. Prevention of under cooling
 Grades of Shell Sand
Core Strength
S. No. Grade Gas (cc/gm) % LOI AFS No.
(kg / sq.cm)

1 A 27 - 34 16 - 21 3.5 - 4.6 52 - 62

2 A SPL 31 - 36 16 - 19 3.6 - 4.2 47± 3

3 B 18 - 26 14 - 18 3.2 - 4.2 52 - 62

4 T 12 - 16 8 - 12 2.4 - 2.9 52 - 58