PROCESS | MADHURAM TECHNOCAST

MELTING SHOP

Madhuram Technocast Melting process consists of two Induction thermal make medium frequency induction furnaces with following ratings and capacity:

The Melting has 500 Kgs.
Another is 300 Kgs.

Madhuram Technocast is an ISO 9001:2008 affirmed Company by TUV (Quality Certification and PED for assembling and supplying of castings Both C.I & S.G Iron).

We have been assembling and supplying quality Grade Cast Iron for every single Engineering Component, Valve Industry, Pump Industry, Electric Motor-Body Parts Casting, Automotive Segments Casting, S.G. Casting and so on. Products modification can be provided at the request of prospect customers.

GREEN SAND

GREEN SAND MOULDING is commonly used in the casting of aluminum, brass/bronze, and iron products throughout the entire Casting Industry & World Wide. Simply put, there is a top, a bottom, and a middle to a mould. The pattern, or impression device, sits in the middle of the mould, and later is surrounded with sand.

These are the basic universal casting components, which can be applied to all casting processes. The top and the bottom of the pieces of the mould form the flask. The flask assembly, the top and bottom, “holds the whole thing together”. The upper or topmost section of the flask of the mould (flask) is called the cope, while the bottom of the mould (flask) is called the drag. The impression device, in the middle, is called the pattern. The sand around the pattern is called the, holding medium. The mould maker uses the pattern to make the impression in the sand. He then sets the pattern aside. At that point, moulder closes the cope and drag, forming the mould. What the mould maker wants is the void left from the impression of the pattern, in middle of the sand, inside the mould. So, he fills that void with a molten material. Basic casting like this, is also called, “Green Sand Moulding, or Green Sand Casting”.

This special need prompted a man to develop special processes. Examples of usage would be: Air movement components (fan blades), hubs, shafts, tubes, rectangles, squares, holes, no holes and so on.

NO BAKE

Madhuram Technocast creates Sand moulds using a wood, metal or plastic pattern. The pattern can be a dump box, match plate, or a loose piece. Sand is mixed with a urethane binder in a high speed mixer. This sand is deposited into box containing the pattern and all essential gating, risers and chills for pouring. The sand mixture sets up hard in a few minutes and the mould is removed from the pattern. Cores for forming internal passages in the castings are made using the same process. The moulds and cores are cleaned and sprayed with a refractory coating. This coating shields the molten metal from direct contact with the sand and seals the sand grain for better surface finish. Cores are carefully placed into the moulds. The moulds are then closed and are ready for pouring.

We utilize this casting process of 80-900 pounds.
This process is used for producing “Large” Castings upto 64” x 64” 18” in size and ranging from 40 to 900 pounds.

All metals/ alloys are QC checked on our spectrometer prior to pouring and adjusted to ensure conformance with specifications. No-Bake moulding has proven its worth as an efficient means to produce medium and low volumes of complex castings in both ferrous and nonferrous metals.

COLD CORE

When it comes to core-making capabilities, Madhuram Technocast utilizes cold-box, warm-box and shell-core latest techniques for perfect casting. These diverse capabilities and our innovative processes in each, result in hard, solid cores to create our consistent high-quality iron castings.

CORE MAKING - COLD BOX TECHNOLOGY

PLC controlled Cold Box Core Shooters
Pneumatic sand transporter and PLC controlled binder dosing units
Core sand drying plants
Core painting and baking ovens with trolley storage
50 Kg core shooter - 1 Nos.
30 Kg core shooter - 1 Nos.
5 Kg core shooter - 1 Nos.

PROPERTIES AND ADVANTAGES OF COLD CORE PROCESS

Rapid model change possible
Excellent thermal stability
Short cycle times and high productivity to rapid hardening
Secure core extraction
High dimensional accuracy
Smooth core surfaces
Low tooling and energy costs
Economic and automatic core production and excellent possibilities for “online production.”