Amazone Castings & Engineering Private Limited

Rajkot, Gujarat

GST No. 24AAICA4256B1Z4

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Basic Information
Nature of Business
Manufacturer
Total Number of Employees
11 to 25 People
Year of Establishment
2010
Legal Status of Firm
Limited Company (Ltd./Pvt.Ltd.)
Annual Turnover
Rs. 1 - 2 Crore
GST No.
24AAICA4256B1Z4
CIN No.
U27300GJ2010PTC060436

CO2 ? Sodium Silicate Core

Here Silica sand, which is prepared in a separate mixer using sand, and Sodium Silicate is added 5 to 6 % of sand quantity 100 kg, with a Dry core break down agent added in it. While sand and break down agent are mixed first then Sodium Silicate in added and mixed for 2 minutes or so ensuring proper mixing. Than CO2 gas is passed through the holes made in pattern or cores. And gas is passed at a uniform pressure tight, the sand mould is hardened. And then core is stripped out of the pattern by ramming smoothly.

Green Sand Moulding

This is done in moulding machines using sand prepared in intensive sand mixers with coal dust, Dextrine (if required), Bentonite and water. In this type of Moulding, Facing sand is used for covering the Pettern and then backing sand is used for moulding in regular way.

After proper inspection of the Pettern and the match plate, if is mounted on the moulding machine and set for leveling tightness and listing of the moulding box from the match plate after making the moulds.

Once this is made ready moulding box is placed on the machine into match plate fix going inside the Lug Holes with buses. After covering the Pettern with facing sand backing sand is added and jointing of the machine is started. Once the sand sets in the moulding box, squeeze board is pleased that above the box and in squeezed into simultaneous jolting for a minute or so. Then the squeeze board is moved out and box relieved from the Pettern. The mould is checked for proper condition and placed on them for pouring. The Cope and drag boxes are made separately with cope box having down spare and air vents. During the process of moulding, the sand prepare is also checked in the laboratory for moisture, Permeability, Green Compression strength, Computability etc. So mat quality of the sand is maintained. 

No Bake System of Core

Though there are a number of practices involved, Kamani Foundry follows the following systems: -

 

3 Part A-B-C- system: Where’s’ part is Resin, while part ‘C’ is a catalyst (or Activator) and part ‘B’ is a Hardner. The quantities Mixed very depending on the type of Pettern/Mould and the bench life needed for the same. General proper GMS followed are: 



Part ‘A’: - 2% of the sand quantity.
Part‘B’: - 8% of Part ‘A’ and
Part ‘C’: - 15% to 20% of Part ‘A’: 



First part ‘A’ and Part ‘C’ are mixed along with sand in the sand mixer for about 90 second to 2 minutes and then Part ‘B’ is added and further mixed for one minute. Immediately after this, sand a discharged from the mixer and put in the core box. The sand mix is rammed by way of hand rammers and leveled on the core box. After allowing the sand to harden slightly, the core is stripped from the Pettern and allowed for ageing further.

 

2 – Part System: In this systems Resin and activator are made in a single from and after mixing it with sand for an initial period of about 2 minutes, Hardner is added and mixed for another one minute. Then the sand mix is put in the core after allowing the sand to harden slightly, the core is stripped from the Pettern and allowed for ageing further. box.

 

Single Part System: Here, it is an air setting chemical is mixed with sand for a minute to 90 seconds and then mould made as a for with further procedure.

Graphite Coating


Here the painting is done essentially in water base graphite paint prepared in the same as mentioned in A1 but left over for a longer time for drying.
 

After the moulds and cores are made, they are taken up for painting which the done as detailed below: -
(a) Green sand moulding :
The mould are spray- painted with graphite based paint which is prepared by mixing ready mix graphite paste / powder in water to the required viscosity so that paints is neither thin nor thick but at the same time the moulds could be painted uniformly
(b)  CO2 Silicate Moulding :
Here the paint is prepared by mixing ready mix by paste / paint with thinner (spirit) to the desired viscosity and then spray painted uniformly in the mould which is ignite after painting so that moulds get dried properly.
(c) No-Bake System :
Here the painting of the moulds can either water base or thinner base and paint – either water base or thinner base is prepared in the same way as mentioned above in A1 / B1 depending on the type of painting. The moulds are left for over or ignited for drying.
(d) Red-Sand natural Cay Mould :
Here the painting is done essentially in water base graphite paint prepared in the same as mentioned in A1 but left over for a longer time for drying.
 

Core

Cores are also painted according to the type, in either water base or thinner base, paint prepared by mixing graphite ready mix paste or powder in water or thinner as the case may be and then spray paints.

(a) Oil Sand Cores :
Generally water base graphite paints are as spray-painted and the torched or heated in the oven at a temperate of 105oC for proper drying.

(b) CO2 Sodium Silicate Cores :
Here the cores are essentially painted with in inner base painted prepare as mentioned in b1 and then ignited for proper drying.
(c) NO BAKE SYSTEM CORE :
Here the painting can be water base or spirit base graphite prepared as mentioned in A1 or B1 and then as spay painted – torched or ignited as the case may be.
(d) SHELL CORE :
These are generally painted in water base Zircon mix paints, prepared in the same way as graphite paints but is important that these cores are dried completely after painting.
However in the all above cases, the moulds and cores are ensured for proper drying, if necessary torching before after core setting. 

Shell Cores

These cores are made through shell core shooters using resin-coated sand.

Here the core box, which is known as “Die” is, heated upto 200 ‘c ranging from 400 ‘c depending on the size of die. Then the resin-coated sand is introduced into the die by air pressure. The sand inside the die takes the shape of the core cavities and gets heated up. Then onwards the time is taken for baking the core, after the core is baked at the time decided, the core as ejected from the die. And the shell core is prepared. 

 


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Alpesh Ramani (Director)
Amazone Castings & Engineering Private Limited
Plot No. 52, Survey No. 126, N. H. 8- B, Shantidham, Veraval-Shapar District
Rajkot - 360024, Gujarat, India
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