Investment Casting - Vijay Rathod
Investment Casting - Vijay Rathod
Project Report
On
SHAPAR – RAJKOT
-: Submitted To:-
K.N.V.INSTITUTE OF BUSINESS MANAGEMENT
Kalawad Road,
Metoda,
Unless and until the principles and theories of management are not
applied in the practical field the managers would not be Successful in managing. In reality,
theoretical and practical Aspects are different in business keeping in view the fact of
Increasing complexity in business environment idea of practical training has been introduced
in the course of MBA. One needs to be very practical in today‘s fast moving and expanding
Market.
The aim of this training is to get an outlook of what we study inside the
class. Also management disciplines are very dynamic so only classroom study would not help
to grasp the entire Knowledge and therefore the students of MBA. Have practical training as
a vital aspect – ‗Applied knowledge is power‘.
According to me, these type of training shows the actual path before
one step toward it. Because it has been said ―well begun is half done‘‘ and for us it was
perfect beginning.
DECLARATION
I also declare that this report has been not submitted to any other
organization or university for the award of any degree.
DATE: SIGNATURE
SEM-III
ACKNOWLEDGEMENT
Since efforts are always needed from many people to give life to the project work, and
I gratefully acknowledge my debt to those who contributed to the same.
Firstly I would like to thank Mr. Kanubhai Patel (Managing Director) for giving me an
opportunity to show my talent and utilize my knowledge along with practical experience in
their company
I would like to thank Mr. Jasmin Kachhadia (Marketing Manager) for giving me an
opportunity to work on the Summer Project “ORGANISATION STUDY OF PREVAIL
CASTING PVT. LTD.” Which has proved to be great experience learning for me.
RAJKOT
Certificate
I hereby certify that Rathod Vijay Ashwinbhai student of MBA Sem. III has completed
THE study of master degree is not related with only theoretical aspects but
management people must know how to handle the organization and study of it in a practical
life. For this purpose I have selected and gone in manufacturing sector and have been
approved to get this training in ‗Prevail Casting Pvt. Ltd‘
Initially I have been inducted towards the entire organization as any employee
gets the induction program training. After it I have started my organizational study and have
gone through every departments of the organization. As I was in manufacturing unit I have
passed my maximum time in to understand production department and its products and
services of the organization. I have been explained the entire process of investment casting
step by step and various other sub processes of other products of the organization. The
operating system of the machinery and dispatch of finished goods. I have also seen
practically as its manufactures unit laboratory testing has to be there of finished goods which
I have been taught has to tested the products in it.
During this one & half month I have got an experience about working
condition of investment casting industry in Prevail Casting Pvt. Ltd. where I have met many
experience people who gave me knowledge of various departments.
INDEX
A. EXECUTIVE SUMMARY 1
B. INDUSTRIAL ANALYSIS 2
D. INTRODUCTION 12
E. DETAILS OF DEPARTMENTS 17
PRODUCTION DEPARTMENT 20
MARKETING DEPARTMENT 59
FINANCE DEPARTMENT 68
ADMINISTRATION DEPARTMENT 73
H. BIBLIOGRAPHY 83
BACKGROUND
The types of materials that can be cast are Aluminum alloys, Bronzes,
tool steels, stainless steels, Satellite, Hastelloys, and precious metals. Parts made with
investment castings often do not require any further machining, because of the close
tolerances that can be achieved.
The technique of investment casting is both one of the oldest and most
advanced of the metallurgical arts. Investment castings are at work in the fiery combustion
chambers of jet aircraft and in the sub-zero vacuum of space. Yet, the root of this technology,
the cire perdue or ―lostwax‖ method dates back to at least the fourth millennium B.C. The
artists and sculptors of ancient Egypt and Mesopotamia used the rudiments of the investment
casting process to create intricately detailed jewelry, pectorals and idols.
Remarkably, civilizations as diverse as China‘s Han Dynasty, the
Benin Kingdom in Africa and the Aztecs of pre-Columbian Mexico employed similar
techniques. The cross-cultural adoption of this complex process implies a great degree of
commerce and communication in antiquity. In Renaissance Europe, the Italian Sculptor,
goldsmith and author, Benvenuto Cellini, cast his bronze masterpiece ―Perseus and the head
of Medusa‖ using the lost wax process. Cellini detailed his achievement in his famous
autobiography, one of the classics of world literature. The investment casting technique was
largely ignored by modern industry until the dawn of the twentieth century, when it was
―rediscovered‖ by the dental profession for producing crowns and inlays. The first
authenticated record of the use of investment casting in dentistry appears in apaper written by
Dr. D. Philbrook of Council Bluffs, Iowa in 1897.
However, the true significance of this process was not realized until
Dr. William H. Taggart of Chicago published his research in 1907. During World War II,
with urgent military demands overtaxing the machine tool industry, the art of investment
casting provided a shortcut for producing near-net-shape precision parts and allowed the use
of specialized alloys which could not readily be formed by alternative methods. The
investment casting process proved practical for many military components—and during the
postwar period it expanded into many commercial and industrial applications where complex
metal parts were needed, however, the process was still relatively obscure. It was in this
period that Hitchiner Manufacturing Co., Inc. was founded. In the decades that followed,
many innovations such as the shell process, the steam autoclave, conveyorization,
automation, and robotics have modernized and transformed the process. In today‘s world,
investment castings touch all of our lives. When we fly on an airplane, drive an automobile,
play golf, use a utility tool, power tool or hand tool, we are using investment castings.
Investment Casting in the UK
Investment casters in the UK produce about 12% of world production, and by value the
industry accounts for 13-14% of UK casting output (significantly more than steel castings).
These are impressive figures and confirm the growing importance of investment casting.
Lost wax casting has been used for at least six millennia for sculpture
and jewellery. About 100 years ago, dental inlays and, later, surgical implants were made
using the technique. World War II and then the introduction of gas turbines for military
aircraft propulsion transformed the craft into a modern metal-forming process.
Our key products are Investment castings by Lost Wax Process as per
customers‘ requirements. We can supervise Investment Casting parts with weight from a few
grams to 90 kg for a lone portion. We can furnish the fully machined castings in equipped to
assemble stipulation.
Prevail Casting is a foremost producer of investment casting.
Established in1991, Prevail Casting employs the lost wax process while playing the part of
the versatile manufacturer. Our expertise, know-how and technology are founders of an
era of experience in production of investment casting.
Our key products are Investment castings by Lost Wax Process as per
customers‘ requirements. We can supervise Investment Casting parts with weight from a few
grams to 90 kg for a lone portion. We can furnish the fully machined castings in equipped to
assemble stipulation.
COMPANY PROFILE
RAJKOT 360001
PH-91-281-2480025
FAX : +91-2827-252271
E-MAIL : [email protected]
[MARKETING EXECUTIVE]
Mob. :+91 98795 81285
BRANCH OFFICE Mr. RAJIV PURI
ADDRESS:
[GENERAL MANAGER-MARKETING, WESTERN
INDIA]
PIMPALE SAUDAGAR
AUNDH ANNEXE
PUNE-411027
Email : [email protected]
YEAR OF
ESTABLISHMENT: 1991
CAPITAL
INVESTMENT: 8.3 CRORE (APPX.) IN INR
SINGLE PIECE
WEIGHT
BOARD OF DIRECTORS
Of
There are many different departments in the company, their name & details are
below.
PRODUCTION DEPARTMENT :
PRODUCTS
ISO CERTIFICATES
PROCESS
LABORATORY
LABORATORY CERTIFICATES
MACHINERY
STORAGE DEPARTMENT
MARKETING DEPARTMENT :
MARKET RESEARCH
ORGANIZATIONAL STRUCTURE
FINANCIAL DEPARTMENT :
ACQUISITION OF FUNDS
ORGANIZATIONAL STRUCTURE
FINANCIAL PLANNING
ADMINISTRATION DEPARTMENT:
TRAINING
CLUTURAL ACTIVITIES
Definition of Production
“The production function relates the output of a firm to the amount
of inputs, typically capital and labor.’’
It is important to keep in mind that the production function describes
technology, not economic behavior. A firm may maximize its profits given its production
function, but generally takes the production function as a given element of that problem. (In
specialized long-run models, the firm may choose its capital investments to choose among
production technologies.)
Casts can be made of the wax model itself, the direct method; or of a wax copy of a model
that need not be of wax, the indirect method. The following steps are for the indirect process,
which, in total, can take two days to one week to complete.
Produce a master pattern: An artist or mold-maker creates an original pattern from wax, clay,
wood, plastic, steel, or another material.[2]
Moldmaking:
A mold, known as the master die, is made of the master pattern. The
master pattern may be made from a low-melting-point metal, steel or wood. If a steel pattern
was created then a low-melting-point metal may be cast directly from the master pattern.
Rubber molds can also be cast directly from the master pattern. The first step may also be
skipped if the master die is machined directly into steel.
The wax pattern is then removed from the mold. Depending on the
application multiple wax patterns may be created so that they can all be cast at once. In other
applications, multiple different wax patterns may be created and then assembled into one
complex pattern. In the first case the multiple patterns are attached to a wax sprue, with the
result known as a pattern cluster, or tree; as many as several hundred patterns may be
assembled into a tree.[3] Foundries often use registration marks to indicate exactly where
they go.[citation needed] The wax patterns are attached to the sprue or each other by means
of a heated metal tool.[2] The wax pattern may also be chased, which means the parting line
or flashing are rubbed out using the heated metal tool. Finally it is dressed, which means any
other imperfections are addressed so that the wax now looks like the finished piece.
Investment:
The binders used to hold the refractory material in place include: ethyl silicate (alcohol-based
and chemically set), colloidal silica (water-based, also known as silica sol, set by drying),
sodium silicate, and a hybrid of these controlled for pH and viscosity.
Dewax:
The mold is then subjected to a burnout, which heats the mold between
870 °C and 1095 °C to remove any moisture and residual wax, and to sinter the mold.
Sometimes this heating is also as the preheat, but other times the mold is allowed to cool so
that it can be tested. If any cracks are found they can be repaired with ceramic slurry or
special cements. The mold is preheated to allow the metal to stay liquid longer to fill any
details and to increase dimensional accuracy, because the mold and casting cool together.
Pouring:
The investment mold is then placed cup-upwards into a tub filled with
sand. The metal may be gravity poured, but if there are thin sections in the mold it may be
filled by applying positive air pressure, vacuum cast, tilt cast, pressure assisted pouring, or
centrifugal cast.
Removal:
Valve Parts include Investment Castings for Butterfly Valve, Globe Valve, Gate Valve, Ball
Valve and Valve Actuators in Steel and Stainless Steel. The smooth surface offered by
Food Industries Parts includes Investment Casting Parts for Food Processing Machineries and
Equipments, mostly made of Stainless Steel. The parts are supplied with Vibro Polishing and
Glass Bead Blasting to improve surface finish.
GENERAL ENGINEERING
MACHINED PARTS
5. I. B.R. Approval
Industries Served
Automotive/Transportation
Material handling
Machine tools
Food processing
Electronics
Art
Toys
Marine
Robotics
Defense
Medical products
Hand tools
scientific instrumentation
INVESTMENT CASTING PROCESS
IN
PREVAIL CASTING
Once the casting has cooled sufficiently, the mold shell is chipped
away from the casting. Next, the gates and runners are cut from the casting, and final
postprocessing (sandblasting, machining) is done to finish the casting. It shows the CAD
solid model, the shell, and the pattern produced in the QuickCast process.
CAD solid model (top), ceramic shell with Quick Cast pattern (left),
This detailed explanation of the investment casting process is intended to help our customers
learn about investment casting to be able to make better purchasing decisions.
WAX INJECTION
Replicas of the desired investment casting are produced by injection molding or for smaller
volumes using rapid prototyping (SLA or SLS). These replicas are referred to as patterns.
Patterns are then attached to a central wax stick, called a sprue, to form a casting. This is called a
wax tree.
The shell is built by immersing the wax tree assembly in liquid ceramic slurry and then into a bed
of fluidized fine sands. Up to eight layers may be applied in this manner depending on the shape
and weight of the part.
DEWAX
Once the ceramic is dry, the wax is then melted out, creating a negative impression of the
assembly within the ceramic and sand shell. This process uses autoclaves to maintain shell
integrity.
CONVENTIONAL CASTING
In the conventional lost wax casting process, the preheated shell (up
to 1800 deg F) is filled with molten metal by gravity pouring the
metal into the ceramic shell. As the metal cools, the parts, gates,
sprue and pouring cup become one solid casting. Shell temperature
and melt temperature will vary depending on the alloy. Transfer Ladel
KNOCKOUT
Once the metal is cooled and solid, the ceramic shell is broken off by
vibration or water blasting.
The parts are then cut away from the central sprue using a high speed saw.
FINISHED METAL INVESTMENT CASTINGS
After minor finishing operations, or possible required machining operations, the metal
investment castings--identical to the original wax patterns--are ready for shipment to the
customer from our metal investment casting China foundry. We are able to provide finished
stainless steel investment casting, steel investment casting, aluminum investment casting, cobalt
alloy investment casting, nickel alloy investment casting and precision investment castings.
WALL THICKNESS
Please call for tolerance specifications for wall thickness or any tolerances in general. Depending
on the metal or alloy, minimum wall thickness can range from 0.04 inches to 0.08 inches.
Tool-Room:
Prevail Casting supports in-house Tool Room to make dies with the shortest lead time for
sample production. We have CAD/CAM facility for die designing and manufacturing by
using 5-axis and 4-axis VMC from DMG, Germany.
LABORATORY
Chemical Testing:
Tensile Testing
Hardness Testing:
3. Inclusion Rating
5. Volume Fraction
CAPACITY MAHARASTRA
Our DMG, Germany makes VMC's with 5-axis and 4-axis machining
ability and Gildemeister; Germany creates CNC-Turning Machines. We have domestic
Fixture design and manufacturing facility as well and provide ―5-axis machining‖ and ―4-axis
Machining‖
These two different types of product like; sand casting & investment casting. Their
product are totally different each other in sand casting there are heavy weighted and
widest out look prouct and other side investment casting means wax product is also
very heavy weight but out look is small size product.
STORAGE DEPARTMENT:
Company has large capacity to store raw material of production process. They maintain
goods input as well as output register.
SEGMENT WISE PERFORMANCE:
All asset and resource are acquired economically, used efficiently and are adequately
protected.
Significant financial, managerial and operating information is accurate, reliable and is
provided timely; and
All internal policies and statutory guidelines are with complied.
The company has an Audit Committee which regularly reviews the report submitted by
internal Audit team. Company has an internal control system towards achieving
efficiency.
MANAGEMENT CONTROL:
In this part company has selected one manager, who is work for
company‘s all employees including managers and workers. A manager of personnel
department is timely visit to all members of the organization for their work condition and
work environment. They always guide about create healthy working environment, make good
relationship with all other members.
LIST OF MACHINERIES
2 -
SEMI AUTOMATIC MAYUR
WAX ENGINEERIG 13
INJECTION PRESS
3
HEAT TREAMENT COMPUTERISED PATEL FURNACE 2
FURNACE
75 Kg. OF 30 KW & AND SHOT BLASTIG
150 Kg. OF 75 KW
4 MODEL NO. 649. GALA
SHOT BLASTING 1
(80 Kg.) MANUFACTURER
MACHINE
5 VB 625 R/D
MEC SHOT
VIBRO POLISHING 2
BLASTING EQUIP
MACHINE
6 - DECKEL MAHO
GLASS BEAD (GERMANY) 1
BLASTING
7 VERTICAL
WORKING AREA
DECKEL MAHO
(X/Y/Z:630/560/560) 1
MACHINING (GERMANY)
CENTRE (5-
AXIS)
8 VERTICAL
DECKEL MAHO
WORKING AREA (GERMANY) 1
MACHINING (X/Y/Z:730/560/560)
CENTRE (4-AXIS)
Alloy Handled
Carbon Steel: SAE - 1020, 1030, 1040, 4140, WCA, WCB, WCC,
LCA, LCB,EN-8, EN-9, EN-36,
Austenitic Stainless Steel: CF8 , CF8M , CF3 , CF3M, CF8C, CF8 (NM),
CF3M (NM), CK-20, CN-7M (Alloy 20)
TOLERANCE
Applicable Reference Tolerance standards are IS 11166, ISO 2768,
VDG-P690.DIN1680, and Class 2.
DIMENSIONAL TOLERANCE:
Dimension (mm) Tolerance (mm)
Up to 25 ± 0.125
25-50 ± 0.25
50-75 ± 0.375
75-100 ± 0.5
100-150 ± 0.75
150-200 ±1
200-250 ± 1.25
250-300 ± 1.5
FLATNESS:
Dim As CAST Mechanical Straightened
Range (mm) (mm)
Upto 25 0.15 0.1
mm
50 0.2 0.15
75 0.3 0.2
100 0.4 0.25
150 0.55 0.4
200 0.9 0.7
CONCENTRICITY:
Computer-Aided Approach
The modern approach to investment casting development is a result of
two major factors. The first is the customer demand in terms of quality consistency (mainly
conformance to geometry and property specifications), shorter lead-time (for sample part as
well as regular production) and continuous reduction in cost (essentially tooling development
and manufacturing costs, since material costs are usually fixed). These cannot be satisfied by
conventional approaches alone.
The next step is to decide the best design and layout of feeders and
gating system. The feeder design involves identifying the last solidifying region (hot spot)
inside the casting and placing a top or side feeder with appropriate shape and dimensions. The
modulus principle may be used for the first approximation, but it has to be verified and
optimized by casting solidification simulation.
Several definitions have been proposed for the term marketing. Each tends to emphasize
different issues. Memorizing a definition is unlikely to be useful; ultimately, it makes more
sense to thinking of ways to benefit from creating customer value in the most effective way,
subject to ethical and other constraints that one may have. The 2006 and 2007 definitions
offered by the American Marketing Association are relatively similar, with the 2007
appearing a bit more concise. Note that the definitions make several points:
Marketing:
The directors of this company are engaged in business over 11years in this district.
The market is tremendous and the said is globalizing all over India.
Therefore the marketing at any level or at any production capacity and management
is very much hopeful to achieve the same without any difficulties and shall be able to face the
competitions easily.
Market segmentation is the art of diving a market in to distinct groups for buyers who
might require separate products and marketing mixes is called on.
Since, the company have only one product, the market cannot be segmented either of
demographic of physiographic bases. So the company has segmented its market has been
divided in to two zones.
NATIONAL MARKET:
INTEERNATIONAL MARKET:
A company not only deals with local or national market but also as
well as International Market like Tyco valves & controls, USA.
Market Research
Marketing research is the function that links the consumer, customer, and public to
the marketer through information--information used to identify and define marketing
opportunities and problems; generate, refine, and evaluate marketing actions; monitor
marketing performance; and improve understanding of marketing as a process. Marketing
research specifies the information required to address these issues, designs the method for
collecting information, manages and implements the data collection process, analyzes the
results, and communicates the findings and their implications.
Market research will minimize risk - Market research can help shape a
new product or service, identifying what is needed and ensure that the development of a
product is highly focused towards demand.
―Set of procedures and practices employed in analyzing and assessing marketing information,
gathered continuously from sources inside and outside of a firm. Timely marketing
information provides basis for decisions such as product development or improvement,
pricing, packaging, distribution, media selection, and promotion‖
ORGANISATIONAL STRUCTURE
Managing Director
C.E.O
General Manager
Marketing Manger
Clerks
Assistance
SALES FORCE MANAGEMENT:
Prevail Casting Pvt. Ltd. has get permission to sale their product in
INTERNATIONAL or FOREIGN MARKET. A company is export their product in many
country like USA, EUROPE and other country.
In our present day economy, finance is defined as the provision of money at the time when it
is refer to every enterprise, whether big, medium of small, needs finance to carry on its
operations and to ach targets. In fact, finance is so indispensable today that it is rightly said to
be the lifeblood of an enterprise. The adequate finance, no enterprise can possibly accomplish
its objectives.
The main aim of finance function is to assess the financial needs of an enterprise and then
finding out suitable sources for raising them. The sources should be commensurate with the
fields of the business. If funds are needed for longer periods then long-term sources like share
capital ventures term loans may be explored. A concern with longer gestation period should
rely more on owner instead of interest-bearing securities because profits may not be there for
some years.
ORGANISATION STRUCTURE
Managing Director
C.E.O
General Manager
Accountant
Clerks
Assistant
FINANCIAL PLANNING
It is the process of estimating the firm‘s future financial requirement. It also refers to the
source by which requirement can be fulfilled. It also speaks the fund flows, when we get and
how to utilize and thus it covers the following activities.
The planning problems are the most crucial point for financial manager
and top executives. Here, Prevail Casting Pvt. Ltd. adopts long term as well as short term
plans as per financial requirement.
ADMINISTRATION DEPARTMENT
PRIMARY HEALTHCARE:
In this area when any person feel can not well about their health, so company provides
primary healthcare treatment to the person.
TRAINING:
PREVAIL CASTING PVT. LTD. has also provide some extra facility
to their employees like; Transportation Facility
SWOT means:
S : - Strength.
W : - Weakness.
O : - Opportunity.
T :- Threat.
STRENGHTS:
Well-maintained infrastructure.
Dedicated, Intelligent and Loyal
This Company has nationally as well as internationally
Market for their products.
They have very different and monopoly type product line.
Wide product range to enable the clients to choose the best alternative.
WEAKNESS:
The major weakness of ―PREVAIL CASTING PVT. LTD.‖ can be said Raw
Materials‘ used to produce the product is very high fluctuate items because of
Company never compromise in any types of Raw material to produce any
product
OPPORTUNITIES:
Large potential market for delivery and more opportunity in national market as
well as international market.
Today day by day the demand of product of the company increases
tremendously. This affects the demand for auto parts.
The Foundry industries depend upon how the raw material prices fluctuates
and respective hike in the sales price of finished products, they further depend
upon competition among various segments of manufactures within country
and from manufacturers of outside the country.
THREATS:
Threats are always at your doorstep wherever you are going to do something. The
major threats that can be categories as natural calamity as well as the action taken
by the competitors.
Company‘s Basic raw material is SCRAP & WAX SILICON SOL, MAGNESIA
POWDER, DREGS REMOVING MATERIAL, SILICA STEEL Prices of
SCRAP & all the mixtures are fluctuating, in furtherance cost of electricity and
cost of labor through under watch they are also matter of concern.
Fluctuating trend in the price of fuel (Diesel, L.P.G.) is always matter of concern
for every industry as to outs.
Above this competition in the industry has increased, which has made it hard to
raise the price of product through cost of the final product is higher.
Change in Government Policy, Foreign Exchange rate may affect the company.
However company is trying to minimize certain risk by taking the steps, which are
in the hand of company.
FINDINGS & SUGGESTION
FINDINGS:
They are appointing only technical persons who operate a CNC machine for
production process.
SUGGESTION:
Control ‖
WEBSITE
www.prevailcasting.com
www.google.com
www.wikipedia.com
www.wtec.org
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