Top 3 Future trends in Casting or Manufacturing Company

Casting  or Manufacturing Company is considered most important for development of any nation. If we look a decade ago, we have changed a lot. However there are some major changes that are going to take place in industrial units. Here are top 3 Future trends in casting industry.

• Use of Aluminum instead of steel: - Aluminum metal is considered costly but very few of us know it is more worthy and efficient than steel. The presence of raw materials is more in nature for manufacturing aluminum than steel. Also every year world increases the production of aluminum to meet the demands.
• Use of Artificial intelligence due to lack of skilled workers:- Skilled workers can help industry owner to manufacture more goods and products in less time than unskilled worker. After covid 19 laborers have moved to their native place which has given rise to lack of skilled workers in industry. In such situation industry owners will invest in implementation of artificial intelligence to overcome the need of skilled workers for casting process and manufacturing Valve and its parts.
• Digitalizing the various departments in Industry for proper, reliable and faster synchronization. - In a casting or manufacturing industry we find many departments in hierarchy. If there is lack of synchronization of various department or there is some delay due to verification process then it can be made faster by digitalizing the various department. Till now we only use spy camera for security concerns but now we can also use digital media to reach those areas which is hazardous for human beings. Use of ai robots, drones etc are just a step to such development.

Conclusion: In upcoming years we are going to see a lot of changes in the field of investment castings company worldwide. Use of Aluminum instead of steel, Artificial intelligence in production unit, and digitalization of every departments in  casting manufacturing Industry will be very common.

Valves: Definition, Its Function, Classifications, Advantages & disadvantages

Valves plays important role in any manufacturing industries. It is the most important mechanical device that is used in small, medium and large scale industries. The industry that manufactures valves and its components to other industries is often called valve manufacturing industry. 

Definition of Valve

A valve, in mechanical engineering, is a device that controls the flow of fluids (liquids or gases) in a pipe or other closed area.

Function of Valve

•  The suspension and start of the flow of liquid or gas is the responsibility of the Valve.
•  Reduce or increase the flow of gas or liquids.
•  Controlling the flow of gas, liquids.

Major Components of Valve

· Hand wheel:-A hand wheel is usually required to use the valve by hand, when starting a process or in an emergency; or sometimes a hand wheel is used to limit valve movement.

· Stem:- The valve stem is an automatic valve that opens the gas chamber (such as air to inflate the tire), and then automatically closes and is kept closed at room pressure, or spring, or both, to prevent gas from escaping.

· Packing Rings:- Control Valve Packing is a marking system that usually has a defective object, in the form of solid or separated rings contained in a packing box. The packaging materials are pressed to provide a signal of active pressure between the liquid in the valve body and the outside air.

· Bonnet:-A meeting that includes the part where the stem of the plug goes with the ways to book a leaky block near the stem. The frequency provides the mechanisms for installing the actuator. Leak markings can be obtained by packing or spraying.

· Body:- The valve body, sometimes called the shell, is the main boundary of the pressure valve. It serves as a key part of the valve organization because the structure keeps all the components together. The body, the first pressure limit of the valve, withstands a lot of pressure loads on the pipe connection.

· Gate:- A gate valve is usually used to completely close the flow of liquid or, in a completely open area.

· Gate Seats:- Gate valve has two seats that protect the signal through the gate. The gate valve has two seats that make a mark on the gate. Like ball valve seats, a seal can be constructed with an O-ring, a double solid insert or a metal seal.

Classification of Valves

·         Classification on the basis of Isolation: Gate valve, Plug Valve, Piston Valve Diaphragm valve, Butterfly valve, Pinch Valve.

·         Classification on the basis of Regulation:- Globe, Needle, Butterfly, Diaphragm, Ball, Plug Pinch.

·         Classification on the basis of Safety Relive Valve: Pressure relief, Vacuum relief.

·         Classification on the basis of Non return: Swing, Lift check valves

·         Classification on the basis of Special purpose: Multi port, Float, Knife gate, Line Blind valves.

Advantages of Butterfly Valves

· Turns Quarterly

· Has Open port

· Used with chemical or corrosive Material

· Integrated, lightweight design

· Available in larger sizes

· Drop in low pressure and recovery in high pressure

· High flow coefficient

Disadvantages  of Butterfly Valves

·         It is difficult to clean

·         Problem due to slurries

·         Throttling or Folding limited to low differential pressure

·         cavitation and possible congestion

·         Unguided disc movement is affected by flow turbulence.

Conclusion: We should select the right valve in setting up of industry. The right choice becomes essential as different types of valves have their own advantages as well as disadvantages. Mangal Steel Castings is the renowned Valve manufacture in Rajkot, Gujarat, India that manufactures valve and valve components for small scale industry, medium scale industry as well as large scale industry.

In case you want to install Valves in your manufacturing industry then you can contact sales team of Mangal steel castings now.

Comprehensive Guide To Steel Casting Process

 

Steel casting is the process of creating steel by pouring molten steel into a mold cavity. In the steel casting process, liquid steel is slowed down to moderate temperature and is allowed to solidify in the mold cavity and is then detached for cleaning. However, heat-treating may be needed to meet the specific properties of the cast steel. In this article, we have briefly discussed the steel casting process used by steel castings company in India.

Types of patterns used in steel casting:

·        Wood patterns: 

These patterns are comparatively less expensive than other materials but are ideal for limited and prototypes production. They can quickly be modified to plastic if there is an increment in the production requirements.

• Metal patterns:

These patterns are costly, but they are needed for high-volume production. However, the material can be bronze, brass, aluminum, iron, etc. The cast aluminum is the most typically utilized material for standard volume requirements. Therefore, metal patterns are needed for both molds or cores generated by the shell process.

• Wax patterns:

These patterns are utilized in the lost wax, or investment, molding process. This process uses dies to create the patterns. The wax patterns are covered with a ceramic slurry to make a shell. Further, the wax is then detached by heat.

• Form patterns:

These patterns may be utilized in the bonded sand or ceramic molding systems. In the bonded systems, inexpensive alternatives for other robust materials and ceramic systems may be alternatives for wax.

The above-given types of patterns used in the steel castings company in India can opt for foam, wood, plastic, wax, metal, etc. The choice is based on the size of parts, quantity, cost, molding method, and casting tolerances needed.

Molding processes involved in steel casting:

Following are some of the molding processes involved in steel casting:

• Greens and molding:

It is one of the broadly used systems, and because of automation in various green sand foundries, the very affordable process. Clay and water in the sand enable molds to be generated with a high degree of firmness and accuracy in the mold cavity.

• Shell molding:

It utilizes a heated pattern and resin bonded sand to generate a fused sand mold with incredible detail and dimensional accuracy. Material and power prices are high than green sand. Hence, this process is not ideal for larger castings.

• Chemically bonded molding:

It utilized sand and other various gases or chemicals to make a dry hard mold. However, the dimensional accuracy is also good, and the process is ideal for all sizes of parts. Therefore, the sand recoupment price is high, and comparatively, the process is costly than green sand.

• Vacuum molding:

It utilized unbounded dry sand. The mold depends on the vacuum of its firmness; the vacuum must be controlled during cooling and pouring. This process can create all sizes of parts, surface appearance and accuracy are also good.

• Investment casting:

Investment casting is also called lost wax. It used a foam or wax pattern by an exact metal mold. Multiple patterns are rooted to a tree and further immerse it into a ceramic slurry. Consequent drying and immersing generate a thick shell of ceramic which changes into the mold. The foam or wax is detached by heat before pouring. This process is restricted to minor castings and is eventually not competitive unless some machining can be terminated.

• Graphite molding: 

Graphite molding employs semi-permanent graphite molds. Dimensional surface appearance and control are excellent. It is ultimately a specialized process ideal mainly for railroad wheels parts.

• Centrifugal molding:

This step generates parts from molten metal that are poured into rotating molds. The rotation of the mold provokes the metal to be grasped to the internal diameter of the mold. It is typically suited for symmetrical configurations and pipes.

• Ceramic molding:

Ceramic molding uses a composition of the catalyst, hydrolyzed ethyl silicate, and refractory materials, which are further poured over a pattern. Therefore, the ceramic shell is cleaned before entirely setting, then fired and arranged for pouring. This process generates a fantastic surface accuracy and appearance, and it is reshaped explicitly to blades, turbines, and manifolds.

Melting and pouring operations used in steel casting:

In the steel casting process, multiple types of melting furnaces are utilized in the production, which is briefly discussed below:

• Electric arc furnaces:

Electric arc furnaces are accountable for producing most of the steel castings (84%). These units comprise a refractory lined roof, steel shell, and refractory covering three gaps for graphite electrodes. The heat achieves the melting from the electric arc. Ultimately the EAF is the most feasible unit for melting steel in that the charging substance can be assorted, and the steel can be distilled in the furnace before tapping.

• Electric induction furnaces:

This step is the most customary unit for minor production quantities. The furnace contains a steel shell with a refractory coating encompassed by a copper coil. An electric current produces heat in the oil.

• Finishing and heat treating:

When a casting has set at a moderate condition, it is unsettled out of the mold. Before it is shipped, it must be cleaned or finished. The first procedure is an abrasive blast which cleanses the surface of all excess mold. Then the extrinsic gating system metal and fins are detached by grinding or sawing and torch cutting. Welding disjointedness is the usual practice in the steel casting industry. 

Next is the heat treatment process, which is used to improve the properties of particular alloys. The scale processed on casting surfaces during heat treatment is detached by abrasive blasting. Steel castings can be neatened by pressing if warpage happens during processing. Overall this operation assures the dimensional precision of the finished part.

• Pre-machining:

Rough or pre-machining has become very familiar in the steel castings company in Indian factory foundries. When the client needs a very exact location of reduced finish stock or finish stock, the foundry can run a pre-machining operation to offer the desired attributes. However, several foundries can also supply components in the finish machining condition.

• Process tolerances and capability:

This step depends on multiple factors like mold material, straightening, pattern quality, pre-machining, etc. all these can affect tolerances. The potential to control the casting process is ultimately vital in today's period.

Conclusion:

We have learned briefly about the steel casting process and the pattern types used by the steel casting manufacturers in India in the above-given information. So implement the above processes and patterns wisely while doing steel casting.