DESIGN FACTOR OPTIMISATION APPLIED TO CASTING OF DEAD WEIGHT OF GINNING PRESS

Mr. Pawan M. Kurwade; Mr. Abhishek K. Anasane; Mr. Saurabh M. Paropate; Mr. Sandip S. Kongre

doi:10.17605/OSF.IO/W92P8

Authors

Mr. Pawan M. Kurwade Assistant Professor, Department of Mechanical Engineering, Sipna COET, Amravati, Maharashtra, India
Mr. Abhishek K. Anasane Assistant Professor, Department of Mechanical Engineering, Sipna COET, Amravati, Maharashtra, India
Mr. Saurabh M. Paropate Assistant Professor, Department of Mechanical Engineering, PRMIT&R, Amravati, Maharashtra, India
Mr. Sandip S. Kongre Assistant Professor, Department of Mechanical Engineering, PRMIT&R, Amravati, Maharashtra, India

DOI:

https://doi.org/10.17605/OSF.IO/W92P8

Keywords:

Casting, Gating System, Dead Weight & Ginning Press.

Abstract

The gating system refers to those channels through which the metal flows from the ladle to the mould cavity. The use of a good gating system is even more important if a casting is produced by a gravity process. One of the key elements to make a metal casting of high quality is the design of a good gating system. It could be even worse, if the molten material is a sensitive metal for receiving damage during the filling, because of dross and slag formation. If poor gating techniques are used, invariably, lower casting quality is achieved, because of damage on the molten metal received during the flow through the gating system. The purpose of this study is to identify the problem associated with gating system for the manufacturing of ginning dead weight which is used for their machineries at Jadhao Steel Alloys, Amravati. The typical casting defects were identified in which the shrinkage defect, blow holes, pin holes, gas holes, sand inclusion and miss run defects etc. are prominent. As the total percentage of defect being around 25-30 % of the total casting produced. It means total % of rejection is around 25-30% which is very high and not acceptable. After careful investigation of the casting process, it was found that all the above defects can be considerably reduced by using a proper gating system. Hence optimization of gating system is considered as a main topic of investigation. According to deep study and analysis of existing gating system used by industry, it was found that old gating ratio was incorrect and after gating system calculations it was found that the total of weight of gating system is very high that has to reduce considerably. After careful observation and analysis of existing gating system used by industry, it was decided to make necessary changes in the design and dimension of gating system. By using proposed gating system, the experiment has been carried out at Jadhao Steel Alloys, Amravati. The result found after experimentation are very sound and productive.

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