This research study sought to determine the strengths and weaknesses of the current maintenance practices at a sand casting manufacturing company which is principally a ferrous foundry producing grey and white iron. The work suggested good practices which could be taken on board and others which could be improved on. The generated recommendations can be used by other foundries to enhance their ...

Foundries represent an important sector of the manufacturing industry and these foundry industries in developing countries suffer from poor quality and productivity due to number of process parameters involved in the casting process. Even in a completely controlled process, defects in casting are observed and hence casting process is also known as process of uncertainty which challenges explana...

In a foundry casting line, contaminants are released from a large area. Casting fumes include both volatile and particulate compounds. The volatile fraction contains hydrocarbons, whereas the particulate fraction mostly comprises a mixture of vaporized metal fumes. Casting fumes lower the air quality in foundries. The design of local ventilation for the casting area is a challenging task, becau...

Abstract Quality issues caused by casting defects are commonly complicated to solve, because the part-specific process parameters not traced individual cast part. This problem can be mitigated traceability of each part with an identifier code. Therefore, a study influence marked surface topography and post-treatments on code symbol quality is desirable for well-designed system. In this work, la...

Based on results from computational studies and plate casting trials, deficiencies in the steel casting feeding rules as currently published by the Steel Founders’ Society of America (SFSA) were determined. A methodology for the development of improved steel casting feeding rules was established based on the Niyama criterion determined from simulation. Newly developed feeding rules using this m...

Feeding of the nickel-based alloys CZ-100, M-35-1, and CW-12MW, as well as of the austenitic stainless steel CN-7M, is investigated, using a combination of casting experiments and simulation. Casting trials are performed at five foundries, to produce a total of 55 plates of varying lengths and radiographic soundness levels. In order to develop the property databases necessary to simulate the ca...

With the global liberalization industries in India are growing at a very fast pace, especially the small and medium enterprises (SMEs) like; foundries, mining industries, food processing industries etc. But due to lack of use of advanced technologies by SMEs, the labourers are exposed to dusty and hazardous environment and they are getting more prone to lungs related diseases. This problem is m...

The classical casting material cast iron is experiencing a renaissance. High strength CGI or alloyed cast iron components are substituting previously used non-ferrous castings in automotive power train applications. The mechanical engineering industry has recognized the value in substituting forged or welded structures with stiff and light-weight cast iron castings. New products such as wind tu...

Like Phenol (C 6 H 5 OH) and Urea {(NH 2 ) 2 C=O)}, Furfuryl alcohol (C 4 H 3 OCH 2 OH), a product of agricultural origin is capable of polymerization with Formaldehyde (H 2 C = 0) under suitable PH conditions. However, usable polymers, at least as no bake for Foundry applications are obtained only when the condensations are carried out in association with Urea, Phenol or both. The series of re...