FOUNDRY SHOP

Casting process: Casting is also the oldest known manufacturing process. It requires preparation of the cavity usually in a refractory material to resemble closely the final object to be made molten metal is poured into this refractory mould cavity and is allowed to solidify. The object after solidification is removed from the mould. Casting process are universally used to manufacture a wide variety of products. Some of the casting process are-

· Shell mould casting

· Precision investment casting

· Plaster mould casting

· Permanent mould casting

· Die casting

·        Centrifugal casting

Figure: Foundry Service from Pattern making Facilities

The machine which is used in foundry shop in BITAC. There are –

1. Induction furnace

2. Tilting furnace

3. Coke fired furnace

4. Cupola furnace

5. Pit / Crucible furnace

6. Core drier

7. Sand blasting unit

8. Weighing scale

9. Overhead crane

10. Tumbling barrel

11. Jolt squeezing

12. Grinding machine

13. Sand muller

1) Induction furnace : In Induction furnace we use electricity to produce heat. It has maximum 1000 Hz frequency, 250 KW current. Its furnace capacity 300 Kg. In this machine we produce heat from electric power and melting cast iron, cast steel, alloy steel etc. It produce about 2200 ⁰C temperature in furnace which is more that iron. So here all type of metal can melting. Its furnace can move.

2)Tilting furnace : In this furnace capacity is 200 Kg. This machine is small type corresponding to the induction furnace. This furnace also moveable.

3)Cupola furnace: This furnace also used to melting metal and its capacity is 1.5 ton.

4)Pit / Crucible furnace: It is small type furnace and it has only 80 Kg capacity.

5)Tumbling barrel: It is used to remove sand from casting material.

6)Weighing scale: It is used to measuring weight. Its maximum capacity 500 lb. This ma chine is made by ENGLAND.

7)Grinding machine: It is used to surface finishing for casting material. Here one hand grinding machine is situated.

8)Overhead crane : Its swiveling capacity 2 tons. It is swiveling by a hand control panel.

9)Jolt squeezing : Expensive for one or two product.production type molding.

Comments

Why a dc generator fails to build up voltage?

How can the problem be remedied : No residual magnetism, reversed field connection and high resistance of field circuit are responsible for the failure of build up process of a dc generator. The factors are explained below: No residual magnetism: For the starting build up process requires some residual magnetism in the magnetic circuit then no voltage will be generated that can produce current flow through field circuit. Reversed field connection: The voltage induced inside the coil of field circuit due to residual magnetism that can permit the flow of current. For the following direction of this flux will be created and the direction of this flux will be same direction as the residual flux. If the field connections are reversed the lines of flux produced by current flow will oppose the residual flux, as a result generate voltage will decrease rather than increase. So voltage build up process failed. Field circuit resistance too high: A field

How to Calculate Heat Rate of Generator Engine?

Types of Power Plant (Technology) Natural Gas Based power plant technology Diesel power plant technology Heat Rate of Engine= Fuel Flow or Fuel burned * Fuel Heating Value / Power Output 1 Liter Diesel = 0.85 Kg Example: Heat Rate of Diesel Generator at 100% Load Engine Model- 2506A-E15TAG2 Engine Capacity=400 eKW Fuel Consumption=84 L = 71.4 Kg Electrical Energy Output = 400 KW Heating Value of Diesel = 42.5 MJ/Kg Heat Rate of Engine= Fuel Flow or Fuel burned * Fuel Heating Value / Power Output Heat Rate of Engine = 71.4 Kg * 42.5 MJ/Kg /400KW Heat Rate of Engine =7.58 MJ/KWH Heat Rate of Gas Generator at 100% Load Engine Model- VHP5904LTD Engine Capacity= 900 eKW Fuel Consumption= 271 Nm 3 Electrical Energy Output= 900 KW Fuel Consumption= 0.28 Nm3/KWH Heating Value of Natural Gas= 35.22 MJ/ Nm 3 Heat Rate of Engine= Fuel Flow or Fuel burned * Fuel Heating Value / Power Output

Packing, Seals and Gaskets

Packing, seal and gasket resists the flow of fluid from machinery face, head, joint and machinery gap or clearance. Packing materials: Fiber, asbestos, cotton, synthetic materials, plastic, Teflon, graphite etc. Packing structure: Twisted, Braided and Consolidated. Gasket: A gasket is a mechanical seal that fills the space between two mating surfaces, generally to prevent leakage from or into the joined objects while under compression. Gaskets allow " less-than-perfect " mating surfaces on machine parts where they can fill irregularities. Gaskets are commonly produced by cutting from sheet materials, such as gasket paper, rubber, silicone, metal, cork, felt, neoprene, nitrile rubber, fiberglass, or a plastic polymer (such as polychlorotrifluoroethylene) Figure : Gaskets Name of the gasket uses

What are the main components of Automobile?

There have five basic parts for Automobile and they are given bellow: 1. Engine: Engine which is known to all as a power plant. Engine is the source of power which makes the car wheels rotate and the car move where it supply power to lubricating, fuel, electric and cooling systems. 2. Frame: Frame support the engine, body and wheels. 3. Power train: Power train transmit the power engine to the car wheels where its contain clutch, transmission, propeller shaft, axles and differential. 4. Car Body 5. Car body accessories: A car body accessory contains the heater, lights, radio, windshield wiper and convertible top raiser.

what is the difference between long shunt and short shunt dc generator?

How do they differ from normal generator? Draw their V-I characteristics and explain them? In short shunt connection the shunt field is connected directly across the armature terminals and the armature connection equals the sum of the shunt field current plus the load current . In this instance the load current flow s through the series field winding so that the load current and series field current are one and same. In long shunt connection the voltage across the shunt field is the same as the terminal voltage of the generator and current in the armature will be the current in the series field. The armature current equals the shunt field current plus the load current. A shunt generator has the field circuit connected directly across the armature. As more devices connected in parallel the load on the generator increases that the generator current increases which results decrease in terminal voltage of the generator.

Definition of Dwell Angle, Spark Angle, Firing order and Heat Path/spark plug reach

Dwell angle: It is the amount of time in degrees that contact point remain closed between each opening is called dwell angle. Spark angle: Spark plug is a device which device electric current from ignition system to combust on chamber of a S.I engine to ignite the compressed air fuel mixture in the form of spark at the end of compression stroke. Heat path/spark plug reach: Heat range is cylinder to heat combustion chamber. Firing order: Firing order is defined as the order on sequence in which firing takes place in every cylinder of a multi-cylinder engine.

Carriage and Main Parts of Carriage

Carriage: Between the head stock and tail stock that had several forms and serve to support move and control the cutting. Main Parts of Carriage : 1. Saddle 2. Cross-slide 3. Apron 4. Tool Post 5. Compound rest Common Operations of a Lathe Machine: 1. Turning: Turning is divided in two types and they are a. Straight Turning and b. Taper Turning. 2. Facing 3. Necking 4. Knurling 5. Parting 6. Thread cutting 7. Forming

Therbligs and Basic 17 motion name of therblig

Therbligs : A graphical representation of the co-ordinated activities of an operators body members. These activities ar described in terms of basic or fundamental motions known as therbligs. At the time Frank Gilbreth was doing his work in the field of motion study, he also concluded that any manual activity could be described in terms of 17 fundamental motions. This comparable to our being able to describe every word in the English language in terms of some of the 26 letters of the alphabet. Each of these fundamental motions is called a Therblig. Basic 17 motion name of Therblig : Name of Therblig Letter abbreviation Search Select Grasp Transport empty Transport loaded Hold Release Load Position Pre-position Inspect Assemble Disassemble Use Unavoidable Delay Avoidable Delay Plan Rest Sh ST G

what is PIV drive? Why is PIV drive more effective than any other system of drive?

PIV Drive: A stepless drive where the transmission of torque takes place infinitly variable without slip is called PIV drive. There are some advantages of PIV drive: there is no slip in the transmission of power. Maximum transmission of power. Speed can be changed at running condition Any range of slip can be obtain It give constant cutting speed for the above reason PIV drive is more effective than any other system of drive

Differentiate among progressive die, compound die and combination die.

Progressive die : The dies which performed two or more operations at different stages every time the ram descends is known as Progressive die. The principle advantage of Progressive die is in the number of operations that can be achieved with one handling of the stock strip. The main disadvantage is that work pieces may become “dished” as they pushed through the die as they generally have very little support. Compound die : A compound die differs from a progressive die in that it performs two or more cutting operations during one stroke of the press at one station only. Compound dies are slower in operation than progressive dies but they have advantages for certain jobs, especially where tolerance are close (1) the cutting operation, by the action of the knockout plate ,ensures flatness of the blank.2 Large parts can be blanked in a smaller press if compound dies rather than progressive dies are used. Combination dies: A die in which a cuttin

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