dspblog

Not me, But we!

2019-01-05T22:48:00.001-08:00

                                                   Our Biggest Threat

 Somewhere in this planet,2050.

                               Prowling in the tainted atmosphere, Rob started searching for his daughter who went out for an evening walk but hadn't returned back to the home. His asthenic torso feared for the trace of his daughter but to his surprise he found her fainted on his farmland. With his frightened soul and trepidation, he took her immediately to the nearest hospital and met the doctor after all the test checkups get completed to get to know what happened to her.
      "Sorry to say this Rob! Your girl is in her last few days!"- doctor vocalized With all his dreams getting shattered rob started shredding tears!
"What turned her into this situation doctor?" rob raged.
Doctor: "Our yesterday's sins, made your little angle suffer today".
Rob:     "Our?, What are you talking about?"
Doctor: "We neglected our mother (Earth), which paid off with a tumor into your little angel. She is suffering from plastic cancer!".
 
                                                  ******
The above story might be fiction but it can be turned into a fate of many if the roots of plastic were not plucked out of this world.
       The biggest threat to human survival is the belief that someone else will take care of this world. Many of us have no idea about the mistakes which we were doing and how they cost us in the future, Right now the biggest enemy for the human survival is plastic, not because of its applications but because of the reactions its going to make periodically with the life resources like food, water, soil etc.
                      Plastic started being radical with the food in kitchen utensils, it started contaminating the fertile soil with gypsum, which may soon result in life-threatening diseases.
                      Every problem takes its birth after the existence of its solution, Even plastic does have a solution, The solution can be achieved from 2 different ways 
1) To stop usage of plastic (Which takes huge time until mankind finds an alternative). 
2) To reduce the amount of usage. (Can be tried)
                    There will be endless debates and discussions running on this demon, but no one shows a way to overcome it.
                    Today I would like to break the wheel and suggest you a method which I do follow to minimize my plastic usage.
                   Make a list of every single plastic thing that you use on your daily needs from your toothbrush in the morning to the alarm clock at night. 
                  Think about all the possible ways that you can shorten the list by eliminating the elements in it, through recycling or up-cycling etc.
Ex: If it is a Plastic chair, think about how creatively you can find a biological solution to it, either by using wood or metal from the dump and recycle them to avoid plastic.
Day by day be an enthusiast and try to eliminate as many as possible from the list.
After a short span of time, you can really observe the changes in your lifestyle.
Are you wondering how can this affect humankind?
It is quite simple if you imagine on a large scale, just multiple how many kgs of plastic you are avoiding *  the number of citizens following it.
 "The biggest threat to human survival is the belief that someone else will take care of this world."
           It is never late to get realized and never early to start! So get determined and try to protect our mother earth from us.
Not me, But we are going to do this.
                                                                                -- with love, DSP.

Let the old out, make the new in

2018-12-31T07:54:00.003-08:00

                                                My Journey with 2018

After my birth, I had seen many calendars turning out, Every new calendar pushed me to dream about a short-term goal, but to my surprise, none of them worked out really. which is quite common with most of the people, We do dream about small changes in our lives at the end of a year, we often feel passionate to achieve it at the beginning of the next year, We remain failed by end of that year. This is what happened to me too.

Till the end of 2017 I used to have the same cycle of experiences periodically, Which made me a bit confused, muddled, vexed etc. For the first time, I wished to break the wheel, by the self-inspection and adoption of new ideology into me.

In the process, one question continuously haunted me, "What made you fail in the past?" which needs to be answered first. Through a rigorous retrospection on several thought experiments, I came to discover that the reason behind my failure is due to the presence of "no me in my acts". Which means every act I do (or) every routine which is happening in my daily lifestyle is just happening naturally, they are not designed by my ideology. I just followed people in many things because it is predetermined in the society, might be daily schedule, might be one-night batting before exams, similarly, everything is happening without the intervention of my ideology. This is the reason I failed in the past, yes because many of the people plan for changes at the beginning of the year, tend to be failed by the end of the year.

Finally, I got answers to all my questions and had a path to make 2018  a better one. The path is that my ideology should follow my decisions, But to make this formula stay alive throughout the year I came across a need of motivation, which again designed by my ideology, The motivation is nothing but a small line

"Why Should I?" 

This magical 3 words made my year! You might be wondering how come three words can change up the situations, but the answer is "yes! they made an impact.!" By the implementation of these three words before my decision making, I came to know that whether I am doing that particular thing as it is predetermined by some other people (or) I am incapable of making something new? Which used to make my eyes open and bring a fresh thought out of my ideology.

I came to 

Believe before  pray

listen    before  speak

think     before  write

try         before  quit 

find reason before my acts

Now its end of 2018, unlike the past I am very happy by this completion and excited to heartily welcome a new one.

If you suffer for the same reason, just examine within your self and unleash your abilities, "Let the old out and the new in!"

                                                                                                           - With love, Dsp

#newyear #2019 #thoughts

My Best Teachers

2018-09-05T07:49:00.002-07:00

On the occasion of sep 5th, I would like to share the lessons which I've learned from my mistakes, my motivation which I found from my inspirations and the knowledge I have gained from my teachers.

I wish to share my flying thoughts which were thaught to me by my two best teachers, in my own words

Existence is to explore, existence is to examine, existence is to evolve our selves better
When 17 years old me asked myself, what is the biggest mistake I have done? 79 years old me might say "I thought, I have time". that's the point of my life where my teachers started reforming me.

Time is free, but it is priceless!
we can't own time but we can use time!
we can't save it, but we can spend it!
but once it is lost, we can't have it again!

What if 86,400 rupees to get deposited into our account every single day after we wake up and at the end of the day its all gone whether we use it or not, The very next day we would get again same 86400 pence and get vanished by the end of the night! what would we do with it?

Every day 86,400 seconds get deposited into our lives whether we use it or not!

What would be the answer we get, when we question ourselves "what is my perfect day?" , A Day which is ideal? A Day which we desire we would have our entire life? I guess it would be the day on which we use 86400 resources perfectly!

Now, what does perfectly means?

A famous quote which I like the most is
"I am not what I think I am, I am not what you think I am!
I am what I think, you think I am".

We live in perceptions of perceptions around millennials of lowest self-esteem!
this is because we peep into our lives through someone else's lives. through someone way of life, But by the end of the day, we are not what we think we should be.

This might happen because of starting influence! the way in which we start our day!
if we start our day switching on to vox before to thinking about the purpose of the day. It is not perfect
if we switching on to Instagram before wishing yourself or before enjoying the recipe of excitement for that day, It is not our perfect day!
Peeping into someone else's lives than before organizing yourself for that day makes the imperfection
overcoming it gives us the pleasure of righteous usage of 86400 resources!

Every single day is an opportunity and every consecutive opportunity is at a higher level than the before one! "Every higher level opportunity of yours, demand the latest version of you", this can be only achieved when we follow our own path at every second of our life

- This is what my two best teachers taught me and I am wishing to address my two best teachers here.."Life and Time"

Life teaches us how to make good use of time!
Time teaches us the value of life!

-DSP

2018-04-24T05:54:00.001-07:00

A DAY IN ORPHANAGE

"The wars don't end when you sign peace treaties or when the years go by. They will echo on until I'm gone and all the widows and orphans are gone."
-Tim O'Brien

writings are the orphan of silence, words never equal experience, Life is a journey with problems to solve, lessons to learn, but most of all experiences to enjoy, one such experience which happened in my life, is not in a beach, nor a resort but took place in a happy home commonly known as orphanage.The word orphanage may sound pretty simple but it comprises a lot of emotions, selfless love, shower of happiness and of course pure smiles on every face.

showing an empathetic attitude towards society may not cost you a single penny but fetches huge fulfilment within oneself, with this very same interest, I found a group of people working with the same motive of helping the needy for the betterment of society, the very next minute I joined them and became a member of the organisation called CEA with the satisfactory progress in work over a period of 3 months I visited several schools, old age homes etc, as a part of contribution in overall development of a child ,we team CEA planned an event and organized it in an orphanage which is popularly known as chiguru orphanage.

CARNIVAL OF KNOWLEDGE is the title we had for our event, shared an enormous amount of knowledge to every kid and also left every volunteer of it in a shore of happiness, on that paramount day we were confident that every child gets benefited by making sure ourselves that every child gonna participate in all the activities which we implemented there.

I personally gonna describe the activity in which I took an active participation as a volunteer and its named as Health awareness which is designed and delivered by my dear friends trivikram, sri varun under the guidance of our beloved seniors sumana,rupesh . The activity repose of letting the children aware of minimum health knowledge which is required in day to day lifestyle, with the positive response of children and completing the activity to an undiminished level we joined our team for the brunch where we shared our unique experiences in the overall conductance.

Soon after the completion of certain activities and various competitions we were onto a procedure for prize distribution based on their performances.

keeping aside the physical activities conducted and personal contributions of our team for a moment. I wish to share a few feelings of experience which registered in my heart on that occasion.

* life may be a chase of acquiring the needs which satisfy the intensification desires but being surrounded by the very basics no kid was found with a sign of sadness on their face. their level of happiness with the materialistic availability thought me that life is not only meant for satisfying needs but it is something more.

* Soon or later within an interaction with a kid personally we will be coming across over questions like where do u from, how do u spend family time, how many people ur family consists of , where do u live, which indirectly thought me we should be happy with what we have as at least we have it, somewhere someone else lacks it.

with all the happiness and unforgettable memories, we team cea spent one of the finest days.

we went to share our knowledge to them,in return they shared their happiness with us.
if it is your occassional day better to celebrate it in an orphanage than in temple ,even your god feels happy by seeing you there.

----DSP

2018-04-23T11:10:00.000-07:00

“SINGLE POINT CUTTING TOOL”

INTRODUCTION:

Machining is a process designed to change the size, shape, and surface of a material through the removal of materials that could be achieved by straining the material to fracture or by thermal evaporation.Machining offers benefits such as excellent dimensional tolerances, external and internal geometrical features, sharp corners, grooves, fillets, It also provides good surface finish and it is also economical if small quantities. Machining process has some limitations like a material waste, time-consuming, energy, capital, and labour intensive.

A machining system constitutes three components namely machine tool, cutting tool, and the workpiece. Machining is observed under three parameters they are
Cutting speed (V) is the largest of the relative velocities of cutting tool or workpiece. In turning it is the speed of the workpiece while in drilling and milling, it is the speed of the cutting tool. In turning, it is given by the surface speed of the workpiece, V = p D1N where D1 is the diameter of the workpiece.
The depth of cut (d) is the distance the cutting tool penetrates into the workpiece. In turning, for example, it is given by d = (D1-D2)/2
Feed (f) is a movement of the tool per revolution. In turning, it is the distance the tool travels in one revolution of the workpiece and is given the units of mm/rev or in./rev.

In traditional machining cutting tools must be harder tough and strong the context of machining, a cutting tool or cutter is any tool that is used to remove material from the workpiece by means of shear deformation. Cutting may be accomplished by single-point or multipoint tools. Single-point tools are used in turning, shaping, planning and similar operations, and remove material by means of one cutting edge. milling and drilling tools are often multipoint tools.

CUTTING TOOL:

In the context of machining, a cutting tool or cutter is any tool that is used to remove material from the workpiece by means of shear deformation. Cutting may be accomplished by single-point or multipoint tools. Single-point tools are used in turning, shaping, planning and similar operations, and remove material by means of one cutting edge. Milling and drilling tools are often multipoint tools. Grinding tools are also multipoint tools. Each grain of abrasive functions as a microscopic single-point cutting edge (although of high negative rake angle), and shears a tiny chip.

Cutting tool material must be harder than the material which is to be cut, and the tool must be able to withstand the heat generated in the metal-cutting process. Also, the tool must have a specific geometry, with clearance angle designed so that the cutting edge can contact the workpiece without the rest of the tool dragging on the workpiece surface. The angle of the cutting face is also important, as is the flute width, number of flutes or teeth, and margin size. In order to have a long working life, all of the above must be optimized, plus the speeds and feeds at which the tool is run.

Linear cutting tools include tool bits (single-point cutting tools) and broaches. Rotary cutting tools include drill bits, countersinks and counterbores, taps and die, milling cutters, reamers, and cold saw blades. Other cutting tools, such as bandsaw blades, hacksaw blades, and fly cutters, combine aspects of linear and rotary motion

Cutting tools are classified into two categories namely

1. Single point cutting tool

2. Multipoint cutting tool

Cutting tools with inserts (indexable tools)

Cutting tools are often designed with inserts or replaceable tips In these, the cutting edge consists of a separate piece of material, either brazed, welded or clamped on to the tool body. Common materials for tips include cemented carbides, polycrystalline diamond, and cubic boron nitride.^[1] Tools using inserts include milling cutters (endmills, fly cutters), tool bits, and saw blades.

Solid cutting tools

The typical tool for milling and drilling has no changeable insert. The cutting edge and the shank is one unit and built of the same material. Small tools cannot be designed with an exchangeable insert

Holder

To use a cutting tool within a CNC machine there is a basic holder required to mount it on the machine's spindle or turret. For CNC milling machines, there are two types of holder. There is shank taper (SK) and hollow shank taper (HSK).

Tool setup

The detailed instruction how to combine the tool assembly out of the basic holder, tool and insert can be stored in a tool management solution.

SINGLE POINT CUTTING TOOL:

It is the simplest form of cutting tool & has only one cutting edge.
Examples – shear tools, lathe tools, planer tools, boring tolls etc.

A single point cutting tool consist of Flank, face, cutting edge, nose, rack angle, clearance angle, cutting edge angle etc. All of these parts control the cutting condition, tool life and cutting speed of the tool. These parts describe as follow.

Geometry and Tool angles of Single Point Cutting Tool:

1. Shank:

The main body of the tool is known as the shank. It is the backward part of the tool which is hold by tool post.

2. Face:

The top surface tool on which chips passes after cutting is known as the face. It is the horizontal surface adjacent of cutting edges.

Flank:

Sometime flank is also known as cutting face. It is the vertical surface adjacent to cutting edge. According to cutting edge, there are two flank side flank and end flank.

3. Nose or Cutting point:

The point where both cutting edge meets known as cutting point or nose. It is front of the tool.

4. Base:

The bottom surface of the tool is known as the base. It is just opposite surface of the face.

5. Heel:

It is a intersecting line of face and base.

6. End cutting edge angle:

The angle between end cutting edge or flank to the plane perpendicular to the side of the shank is known as end cutting angle.

7. Side cutting edge angle:

The angle between the side cutting edge or flank to the plane parallel to the side of the shank known as side cutting edge angle.

8. Back rake angle:

The angle form to smooth flowing of chips from face, known as rack angle. It allows to smooth flow of chips. Back rack angle is the angle between face and the plane perpendicular to the end cutting edge.

9. Side rack angle:

The angle between the face and plane perpendicular to the side cutting edge is known as side rack angle. It allows chips to flow smoothly when material cut by side cutting edge.

10. End relief angle:

It is also known as clearance angle. It is the angle which avoids tool wear. It avoid the rubbing of flank with work piece. End cutting angle made by end flank to the plane perpendicular to base.

11. Side relief angle:

It is the angle made by the side flank to the plane perpendicular to the base. It avoid rubbing of side flank with work piece.

12. Nose radius:

The intersecting area of both cutting edges is known as nose of the tool. It does not have a sharp profile. Sharp profile may cause scratches on work piece which gives poor surface finish. To avoid this and obtain good surface finish this area is at some radius known as nose radius. If the radius is too small is gives poor surface finish and if it is too large gives poor

Designation of cutting tool / Tool signature –

Tool signature is the description of the cutting part of the tool. There are two system for tool signature.

Machine reference system (or American Standard Association system) (ASA)
Tool reference system (or Orthogonal rake system) (ORS)

American Standard Association (ASA)

The ASA system consists of seven elements to denote a single point cutting tool. They are always written in the following order. Back rake angle, Side rake angle, End relief angle, Side relief angle, End cutting edge angle, Side cutting edge angle, and nose radius.

For example, tool signature 0, 10, 6, 6, 10, 12, 1 means

Back rake angle = 0°

Side rake angle = 10°

End relief angle = 6°

Side relief angle = 6°

End cutting edge angle = 1

Side cutting edge angle = 12°

Nose radius = 1mm

.ORTHOGONAL RAKE SYSTEM

The ORS system comprises seven parameters to describe a tool. The main elements of ORS designated in the following order Angle of inclination, Normal rake angle, Side relief angle, End relief angle, End cutting edge angle, Approach angle and Nose radius.
Example: Tool signature 5, 10, 6, 6, 5, 90, 1
Angle of inclination = 5°
Normal rake angle = 10°
Side relief angle = 6°
End relief angle = 6°
End cutting edge angle = 5°
Approach angle = 90°
Nose radius =1mm

RAKE ANGLE:

Rake angle is a parameter used in various cutting and machining processes, describing the angle of the cutting face relative to the work. There are two rake angles, namely the back rake angle and side rake angle, both of which help to guide chip flow. There are three types of rake angles: positive, negative, and zero.

Generally, positive rake angles:

· Make the tool more sharp and pointed. This reduces the strength of the tool, as the small included angle in the tip may cause it to chip away.

· Reduce cutting forces and power requirements.

· Helps in the formation of continuous chips in ductile materials.

· Can help avoid the formation of a built-up edge.

Negative rake angles, by contrast:

· Make the tool more blunt, increasing the strength of the cutting edge.

· Increase the cutting forces.

· Can increase friction, resulting in higher temperatures.

· Can improve surface finish.

A zero rake angle is the easiest to manufacture, but has a larger crater wear when compared to positive rake angle as the chip slides over the rake face.

CUTTING TOOL MATERIALS:

Basic properties that cutting must posses are:

§ Tool material must be at least 30 to 50% harder than the work piece material.

§ Tool material must have high hot hardness temperature.

§ High toughness

§ High wear resistance

§ High thermal conductivity

§ Lower coefficient of friction

§ Easiness in fabrication and cheap

Different cutting tool materials used for cutting operations in practice are high carbon steel, high speed steel, non -ferrous cast alloys, cemented carbides, ceramics and sintered oxides, ceremets, diamond, cubic boron nitride, UCON and sialon.

High Carbon Steel tools

§ Its composition is C = 0.8 to 1.3%, Si = 0.1 to 0.4% and Mn = 0.1 to 0.4%.

§ It is used for machining soft metals like free cutting steels and brass and used as chisels etc.

§ These tool loose hardness above 250°C.

§ Hardness of tool is about Rc = 65.

§ Used at cutting speed of 5m/min.

High speed steel (H.S.S)
General use of HSS is 18-4-1.
18- Tungsten is used to increase hot hardness and stability.
4 – Chromium is used to increase strength.
1- Vanadium is used to maintain keenness of cutting edge.
In addition to these 2.5% to 10%, cobalt is used to increase red hot hardness.
Rest iron

§ H.S.S is used for drills, milling cutters, single point cutting tools, dies, reamers etc.

§ It looses hardness above 600°C.

§ Some times tungsten is completely replaced by Molybdenum.

§ Molybdenum based H.S.S is cheaper than Tungsten based H.S.S and also slightly greater toughness but less water resistance.

Cemented carbides

§ Produced by powder metallurgy technique with sintering at 1000°C.

§ Speed can be used 6 to 8 times that of H.S.S.

§ Can withstand up to 1000°C.

§ High compressive strength is more than tensile strength.

§ They are very stiff and their young’s modulus is about 3 times that of the steel.

CUTTING FLUID:

Cutting fluid is a type of coolant and lubricant designed specifically for metalworking processes, such as machining and stamping. There are various kinds of cutting fluids, which include oils, oil-water emulsions, pastes, gels, aerosols (mists), and air or other gases. They may be made from petroleum distillates, animal fats, plant oils, water and air, or other raw ingredients. Depending on context and on which type of cutting fluid is being considered, it may be referred to as cutting fluid, cutting oil, cutting compound, coolant, or lubricant

Purpose of application of cutting fluid:

· Cooling cutting tool and to reduce various effects of cutting temperature on workpiece and cutting tool.

· To improve machinability through reduction of cutting force and improve in surface enhancement and integrity.

TOOL WEAR:

Tool wear describes the gradual failure of cutting tools due to regular operation. It is a term often associated with tipped tools, tool bits, or drill bits that are used with machine tools.

Types of wear include:

· flank wear in which the portion of the tool in contact with the finished part erodes. Can be described using the Tool Life Expectancy equation.

· crater wear in which contact with chips erodes the rake face. This is somewhat normal for tool wear, and does not seriously degrade the use of a tool until it becomes serious enough to cause a cutting edge failure.

Can be caused by spindle speed that is too low or a feed rate that is too high. In orthogonal cutting this typically occurs where the tool temperature is highest. Crater wear occurs approximately at a height equaling the cutting depth of the material. Crater wear depth ~ t₀ t₀= cutting depth

· built-up edge in which material being machined builds up on the cutting edge. Some materials (notably aluminum and copper) have a tendency to anneal themselves to the cutting edge of a tool. It occurs most frequently on softer metals, with a lower melting point. It can be prevented by increasing cutting speeds and using lubricant. When drilling it can be noticed as alternating dark and shiny rings.

· glazing occurs on grinding wheels, and occurs when the exposed abrasive becomes dulled. It is noticeable as a shine while the wheel is in motion.

· edge wear, in drills, refers to wear to the outer edge of a drill bit around the cutting face caused by excessive cutting speed. It extends down the drill flutes, and requires a large volume of material to be removed from the drill bit before it can be corrected.

CONCLUSION:

The single point cutting tool is mainly used to metal remove from work piece become with require shape and size of the product. It remove a large amount of metal in quickly again rotating the work piece. Boring, turning are performed by using single point cutting tool in the lathe machine. In involves examination of optimum cutting parameters such as cutting speeds, tool change time, tool regrinding time, the machine running cost, depreciation .Due to several reasons like wear, friction and thermal aspects, there will be the failure of the tool in long run or premature failure

2018-04-22T11:10:00.001-07:00

“PROTOTYPE OF LADLE TO POUR MOLTEN METAL”

1.ABSTRACT:

Pouring is a critical operation in the production of a casting and one which should be carefully conducted. The ladle equipment should be designed for high structural strength and, in the case of geared ladles, for foolproof mechanical operation. Because of the elevated temperatures involved, a reasonable factor of safety should be used when lining a ladle or when deciding whether an old lining is fit for use.

To avoid accidents, the frequent and careful inspection should be made of all parts of the metal-handling equipment (bowls, bails, trunnions, etc.) to detect badly scaled or cracked areas. Defective equipment causes bad castings. When geared ladles are used, any indication of trouble should be immediately checked by carefully examining all gears for excessive tooth wear or broken teeth. Any ladle in a doubtful condition should not be used.

Ladles used aboard repair ships are of two basic types. The lip-pouring ladle is shown in figure 186 and the teapot, or bottom-pouring ladle is shown in figure 187. Crucibles, such as shown in figure 188, are a type of lip-pouring ladle. Teapot crucibles

Ladle bowls are usually of welded or pressed steel construction. Trunnions on the larger ladles are often attached by both riveting and welding for maximum safety.

INTRODUCTION:

In the casting industry, all castings are poured out of ladles. The two prominently used designs for pouring are the teapot ladle and bottom pour ladle. The teapot ladle is a cylindrically shaped ladle with a spout, out of which molten steel is poured. The bottom pour ladle is also a cylindrically shaped ladle but pours from an opening in the bottom of the ladle that is controlled by a plug on the end of a stopper rod. Both techniques have considerable longevity in the industry but, also have aspects of the pouring process upon which improvements could be made. One of these aspects is the necessary pour height. For this paper, pour height is defined as the vertical distance from the top of steel in the ladle, to the top of the pouring cup. Another aspect that both the teapot and bottom pour ladles could improve upon is controlling the pour; both ladle pours are currently performed by an operator. Because of this, neither technique has adequate pour control to guarantee an optimal pour rate. Some operators have good pour control by eyeing their pours, but even the best operators will have variability in the process. Cause and effect of pouring height and control will be addressed in this project.

Ladle linings have an important bearing on the cleanliness of castings produced. If not sufficiently refractory, linings will melt and form slag, which is difficult to keep out of the casting. Because of the high temperature involved, this is most apt to occur in pouring steel. Slagging off the ladle lining is less with grey iron and bronze, and negligible with aluminium.

If the lining material has insufficient dry strength, it will crumble around the upper part of the ladle. The upper part of the lining is not in contact with the molten metal and does not develop strength by fusing or fluxing. When the ladle is tilted to a pouring position, parts of the crumbled rim will fall into the stream of metal entering the mould or into open risers.

A lining mixture which will have the desired properties can be obtained by thoroughly mixing the following materials in a sand muller.

Used steel backing sand (All-purpose backing sand - chapter IV)	81.5 percent
Silica flour	15.0 percent
Bentonite	2.0 percent
Dextrine	1.5 percent
Water	5.0 percent of the dry ingredients

A mixture of silica sand or ganister, fire-clay, and water can also be used when available. This mixture contains 85to 95 percent of silica sand or ganister; the rest is fireclay. The exact percentage of silica sand or ganister and fire-clay are determined by how workable a mix is desired. More clay gives a more workable and sticky mixture but increases the amount of shrinkage when the lining is dried. With all types of refractory mixes, only enough water should be added to make the mixture workable. An excess of water, although making the mixture easier to handle, causes more shrinkage and cracks in the lining when it is dried. For low shrinkage and fewer cracks, use small amounts of water and clay.

Before ramming a lining in the ladle, arrangements must be made for venting the lining during drying. This is done by drilling 3/16 inch or 1/4-inch holes through the sides and bottom of the ladle shell on 3 to 4-inch centres. If this is not done, drying will take too long. Numerous injuries to personnel have resulted from the use of improperly dried ladles. When moisture is pocketed under molten metal, a large volume of water vapour is rapidly formed and the metal is blown out of the ladle with explosive force. In addition to this, even slight traces of moisture in ladle linings will cause porosity and casting unsoundness. The most practical way to determine when a ladle is dry is to apply heat until steam flows from the vent holes, and then continue to apply heat until this flow stops completely.

With a properly vented ladle shell, the lining is then rammed in place. It is best to use a wood or metal core to form the inside of the ladle. The form can be made with taper and allowance for lining thickness. After the bottom of the ladle is rammed into place, the form is centred with wedges and the sides of the lining rammed. A harder and denser lining can be made, and the water kept to a minimum when a form is used. Also, the job is a lot easier than trying to ram a lining against vertical walls. When ramming a lining in layers, be sure to roughen the top of each layer before ramming in the next layer. After the lining has been rammed, the form is rapped lightly to loosen it and then drawn from the ladle. To make a drawing of the form easier, and to keep the form from absorbing water from the mix, it should be covered with a thin layer of grease or with aluminium foil. If aluminium foil is used, it is peeled from the lining after the core has been removed. Care should be exercised so that aluminium foil does not fold and cause a deep crack in the lining. The ramming of the lining must be very hard and uniform. If the lining shows a tendency to crack into layers when the form is withdrawn, each layer was not roughened enough before the next was rammed in. Such a ladle can be dangerous to use.

The thickness of the lining varies with the metal to be handled and with the size of the ladle. For example, a ladle for the pouring of steel requires a heavier lining than one for cast iron, bronze, or aluminium because steel, at the high temperatures required, attacks the lining material much more rapidly than any of the other metal s.

A lining for a ladle to hold and pour 75 pounds of steel will have a thickness of about 1 inch on the bottom and 1 inch on the sides at the bottom and will taper to about 3/4 inch at the top of the ladle. This thickness is also satisfactory for any of the other metals. For the lower-melting-point metals, the main consideration in determining the thickness of lining is proper insulation to prevent chilling of the molten metal and to avoid damage to the ladle shells because of overheating.

Drying of a new or patched lining is an operation that can cause a lot of trouble if it is not done properly. A new lining or patch should be heated gently at first to get rid of most of the water without blowing a hole in the lining or cracking it because of steam pressure. Aboard ship, this can best be done by first drying the ladle in a core oven and then completing the drying with a torch. The torch should be positioned, with respect to the ladle, to ensure complete combustion of the gas and delivery of maximum heat to the lining. If a new lining is heated too fast at the start, the water travels back to the shell and makes that part of the lining weak and soggy. After the lining or patch is thoroughly dried slowly, the temperature can be safely increased to as high as obtainable. It is desirable to maintain a new lining at red heat for several hours before using it. If a slowly heated new lining cracks, the ramming mixture contained too much clay or water.

Pouring lips of ladles are a frequent source of trouble because they are often patched, and then proper drying of the patch is overlooked. A wet patch on a pouring lip will put gas in the metal and cause blowholes in the castings.

Pouring of a ladle is best done when the lining is cold. All adhering slag and metal must be removed in the area to be patched. If possible, undercut the old lining to help hold the patch. Brush loose dirt from the old lining and wet the lining thoroughly. Patch large holes with the same mixture used for lining. Patch small holes and cracks with a mixture of four parts clean sand and one-part fireclay.

Ladles for steel are commonly used only once per lining because of the fluxing action of the metal at the elevated temperatures. In an emergency, if great care is used in skimming slag, ladles may be used twice for steel, but it is not good practice. This does not hold true for the other metals, however, and the ladle may be used for many heats. Care should be taken to remove all metal and slag after each use, but it is impossible to remove all the debris. Therefore, ladles should be used for only one metal. A separate ladle should be used for each metal or the metal will become contaminated and unfit for use.

3.1 Ladle Design:

The new ladle design is intended to serve as a replacement for the teapot and bottom pour ladles in the 1,000 to 10,000-pound pour range. This design may be tested and found to be beneficial to larger and smaller ranges, but it is suspected that this is the ladle capacity range that will see the most benefit from a new system. Teapot ladles are used in weight capacities up to about 5,000 pounds and bottom pour ladle s capacity is from approximately 5,000 pounds and up. In this section, ladle shape, size, and features will be discussed. Comparisons to the teapot and the bottom pour ladle will also be conducted and explained

The shape of the ladle:

The first part of the new system is the ladle shape. The shapes currently used for the teapot ladle and bottom pour are shown in Figure 3.1. There are two proposed designs for the new system and they are shown in Figure 3.2. The ladle is designed to pour by tilting it, like the teapot ladle. There are two main differences between the ladle designs in Figures 3.1 and 3.2. The first difference is that the base shape of the new ladle is square. The second is that the front side of the ladle is cut back to create an overhanging side.

SAMPLE SHAPE OF TEAPOT LADLE AND BOTTOM POUR LADLE

3.3 Size of the Ladle:

As stated earlier, the size of the new ladle is designed to have carrying weight to replace the teapot and bottom pour ladles in the 1,000 to 10,000-pound range. To accomplish this weight range, approximate dimensions are shown in Table for four sizes. Each of the sizes in the table allows for three inches of refractory on each of the sides and fills the ladle until four inches below the rim

DIMENSION FOR LADLE DESIGN

3.4 Lip and Throat Design:

One of the issues discussed in the literature review was the lip design for the ladle. It was determined that a lip design with a rounded shape reduces the amount of air entrainment during pouring because it reduces the surface area of the pour channel and controls the shape and roughness of the pour stream during pouring; both of which affect 18 air entrainments in the final casting. This is the reason the lip is designed. This lip is designed so that the metal is channelled to the lip and should have a half- circle profile where the metal exits the ladle. It should also have sides that will keep metal from flowing over the front edge of the ladle during the pour.

PROCEDURE:

1. Place the pattern on the turn overboard.

2. Place the drag around the pattern of the ladle with upside and sprinkle the parting sand at the bottom.

3. Fill the Moulding sand over the pattern pack, Ram, Jolt & squeeze.

4. Level the bottom drag surface by leveller & turn over the drag.

5. Sprinkle the parting sand, place the cope on the drag to suit the drag slot.

6. Select the in and out the gate in the drag, Place the sprue pins.

7. Fill the moulding sand around the sprue pins pack, Ram, Jolt and Squeeze & level the

8. surface.

Make vent holes on both the boxes with the help of vent wire.

9. Remove the sprue pin & Separate cope from drag.

10. Remove the pattern carefully with the help of draw pin, Cut gateways to flow the molten metal.

11. From the funnel shape on runner & riser, Hole to pour the molten metal on the top of the coping box.Join the two boxes with clamps,

12. Now the mould is ready to pour the molten metal.

13. Later we have soldered the metal rod to the ladle, for its mobility

RESULT:

Hence, we prepared a prototype of a ladle to pour molten metal by using casting (or) welding method.

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