Company Overview:Established in 1987, under the inspiring guidance of Mr.

Rajeev Singh Dugal, JMT Auto Limited, formerly known as Jamshedpur Metal Treat Limited is one of the leading Auto component manufacturers in Eastern region with manufacturing facilities spread across 3 locations in India viz., Jamshedpur (Jharkhand), Dharwad (Karnataka), and Lucknow (Uttar Pradesh) and business spread across countries like USA, Belgium, South East Asia, Brazil, Germany, Italy and Mexico. The Company identified Auto Components as its key business area and acquired core competency in manufacturing 1200 Automobile components ranging from Engine components, Gears, Shafts, Pins, Bushes, Idler Bearings, Carrier Housing, Gear Rings, Axles, Synchro Cones, Carriers, Gear Box Assemblies, Seal wear rings, Oil Pump Cover ,Drums Sleeves, Carrier Assemblies, Pipe Assemblies, Flywheel Assemblies, Sear Wear ring, Cone And Cup(Heat Treatment),Bushes, Oil Pump Gear, Seat Valve, Lever Rocker Assembly, Steering Spindle, Assemblies, Engine Gears, Spindles, Drums for light, Medium & Heavy Commercial Vehicles, Tractors and Diesel Engines. It is fully equipped to manufacture all kinds of SG iron castings, grey iron castings, cast iron castings, graded cast iron castings, foundries non ferrous castings, graded iron castings along with foundries ferrous castings weighing from 0.500gms to 1000 Kg single piece. The annual production capacity is 2400Tons. JMT Works produces and markets different grades of Cast Iron Castings, Foundries Ferrous Castings, Grey Iron and SG Iron Castings for the domestic and international markets.

Process Flow Diagram:-

PATTERN:The process of making a wooden or metallic pattern is known as pattern making. Pattern acts as a principle tool during the casting process and can be defined as a model of desired casting, so constructed that may be used for forming an impression or cavity called mould in moulding sand or other suitable material. This mould or cavity when filled up with molten metal, forms the desired shape of casting after solidification of the poured metal. This company has around 263 number of pattern made up of ferrous, non- ferrous and wooden material. Products:- CARRIER - FLY WHEEL - BEARING - ALTERNATOR SUPPORT - DRUMS - CASTINGS FOR EXCAVATORS / CASTINGS FOR TRACTORS

Casting
Foundry or casting may be defined as a process of forming desired metallic products by melting the metal, pouring this molten metal into a mould and then allowing it to solidify. When this solidified shape of metal is separated from the mould it will be of same shape as the mould. The mould is a cavity or impression in the moulding sand which is produced by means of pattern. The process of producing this cavity is known as moulding.

Comparative Advantages, Disadvantages and Applications for Various Casting Methods :

Sand Casting Advantages Least Expensive (less in than Disadvantages Recommended Application

small Dimensional accuracy inferior to Use when strength/weight ratio 100) other processes, requires larger permits tolerances Tolerances, surface finish and low usually exceed machining cost does not warrant a weight more expensive process calculated

quantities

Ferrous and non - ferrous metals may be cast Castings

Possible to cast very large parts. Surface finish of ferrous castings • Least expensive tooling usually exceeds 125 RMS

Permanent and Semi-permanent Mold Casting Less expensive than Investment or Only non-ferrous metals may be Use when process recommended Die Dimensional than Castings cast Tolerances Sand by this process for parts subjected to hydrostatic pressure closer Less competitive with Sand Cast cores Castings are dense and pressure tight Higher tooling cost than Sand Cast Plaster Cast Smooth "As Cast" finish (25 RMS) More Closer dimensional tolerance than Sand Cast Limited number of costly than Sand or Use when parts require smooth tolerances than possible with Sand sources or Permanent Mold Processes are required no cores and quantities in excess of 300 Castings process when three or more sand Ideal for parts having low profile,

Permanent

Mold-Casting "As Cast" surface finish and closer

• Intricate shapes and fine Requires minimum of 1 deg. draft details including thinner "As Cast" walls are possible

• Large parts cost less to cast than by Investment process Investment Cast Close dimensional tolerance Costs are higher than Sand, Use when Complexity precludes

Permanent Complex walls shape, are fine intricate core sections and thin possible

Mold

or

Plaster use of Sand or Permanent Mold Castings The process cost is justified

detail, process Castings

through savings in machining or Ferrous and non-ferrous metals may be cast Weight savings justifies increased As-Cast" finish (64 - 125 RMS) Die Casting Good dimensional tolerances are Economical only in very large Use when quantity of parts justifies possible Excellent part-part quantities due to high tool cost the high tooling cost cost brazing

dimensional Not recommended for hydrostatic Parts are not structural and are pressure applications subjected to hydrostatic pressure

consistency Parts require a minimal

post For Castings where penetrant (die) or radiographic inspection are not required. Difficult to guarantee minimum mechanical properties

machining

SAND CASTING PROCESSES This type of metal casting involves making a mold in a sand mixture and then pouring liquid metal into the sand cavity. This is a simple six-part process: (1) Use a pre-existing pattern to create a sand mold, or craft one by hand. (2) Add your gating system (to control the liquid metal). (3) Remove the pattern (if used). (4) Pour in the metal. (5) Cool. (6) Remove the casting. This is the best form of casting for a small operation that will be making castings in small batches. Green Sand Molding The most common method used to make metal castings is green sand molding. In this process, granular refractory sand is coated with a mixture of bentonite clay, water and, in some cases, other additives . The additives help to harden and hold the mold shape to withstand the pressures of the molten metal. The green sand mixture is compacted by hand or through mechanical force around pattern to create a mold. The mechanical force can be induced by slinging, jolting, squeezing or by impact/impulse.

Engineering:
Their engineering staff coordinates customer plans and designs to develop castable parts. Produce mainly S.G Iron Graded Casting S.G Cast iron is defined as a high carbon containing, iron based alloy in which the graphite is present in compact, spherical shapes rather than in the shape of flakes, the latter being typical of gray cast iron . S.G IRON CASTING It is produced by treating the molten alloy with magnesium, or cerium , or a combination of two elements, or such elements like Ca, Ba, Li, Zr causing spheroidal graphite to grow during solidification. Use of magnesium to have 0.04-0.06% residual content is more easy to adopt and economical, which is followed by addition of ferro-silicon. Certain elements , if present, like 0.1% Ti, 0.009% Pb, 0.003% Bi, 0.004% Sb prevent the production of S.G iron , but their effect can be removed by adding 0.005-0.01% Ce.

Decoring Area
Sand moulds will be knocked out in specified areas, and the castings containing cores will be moved for de-coring, to ensure that the used core sand can be segregated from the moulding sand. Investment moulds and shells will be knocked out and the waste material collected for specialised removal. Cores from ceramic moulds or shells will, where appropriate, be removed by vibratory methods or chemical leaching. Moulding equipment, such as boxes, clamps, etc, will be returned to the mould production area.

Shot Blasting
Very high performance shotblasting machine able to shot blast small and medium dimension work pieces and castings. he pieces are fed by a metallic belt conveyor. These machines can treat very fragile pieces because during the shotblasting process, the parts being shot blasted do not touch one another. The machines are provided with turbine variable speed drive (inverter) to adjust the abrasive throw.

Pre- Machining After shot blasting the material is now operated in centre lathe where various operations like turning, facing, boring etc takes place then the material is surface finished through grinding machines

CORE SHOP

Coldbox systems utilize a family of binders where the catalyst is not added to the sand mixture. Catalysts in the form of a gas or vapor are added to the sand and resin com ponent so the mixture will not cure until it is brought into contact with a catalyst agent. The sand-resin mixture is blown into a corebox to compact the sand, and a catalytic gas or vapor is permeated through the sand mixture, where the catalyst reacts with the resin component hardening the sand mixture almost instantly Several coldbox processes exist, but here in JMT they amine vapour In general, coldbox processes offer: good dimensional accuracy of the cores because they are cured without the use of heat; excellent surface nish of the casting; excellent characteristics for high-production runs since production cycles are short; excellent core and mold shelf life

PLANT & MACHINERY

Disa Moulding Machine model ARPA-450 & ARPA 900 - TM-160 Centrifugal Sand Mixer

- Automatic Sand Preparation & Conveying system with Sand Coolers. - 2-Ton Dual Track Inductotherm Melting Furnace 2 nos.

Molding:Molding Temperature is around 1500-1550 deg C It contains 50% of their rejected material, 40% of the scrap waste and 10% other composition material.
QUALITY ASSURANCE

Match Plate Inspection - Sand preparation analysis - Checks of Core before placing in Mould - Spectrographic of Bath Metal & Pouring - Final Inspection Of Finished Product

Sand Testing
Sand testing is a foundry process used to determine if the foundry sand has the correct properties for a certain casting process. The sand is used to make moulds and cores via a pattern. In a sand casting foundry there are broadly two reasons for rejection of the casting metal and sand each of which has a large number of internal variables

Sand control:1. Fineness number (grain size/AFS Number) of the base sand 2. Moisture content in the mixture (ranges from 2-7% depending on the casting method) 3. Permeability (ability of compacted mould to pass air through it) (ranges from 120220) 4. Total clay content (dust content) (range 12-18) 5. Active clay content (presence of active bentonite/clay which can readily bond) (range 8-14) 6. Green Compressive strength (range 1000-1300gm/cm2)