Plant Layout contd. & Foundry

Dear Students,
Kindly make layouts i.e. Product and Process layouts. The objectives of a good plant layout are laid down.

1.Minimising & efficiently control of material handling and transportation.
2.Bottlenecks and congestion to be eliminated for smooth and continuous flow.
3.Movement of persons to be minimised for effective utilisation of equipment & space.
4.Working place to be safe,well ventilated, and free from dust,noise, fumes & odour.
5.Waiting time for semifinished product should be minimised.
6.Cubic space should be utilised in effective manner.
7.To increase productivity with reduced capital investment.
8.To provide flexibility of manufacturing and management.
9.To allow the movement of material with desired speed and lowest cost.
10.To promote job satisfaction and good relation between management & employees.

FOUNDRY.........FORGING..........FORMING

FOUNDARY: Foundary is a place, where casting is done.Casting is a process of pouring molten metal in a cavity called MOULD.When this mould is filled with molten metal, it solidifies and produces a casting.

PATTERN:Pattern is a model of desired product(casting)i.e. constructed in such a way that it can be used for forming an impression called mould.Pattern is replica of casting.

Pattern Materials:
* Wood
* Metal(Cast Iron, Brass, Aluminium alloys & White Metal etc)
* Plaster
* Plastic Compound
* Wax

The following factors are to be considered for selection of pattern material.
1. Design of casting
2. Quality and quantity of casting
3. Shape and size of casting
4. Types of moulding
5. Types of process of casting
6. Moulding material
7. Possibility of design changes
8. Chances of repeat orders
9. Pattern material should be light in weight, easily worked, shaped and joinable.
10.It should be durable,strong, hard, resistant to wear abrasion, corrosion and chemical reaction.
11. Dimensionally stable,unaffected by variation in temprature and humidity.
12. Low cost, easily repairable and re-usable.
13. Ability to take a good finish.

Refer Casting processes figure at my site 9262k and draw of your own and write basic steps taken in a casting process as explained in the class i.e. from pattern making to dispatch of the cast product.
Main shops in the FOUNDRY.
Pattern Shop, Moulding shop and melting shop( Furnace).
Name the types of patterns and draw the figures. Write why & where are these used.
Types: Solid and single piece, Split(two Pieces), Multi-piece,Match plate, Gated, Skeleton,Sweep, Pattern with loose pieces, Cope & drag pattern, Follow board pattern and Segmental pattern.