SHREE N.M.GOPANI POLYTECHNIC INSTITUTE

Transcription

1 SHREE N.M.GOPANI POLYTECHNIC INSTITUTE KINARA, RANPUR , DIST. AHMEDABAD. ( AN ISO 9001 : 2008 CERTIFIED POLYTECHNIC) PROJECT REPORT: METALLURGY (MET 1) BATCH INDUCTION FURNACE 1

2 DEMO MODEL OF INDUCTION FURNACE GUIDED BY:- S.K.SITAPARA HELPED BY:- SANGHANI MAULIK (SANGHANI ENGG) PREPARED BY:- DHWANISH.N.SHAH PREYASH SHAH S DIPAK PATEL S PARESH PATKAR S MITESH PATEL S NARENDRA MAHTO S ANKUR JYOTISHI S IDRIS VHORA S BRIJESH PATEL S

3 We are very thankful to Shree:- H.H.JADAV SIR. And the other staff members who have given us proper guidance and advice in this project. Also we are especially thankful to all classmate and friends who encouraged and help us in this project. 3

4 CERTIFICATE This is to certify that the below students Reg no :- Of Diploma programme in Metallurgy has satisfactorily completed their project with in four walls of N.M.G.P during term 092. Date of submission:- Staff incharge:- Head of department:- 4

5 INDEX 1. ACKNOWLEDGEMENT 2. ABSTRACT 3. AIMS OF PROJECT 4. INTRODUCTION 5. CONSTRUCTION 6. WORKING 7. AFECTING FACTOR 5

6 ACKNOWLEDGEMENT WHILE PREPARING THIS PROECT OF HOME MADE INDUCTION FURNACE. THE PROJECT HAS BECOME QUITE HELPFUL TO US, SO WE ARE HEARTLY THANKFULL TO THE ORGANIZATION: SANGANI ENGINERING. OUR RESPECTABLE MR. H.H.JADAV GAVE US A PRICELESS GUIDANCE & ENCOURAGEMENT. AND WE ARE THANKFULL TO HIM FOR HIS CO- OPERATION AND KIND BEHAVIOUR WITH US. WE ARE ALSO THANKFULL TO THE WHOLE FACULTY OF METALLURGY DEPARTMENT FOR GIVING US THEIR SUPPORT. 6

7 ABSTRACT THROUGH THIS TOPIC WE WOULD TRY TO EXPLAIN THE FEW DETAIL ABOUT THE HOME MADE INDUCTION FURNACE. FOR THE MELTING OF DIFFERENT MATERIALS LIKE LEAD, GUN METAL, ALLUMINIUM. IN THESE DAYS THERE IS LOT OF INDUCTION FURNACE AS IT IS USEFULL IN MELTING THE WASTE MATERIAL AND RE USE IT ONCE AGAIN. WE HAVE SELECTED THIS PROJECT BECAUSE TODAY THERE IS MASS REQUIREMENT AND EASY TO MANUFACTURE ANY PRODUCT BY PREPARING ITS MOULD AND POURING THE MOLTEN METAL IN THE MOULD. HERE WE HAVE TRIED TO MAKE A SIMPLE STRUCTURE OF HOME MADE INDUCTION FURNACE. 7

8 AIMS OF PROJECT The aim of project is described as follows. To develop on altitude of inquiry To work as a leader and member of a team. To measure physical phenomena. To develop ability of report writing. To develop planning and decision making skill To develop and store the records how to keep 8

9 INTRODUCTION Induction furnaces are the most widely used type of furnace for melting iron and are increasingly popular for melting non-ferrous metals. They are popular because they provide excellent metallurgical control and are relatively pollution free. Induction furnaces use alternating currents to create heat and melt the metal. The refractories are usually made of silica, alumina or magnesia. The two most common induction melting furnace designs are the coreless and channel furnaces. Coreless induction furnaces are used for smaller (5-10 ton) operations. Coreless furnaces are preferable where gas pickup and volatile metal alloy loss is a problem. 9

10 MATERIAL LIST SR PART NAME SPECIFICATION QTY. NO. 01 OUTER STRUCTURE M.S PLATE OF LOWER GAUGE. 1 Nos. 02 INSULATION RAMMING MASS, CERAMIC INSULATION 1 Nos. 03 HEATER MADE FROM COPPER 1 Nos COIL 04 INSULATION GLASS WOOL 1 Nos. 05 CRUCIBLE FURNACE MAD FROM GRPHITE 1 Nos. 06 TEMEPARUTE CONTROLLER HELPS TO CONTROL AND SET THE 1 Nos. 07 BRAZING POWDER 08 STAND OF OUTER STRUCTURE 09 HANDLE TO OPEN THE FURNCAE 10 HANDLE TO GET OUT THE CRUCIBLE FROM THE FURNACE TEMPERATURE TO INCREASE THE BONDING STRENGHT OFTHE MATERIAL 500 MG BACK COULERED 4 PLASTIC STAND Nos. FIBRE 1 Nos. M.S AND FIBE CVERED TWO LAST ENDS 1 Nos. 10

11 CONSTRUCTION THE HOME MADE INDUCTION FURNACE IS CONSTRUCTED AS FOLLOWS: THE OUTER STRUCTURE OF THE FURNACE IS CREATED OF THE M.S. THE INNER SIDE OF THE M.S STRUCTURE IS COATED WITH COIL COAT, RAMMING MASS, CERAMIC INSULATION. AFTER PREPARING THE LAYER OF THIS INSULATION A HEATER IS ATTACHED TO NEXT TO THE INSULAION LAYER. THE HEATER IS MADE UP OF COPPER COIL AND IT IS SELECTED ACCORDING TO THE CAPACITY OF THE FURNACE. AFTER THE FIXING OF THE HEATER AND AFTER THE WIRING IS COMPLETED, THE HEATER IS COVERED WITH A ONE MORE TYPE OF INSULATION, CALLED GLASS WOOL. ONE ANTENNA IS LEFT INSIDE THE INSULATION OF GLASS WOOL WHICH PROVIDES HEAT TO THE CRUCIBLE FURNACE. THE WIRING OF HEATER IS DONE WITH THE TEMPERATURE CONTROLLER AND THIS TEMPERATURE CONTROLLER IS CONNECTED WITH THE SINGLE PHASE SUPPLY. THE TEMPERATURE CONTROLLER SHOWS THE TEMPERTURE IN DEGREE AND IT ALSO INCLUES THE DIGITAL METER FOR THE PERFECT READING 11

12 WORKING After placing the crucible in the the furnace the further pricess is started The temperature is been set on the temperature controller. Firstly the crucible is been reheated in the furnace only at 100 to 150 *c Then the material which is to be melted is added to the crucible after reheating. It takes 45min for the furnace to have the temperature between 750 t After the proper charging of the material as per our requirements the additives are added. After 45min we can see the rmetal(alluminium) start melting. Then when the metal get proper melting the flux is been added to remove the slag from our molten metal. Then after removing the slag the sample is taken in thermocouple cup and is tested. The further process is done after taking reading. And finally if we get the proper composition the metal is ready to be poured. 12

13 Merits Induction furnace can melt relatively small quantities of a wide variety of metals and alloys quickly, conveniently and cleanly. Magnetic stirring of the melt produces excellent uniformity of the melt composition. Rate of energy input can be readily controlled. Furnace atmosphere can be easily controlled. A number of alloys one after the other can be easily melted in this type of furnaces. Additions of elements like Ni,Co,Cr,W,Mo,V,etc.can be made easily and conveniently. Higher Yield : The absence of combustion sources reduces oxidation losses that can be significant in production economics. This can amount to 2 to 7 percent yield savings in aluminum melting. Faster Startup : Full power from the power supply is available, instantaneously, thus reducing the time to reach working temperature. Cold chargeto-tap times of one to two hours are common. Flexibility : No molten metal is necessary to start medium frequency coreless induction melting 13

14 equipment. This facilitates repeated cold starting and frequent alloy changes. Natural Stirring : Medium frequency units can give a strong stirring action resulting in a homogeneous melt. Cleaner Melting : No by-products of combustion means a cleaner melting environment and no associated products of combustion pollution control systems. Automatic Operation : Precise automatic control of power reduces furnace manpower to that required only for charging, tapping, and metallurgical measurements. Compact Installation : High melting rates can be obtained from small furnaces. A coreless furnace capable of melting 2,500 lbs./hr. of aluminum has a crucible measuring 3' in diameter by 6' in depth. Reduced Refractory : The compact size in relation to melting rate means induction furnaces require much less refractory than fuel-fired units. New hydraulic ram systems allow relining times to be greatly reduced as old worn linings can be quickly pushed out for easy replacement. Better Working Environment : Induction furnaces are much quieter than gas furnaces, arc furnaces, or cupolas. No combustion gas is present and waste heat is minimized. Energy Conservation : Overall energy efficiency in induction melting ranges from 55 to 75 percent, and is significantly better than combustion processes. 14

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16 Demerits Initial cost is high Due to high speed of melting bath sampling cannot be carried out. Refining process cannot be used due to the difficulties in maintaining hot fluid, and reactive slag on the metal surface. 16

17 REMARKS THANK YOU 17