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    CH 1-Foundry Plant Lay Out

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    gosaye desalegn
    This document provides an overview of foundry plant layout and the casting process. It discusses the importance of plant layout, including factors like material flow, costs and efficiency. There are different types of foundry layouts depending on the production process, such as job shops, flow shops and hybrid layouts. The casting process involves steps like melting metals, pouring into molds, solidification and then post-processing. Common casting methods include sand casting, permanent mold casting, die casting and investment casting. The document also outlines advantages and limitations of the casting manufacturing process.

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    CH 1-Foundry Plant Lay Out

    Uploaded by

    gosaye desalegn
    2K views29 pages
    This document provides an overview of foundry plant layout and the casting process. It discusses the importance of plant layout, including factors like material flow, costs and efficiency. There are different types of foundry layouts depending on the production process, such as job shops, flow shops and hybrid layouts. The casting process involves steps like melting metals, pouring into molds, solidification and then post-processing. Common casting methods include sand casting, permanent mold casting, die casting and investment casting. The document also outlines advantages and limitations of the casting manufacturing process.

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    Ch 1-Foundry Plant Lay Out

    Original Title

    Ch 1-Foundry Plant Lay Out

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    This document provides an overview of foundry plant layout and the casting process. It discusses the importance of plant layout, including factors like material flow, costs and efficiency. There are different types of foundry layouts depending on the production process, such as job shops, flow shops and hybrid layouts. The casting process involves steps like melting metals, pouring into molds, solidification and then post-processing. Common casting methods include sand casting, permanent mold casting, die casting and investment casting. The document also outlines advantages and limitations of the casting manufacturing process.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    2K views29 pages

    CH 1-Foundry Plant Lay Out

    Uploaded by

    gosaye desalegn
    This document provides an overview of foundry plant layout and the casting process. It discusses the importance of plant layout, including factors like material flow, costs and efficiency. There are different types of foundry layouts depending on the production process, such as job shops, flow shops and hybrid layouts. The casting process involves steps like melting metals, pouring into molds, solidification and then post-processing. Common casting methods include sand casting, permanent mold casting, die casting and investment casting. The document also outlines advantages and limitations of the casting manufacturing process.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 29
    At a glance
    Powered by AI
    The key takeaways are about the different types of casting processes and foundry layouts discussed in the text.

    The types of foundry layouts discussed are process layouts, product layouts, and combinations of both.

    Some advantages of permanent mold casting are consistent dimensions, precision and tighter tolerances. Disadvantages include the molds being very expensive to produce.

    Chapter: 1

    Foundry plant
    lay out
    1.1 Importance of plant lay out
    1.2 Aspect of foundry plant lay out
    1.3 Types of foundries and their lay
    out
    1.4 Principles of plant lay out
    1.5 Criteria of casting classification
    1.6 Classes of castings

    Introduction
    Casting is one of the earliest metal shaping
    methods known to human beings.
    Generally casting means pouring molten metal
    into a refractory mould with a cavity of the shape to
    be made, and allowing them.
    To solidify - on solidified the object is taken out from
    the mould either by breaking or by taking the mould
    apart, the solidified object is called casting.
    Thus in a single step, simple or complex shapes
    can be made from any material that can be melted.
    A casting is a shape obtained by pouring liquid
    material into a mould or cavity and allowing it
    to freeze and thus to take the form of the
    mould.

    Casting was probably discovered around 3500


    Before Christ in Mesopotamia. These moulds
    were essentially of single piece.
    Bronze age, which is estimated at 2000 BC
    brought more refinement into the casting process.
    Moulds were made of baked clay and the lost wax
    process was used for making ornaments etcetera.
    The technology was greatly improved by the
    Chinese from around the year 1500 BC.

    1.1 Importance of plant lay out


    The arrangement of physical facilities such as
    machines, equipment, tools, furniture etc. in such
    a manner so as to have quickest flow of material at the
    lowest cost and with the least amount of handling in
    processing the product from the receipt of raw material
    to the delivery of the final product. The principal factors
    are:
    Location, with respect to the marketing area
    Raw material supply
    Transport facilities
    Availability of labour
    Availability of suitable land
    Environmental impact and effluent disposal
    Local community consideration

    1.2 Aspects of foundry plant lay out


    A well designed plant layout is one that can be beneficial in
    achieving the following objectives:
    Proper and efficient utilization of available floor space
    Transportation of work from one point to another point
    without any delay
    Proper utilization of production capacity.
    Reduce material handling costs
    Utilize labour efficiently
    Reduce accidents
    Provide for volume and product flexibility
    Provide ease of supervision and control
    Provide for employee safety and health
    Allow easy maintenance of machines and plant.
    Improve productivity

    1.3 Types of Layouts


    Process layouts (Job shop):Process layout (also called
    a job-shop or functional layout) is a format in which
    similar equipment or functions are grouped together,
    such as all lathes in one area and all stamping machines
    in another.
    Product layouts (Flow shop):A product layout (also
    called a flow-shop layout) is one in which equipment or
    work processes are arranged according to the
    progressive steps by which the product is made.
    Hybrid layouts (Cellular):A Hybrid (cellular) layout
    groups dissimilar machines into work centers (or cells)
    to work on products that have similar shapes and
    processing requirements
    Fixed-Position layouts: In a fixed-position layout, the
    product (by virtue of its bulk or weight) remains at one
    location.

    Metal Production Processes

    Different metals used for


    casting

    Flow Chart of a Typical Foundry Process

    FOUNDRY: A commercial establishment for founding or


    producing casting.
    Or
    A facility that melts metals in special furnaces and
    pours the molten metal into moulds to make products.
    Foundries are usually specified according to the type
    of metal dealt with, as iron foundry, brass foundry,
    etc
    Foundries are also classified according to the nature
    of their work and their organizational framework.
    A JOBBING Foundry is one having a physical plant
    that usually contracts to produce a casting or a small
    number of castings of a given kind.

    A PRODUCTION Foundry is a highly mechanized


    shop which requires that large numbers of a given
    kind of casting be made in order to produce them
    at a low cost.
    A SEMI PRODUCTION Foundry are those in
    which a portion of the work is of a jobbing nature
    and the balance is production casting.
    A CAPTIVE Foundry is one which is an integral of
    some manufacturing company and whose castings
    are mainly for the parent organization.
    An INDEPENDENT Foundry is one which is a
    separate entity to produce castings for any
    number of customers.

    Typical Foundry layout

    Moulding

    Sand

    - pattern making
    - Core making
    - Gating system

    Mould

    Melting Pouring

    casting Heat Treat

    Furnaces Solidification

    Shakeout

    Clean

    Inspect

    Addl. Heat Treatment


    Defects, pressure tightness, dimensions

    Outline of production steps in a typical sand


    casting operation

    ADVANTAGES OF CASTING PROCESS


    Process is cheap
    More suitable for mass production
    Most suitable for manufacturing
    complex/complicated/intricate shaped products.
    Large parts weighing several tonnes and also small
    components weighing a few grams can be cast.
    No limitation on the size of component.
    Directional properties absent in castings.
    Components with uniform properties as well as
    with varying properties at different locations can be
    cast.
    By use of cores, saving in machining of holes
    achieved.
    Internal stresses are relieved during solidification in
    many types of castings.
    Even some materials which cannot be made by
    other processes made by casting: eg. Phosphor-

    DISADVANTAGES
    Dimensional accuracy and surface finish of the
    castings made by sand casting processes are a
    limitation to this technique. Many new casting
    processes have been developed which can take
    into consideration the aspects of dimensional
    accuracy and surface finish. Some of these
    processes are die casting process, investment
    casting process, vacuum-sealed moulding process,
    and shell moulding process.
    Cast product properties inferior in many cases
    when
    compared
    with
    other
    manufacturing
    processes.
    Elevated temperature working in castings, as
    material has to be melted.
    Thin section limitations exist.

    1.5 Criteria of Casting


    classification
    TYPE OF METAL,
    THERMAL PROPERTIES OF BOTH THE METAL AND
    MOULD,
    GEOMETRIC RELATIONSHIP BETWEEN THE
    VOLUME AND SURFACE AREA ,
    SHAPE OF MOULD.

    1.6 Classes of castings


    1.
    2.
    3.
    4.
    5.

    Green Sand Casting


    Permanent & Die Casting
    Investment (Wax & Foam)
    Continuous
    Centrifugal

    Sand Casting

    Pattern is formed into a sand cast.


    Liquid metal is poured into the sand
    cast.
    A sand cast is a ONE time use casting
    Mold is destroyed to remove
    casting/part

    Sand Casting
    Produce castings ofvirtually any size and
    weight.
    Common for prototyping & low volume
    production.

    Sand Mold
    Section view of mold showing spru,
    runner and gating system, risers
    (feeders), cores and pattern draft.

    Permanent Mold
    Casting

    Mold is made of iron or steel


    Molds are good for multiple uses
    Used when poring large quantities of
    identical parts

    Permanent Mold Casting


    Advantages: Consistent, Precise, tighter
    tolerances
    Disadvantages: very expensive to produce
    molds

    Permanent Die Casting


    Similar to permanent mold casting
    except that the metal is forced into the
    mold under pressure
    Large quantity production.

    Investment Casting (Lost Wax)

    Over 1,000 year old technology


    Pattern is made of wax.
    A ceramic shell is built around the wax pattern.
    Wax pattern is melted out of the shell.
    Molten metal is poured into the shell.

    Investment Casting (Lost


    Foam)

    Styrofoam pattern is coated with a


    refractory material and dry sand is
    compacted around pattern.

    Metal is poured
    onto the foam &
    instantly
    vaporized.

    No draft required

    Continuous Casting
    Used to make large steel fixtures (iron
    plates, beams)
    Metal is melted in hopper & gravity fed
    Metal taken as needed
    Unused metal recycled into hopper

    Centrifugal Casting
    Used to produce
    objects with large
    holes such as cast iron
    drain pipe
    Mold is spun ~ 1000
    RPM
    Impurities gravitate to
    the inside surface
    Impurities machined
    off

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