INDUSTRIAL VISIT

TO

HINDUJA FOUNDRIES, SRIPERAMBUDUR, CHENNAI

Site Visit Report

Prepared by
NANDHAKUMAAR, R.K., (2010110025)
B.E. Materials Science & Engineering
Anna University, CEG
 2

VISIT SUMMARY

The group of 2nd-year Material Science & Engineering students spent

about 3 hours at India’s largest jobbing foundry - Hinduja Foundries at
Sriperumbudur on Aug 27, 2011. A short presentation by Mr Suresh
(Manager, Human Resources) and his team members introduced us to
HFL’s operations and company history. We were then taken on a tour of
their foundry and machining sections which included Pattern Shop, Sand
Plant, Melting & Pouring, Core Sections. Though brief and fast-moving, it
was informative and educational to see actual machines and processes in
a real foundry and relate them to theory.

INTRODUCTION
Hinduja Foundries Ltd (HFL) (formerly Ennore Foundries Ltd) is part of the
$12 billion Hinduja Group. HFL is India’s largest casting maker. HFL has 3
facilities in Chennai and Hyderabad which manufacture 100,000 MT of
castings in the form of cylinder blocks, heads, housings, manifolds, brake
drums etc., made of Aluminum, Cast Iron and SG iron.
HFL has plants in Ennore, Sriperumbudur and Hyderabad. Sriperumbudur
also has an Aluminum Foundry & Machine Shop. All its plants are certified
by ISO/TS10949: 2002, ISO 14001: 2004, ISO 9001: 2000. We were told
that HFL’s employee profile is: technicians 62%, engineering diploma
25%, graduates 7%, engineering professionals 6%.
HISTORY
HFL was established in 1959 as Ennore Foundries, named after the
fishermen’s village located 15 km north of Chennai. Initially promoted by
British Leyland, HFL started commercial production in 1961. Since then,
HFL has supplied castings to all major clients in the automobile industry.
HFL initially supplied the needs of Ashok Leyland only but today it is the
largest casting maker in India. Later, HFL acquired ductron castings in
Hyderabad and set up a green-field foundry in Sriperumbudur. HFL is
India’s largest automotive jobbing foundry with a capacity of 100,000 MT
of Grey Iron Casting and 3000 MT of aluminum gravity die-casting. Its
major clients are Ashok Leyland, Hindustan Motors, Hyundai, Maruti,
Simpson, Caterpillar, Tata, Swaraj Mazda, & Mahindra.
 3

PRODUCTS
HFL’S products range from 10-300 kg in grey iron to 0.5-16.5 kg in
Aluminum gravity die castings. Products include Cylinder Blocks & Heads,
Flywheels & Housings, Transmission Casings, Clutch Plates & Housings,
Brake Drums, Intake Manifolds for light & heavy vehicles. One of every
three vehicles is fitted with HFL-made Cylinder Block Casting.
We saw many of the engine blocks & heads shown below.
3 Bore Cylinder Block - Car 23 Kg 4 Bore Cylinder Block - Car 35.1 Kg 4 Bore Cylinder Block - Car 28.5 Kg

4 Bore Cylinder Block - Car 28 Kg 6 Bore Cylinder Block - HCV 148 Kg 4 Bore Cylinder Block - MUV 66 Kg

6 Bore Cylinder Block 6 Bore Cylinder Block 6 Bore Cylinder Head - HCV 57 Kg

Power Generation 271 Kg Heavy Duty Trucks 298 Kg

 4

4 Bore Cylinder Head-LCV 33 Kg 6 Bore Head Power Generation 167 Kg 4 Bore Cylinder Head MUV 34 kg

Tractor 4 Bore Cylinder Head 34 Kg Tractor 4 Bore Cylinder Head 37 Kg3 Bore Cylinder Head - Car 5.35 Kg

4 Bore Cylinder Head - Car 6.73 Kg Omni MPI Manifold - Car 1.53 Kg ZF Gear Box Casing - HCV 16.3 Kg

HOLDINGS
Hindujas acquired LRLIH Limited, U.K. and Iveco Limited in Europe 1987.
Iveco is the second largest Commercial Truck manufacturing company in
Europe and a part of FIAT Group in Italy.
Hinduja Group was founded in 1914 at Mumbai by Paramnand Hinduja.
Today it is a global conglomerate with a presence in over 25 countries.
The group has over 25,000 employees working in such diverse industries
as Transport, Energy, Information Technology, Agri-Business, Project
Development, Banking & Finance, and Trading.
 5

FOUNDRY SECTIONS WHICH WE TOURED

Pattern Shop: A well-equipped pattern shop with skilled technicians and
engineers take care of pattern making, mounting and maintenance .
1. Materials used Cast Iron, Gun Metal, Wood etc
In-house Patterns Capable of simple turning-type patterns
made of Grey Iron and Aluminium
2. External Patterns Procured from Mumbai, Bangalore, Shimoga,
Mangalore & Mumbai.

The machines we saw are shown below.

Technical Data Mycenter HX-630i
Table Size 630 x 630 mm (a) Horizontal machining center
Travel X - Y - Z 1.000 x 800 x 820 mm Mycentre HX-630i
Spindle Taper BT 50
Spindle Speed 35 ~ 12.000 rpm
Tool Storage Capacity 50 Tools (Opt. 100, 150,
200, 300)
Tool Change Time 1,5 s / 5,5 s
Rapid Feed (X,Y,Z) 50 m/min
Rapid Feed (B) 8.000 deg/min
Power Requirement 55 kVA

 Ideal for simultaneous 4-Axis machining of large size parts

 High precision: Positioning Accuracy: +/-0,002 mm; full stroke Repeatability: +/-0,001 mm;
 Fast 2-Pallet Rotary APC maximizes machining uptime, operator convenience and safety
 6

 Twin servo motors and fine pitch ballscrew drives on all axes.
 Exceptional chip evacuation, Solid Boxways, Rigid Mechanite Cast Iron Construction
 4-Step 40 taper or 2-Step 50 taper Geared Spindles; high-torque, high-speed machining
 Intelligent Advance Control System, Ballscrew Cooling standard

(b) 3-D CMM: GMT GRANO 12-20-10 GMT GRANO 7-10-6

The GMT CMM combines accuracy with functionality and practicality. It is

the ideal measurement system for small-to-medium sized general
mechanic and prismatic components. A variety of state-of-the-art
accessories, suited for all dimensional inspection tasks, are available.

GMT 3D CMMs are manufactured with proven technology and come fitted
with air bearings to ensure accuracy, reliability and repeatability. The
machine is accurate to less than 5 microns. It can be upgraded to Direct
Computer Controlled (DCC). Dimensional stability in a wide temperature
range makes granite one of the best known natural materials used in
dimensional metrology. GMT has 4 decades of experience in finishing
granite for this application.

Bridge type CMM comes with stationary table and moving bridge placed
on an ergonomically designed machine table. Base, cross beam and Z-
axis are made of rigid granite; all axes have friction-free air bearings.
The drive unit and scale of the X and Y axes are protected by a bellow.
GMT Manual CMM can be upgraded to CNC version if required. Individual
axis locking system is provided for Manual CMM's.
 7

Sand Plant Here we saw a sand molding machine and a sand cooler.
(a) Sand molding machine max. 330 m/h | HPM / D-HPM
 zoom

‣ fastest flask-operating moulding machine in the world

‣ for high-speed moulding plants
‣ simultaneous filling and compaction
‣ state-of-the-art compaction process AIRPRESSplus 2000
‣ reliable electronic control of the production process

Procedures which ensure dimensional accuracy in casting production

1. Pattern Blowing is done when pattern-bolster returns to filling station
2. Pattern Spraying is done as mould-package is lifted to filling position
3. Filling is done (a) by means of a stationary filling device (b) Weight-
dependent dosage by means of load cells (c) Uniform filling into filling
device by means of guide plates & sand distributor flap (d) Pattern-
dependent filling by controlled opening of hopper discharge shutter
4. Compaction (a) 1 or 2-stage process AIRPRESS+ 2000 (b) TWINPRESS
possible (c) controlled & adjustable airflow intensity ensures optimum
pre-compaction (d) close-to-pattern contour & at critical points (e)
active squeezing by fixed multi-piston squeeze head with separately
adjustable squeeze force & time for individual pressure circuits
5. Pattern Draw station with central, synchronized system for lifting.
6. Pattern Changing within cycle time, by 2 transfer cars & waiting
positions in front of moulding machine, with pattern bolsters
circulating horizontally on a powered roller conveyor.
 8

Foundry sand cooler 30 - 250 t/h | ASK

For effective moulding, sand preparation with guaranteed quality
‣ Flow rate of 30 up to 250 t/h
‣ Continuous mixing of the contents of several flasks
‣ Cooling to a maximum temperature of 40-45 °C
‣ Uniform moistening to a moisture of approx. 2,5%
Effective return sand conditioning

 capacity range 30 to 250 t/h

 integrated control system
 maximum cooling capacity
 optimum moistening and homogenization

Return sand conditioning

Continually increasing demands on foundries in respect of quality,
dimensional accuracy, surface finish and efficiency of casting production
create the necessity for an effective cooling of hot return sand following
the separation of sand and casting. The conditioning mainly comprises
the screening, cooling, homogenization, moistening and optionally the
predosage of additives.
The subsequent storage in a return sand hopper plant allows a relaxing of
the return sand which is delivered to the moulding sand mixer at an
almost uniform moisture and composition through a hopper management
system.
Melting & Pouring
‣ Cupola is a furnace used in foundries to melt cast iron, Ni-resist iron
and some bronzes. Its diameter varies from 0.5 - 4.0 m, cylindrical in
shape, supported vertically by four legs; looks like a large smokestack.
‣ Bottom of the cylinder is fitted with doors which swing down and out to
'drop bottom'. The top where gases escape can be open or fitted with a
 9

cap to prevent rain from entering. Some cupolas have emission-control

caps designed to remove gases and particulate matter.
‣ Shell of cupola is made of steel & lined with refractory brick & patching
material. Bottom is also lined but with clay & sand mixture ("bod"); this
lining is temporary. Finely divided coal ("sea coal") can be mixed with
the clay lining so when heated the coal decomposes and bod becomes
slightly friable, easing the opening up of the tap holes. Bottom lining is
compressed or 'rammed' against the bottom doors. Some cupolas are
fitted with cooling jackets to keep the sides cool and with oxygen
injection to make the coke fire burn hotter.

Operation of Cupola
‣ Starting a production run is called a 'cupola campaign', the furnace is
filled with layers of coke and ignited with torches. Smaller cupolas are
ignited with wood. After coke is ignited, air is introduced to the coke
bed through ports in the sides called tuyeres.
‣ When coke is hot, solid pieces of metal are fed into furnace through an
opening in the top. Metal and coke are fed alternately; limestone is
added to act as a flux. Metal melts, drips down through the coke bed
and collects in a pool at the bottom. The melting process is a reaction
 10

between fuel and blast air; C in the coke combines with O 2 in air to
form CO which further burns to form CO2. Some C is picked up by
falling droplets of molten metal which raising its C content. SiC
and ferromanganese briquettes may also be added to the charge
materials. SiC dissociates and C & Si enter molten metal.
Ferromanganese melts and combines with the molten metal in the
'well' at the bottom of cupola. Additions to the molten iron may be
varied depending on properties required.
‣ The cupola operator is known as the 'Cupola Tender' or "Furnace
Master". The tender keeps a close watch on the amount of iron rising in
the well. When the metal level is sufficiently high, he opens the "tap
hole" to collect the molten metal in a ladle or container. When enough
metal is drawn, "tap hole" is plugged with a clay plug.
‣ The cupola tender observes furnace through a sight glass or peep
sight in the tuyeres. Slag, which rises above the molten metal, is let
out of the cupola through a slag hole to the rear or side of the tap hole.
Proper fluxing keeps the viscosity of slag low so that it flows easily. To
check on fluxing, slag is collected in a small cup shaped tool, allowed
to cool and harden. It is then fractured and examined. A greenish
colored slag means fluxing is proper and adequate. In basic refractory
lined cupolas the slag is brown.
‣ Production run is terminated by “dropping” the bottom and allowing
the remaining materials to fall to the floor between the legs. This
material is allowed to cool and then removed. Cupolas may be used for
many 'campaigns' which may last from a few hours to even months.
Quality Control
During production, molten metal samples are poured into small molds. A
chill wedge is often poured to monitor the iron quality. These small,
approx 18 mm (3/4") wide x 38 mm (1-12") tall triangular shaped pieces
are allowed to cool until the metal has solidified. They are then extracted
from the sand mold and quenched in water, wide end first. After cooling
the wedges are fractured and metal coloration is assessed. A typical
fracture will have a whitish color towards the thin area of the wedge and
grayish color towards the wide end. The width of the wedge at the point
 11

of demarcation between the white and gray areas is measured and

compared to normal results for particular iron tensile strengths. This
visual method serves as a control measurement.
Core Section
There are two types: Coreless, Cored or channel type. Coreless induction
furnace is widely used for melting of all metals. Channel type furnaces
are used as reservoir of liquid metal in cast-iron melting.
1. Coreless induction furnace.
• For cast iron & SG iron, frequency of 50Hz is employed. Induction
furnaces work on principle of a transformer. AC current is passed
through a water-cooled Cu-coil surrounding refractory lining of furnace
• Induction coil acts as primary while metallic charge as secondary
• Alternating EMF induces eddy currents in the charge, so that electrical
energy is converted into heat energy which heats up the charge
• Heat generated depends on resistivity of the charges
• Induction furnaces for steel operate in frequency range 500 -2000Hz

8 tonne capacity coreless induction furnace

Melting Practice: A typical induction melting cycle is as follows

• Ensure furnace lining is properly made/repaired before charging
• Charge furnace manually or mechanically
• Switch on furnace and melt charge to the desired temperature
• Determine bath chemistry of molten metal. Based on bath chemistry,
add further additions and give power to melt down
• When metal condition is to be checked, lower the power
• Determine bath chemistry again to ensure desired metal composition
• Check metal temperature using dip type pyrometer
 12

• Tap molten metal into a preheated ladle for pouring into moulds
• For cast iron, inoculation is done in ladle. For steel, de-oxidation is
done by aluminium and other de-oxidising agents.
• For melting cast iron, furnace is lined with acid lining materials. For
carbon & other alloy steels, furnace is lines with basic lining materials.
Advantages
• High degree of flexibility in operations
• Easy operation
• Very less work place pollution
• Clean metal can be obtained
• No violent reactions in the bath
• From no load to full load, maximum power can be given
• Low melting loss (less than 3%)
Limitations.
• Only known and pedigree scraps can be used
• Cost of charge will be high compared to arc furnace & other furnaces
• Charge must be close-packed with minimum air gap for quick melting

2. Core or Channel type furnace.

• Mainly used for melting and storing of liquid cast iron
• Makes a very good combination with Cupola or duplex operations
• Heating of metal is based on principle of single phase transformer
• Induction heater has an iron core as primary circled by U–shaped
channels as secondary
• Core furnaces can be run continuously

CLOSING REMARKS
We also saw hot and cold box types of core preparation. I think we could
learn a lot more from a second trip to the same foundry. I also think that
some pre-visit preparation based on advice from HFL would be very
helpful.

All in all, it was a good learning experience.

13