Laxminarayan Technologies Gokul Shirgaon, Kolhapur, Maharashtra

Wax Room

Applications : The Wax Melter is a wax-melting, conditioning and holding machine. Purchased solid slabs of IC Wax is melted, conditioned to a certain uniform temperature and transferred to the wax injection machines. The machine may also be used to blend various waxes for required properties or to add filler material in required proportions. The machine consists of 4 main functional assemblies the melting Chamber, the conditioning tank, the piston pump and the heated wax transfer hose.Melting Chamber :- The melting chamber is a wax melting device that can hold about 30Kgs of solid wax. Four strip heaters quickly heat up the Aluminium base to provide a melting rate of about 15Kgs/hr. The chamber is located at the top of the Conditioning tank. Wax slabs are stacked in the melting chamber. The molten wax flows into the SS Conditioning tank and is stirred continuously at a constant temperature to form a uniform blend.Conditioning Tank :- The SS Conditioning tank has an MS heated thermic fluid jacket to maintain constant & uniform temperature. A sturdy and well-designed full sweep stirrer mounted on thrust bearings is provided to ensure homogeneity of the wax blend in the conditioning tank ready to feed the piston pump on demand. A heated SS heavy-duty ball valve is provided for Wax drain. Piston Pump : (optional feature)The machine is optionally provided with a temperature controlled pneumatic actuated piston pump. The pump can provide a max. discharge of 6 lpm. The conditioned wax is pumped directly to the reservoir of the injection machine through a heated temperature controlled pipe provided for pump discharge.Control Panel :- The machine mounted control panel is provided with mains indicators, heater on/off indicators, Power switches, Fuses & control switches. The panel is designed with separate power circuit and control circuit and provided with emergency cut-off switch. All the 4 temperature zones are continuously monitored and controlled using 4 separate PID type Digital temperature Indicator Controllers. A level sensor with low level alarm is provided to control molten wax level in the conditioning tank.Available in 50Kgs, 100Kgs and 150Kgs capacities in standard design. Larger capacities are available subject to requirement.The entire machine is mounted on full swivel castor wheels, so that the machine is mobile and can be taken to injection machines to load wax. The entire exterior of the machine is powder coated.Safety :- All required safety’s for electrical and thermal protection are provided. The safety’s are incorporated in the design as well as additionally provided where required.

Applications : Runner bars and down sprues of different sizes and shapes are required for clustering of the wax patterns to form ‘trees’. Gravity casting is a preferred method to produce these in large numbers to support production. The ‘Sprue Maker’ is designed for gravity casting of runner bars and sprues – with or without metallic inserts. A sprue maker consists of a Wax melting chamber, Wax reservoir, Pneumatic Piston Pump, Set of sprue dies and Cooling water chamber.Melting Chamber :- The melting chamber is a wax melting device that can hold about 30Kgs of solid wax. Wax is continuously melted and flows into the wax reservoir where it is stirred continuously at a constant temperature to feed the piston pump on demand. The chamber is located at the top of the wax reservoir. Electrical strip heaters quickly heat up the Aluminium base to provide a melting rate of about 15Kgs/hr. Wax slabs are stacked in the melting chamber. Piston Pump :-The machine is provided with a temperature controlled pneumatic actuated piston pump. The pump can provide a max. discharge of 3 lpm. The molten wax is discharged from the pump outlet through a heated pipe. The delivery of the pump fills the carriage mounted dies by gravity. Dies Set :- Two sets of dies designed to carry an Aluminium metal insert for use with a Ceramic pouring cup and Plastic coated handle is supplied along with the machine as part of standard supply. Sprue moulds of client specific design can also be supplied instead on demand.Die cooling :-The dies are mounted on a rotary carriage for movement from wax filling point to immersion into cooling water chamber to stripping station. This enables quick movement and high productivity.

Applications : The prepared slurry from the slurry mixer is fed to the slurry pot. This machine is also known as dipping pot, as wax trees are dipped into slurry held in this pot. This slurry is kept under continuous stirring through out its use, in order to prevent the settling or separation of heavier refractories used in the slurry. The dipping pot is a rotating drum type tank, which rotates against a fixed baffle for stirring located within the inner periphery of the tank.Rotating drum type, stirred uniformly with ‘U’ type baffle, designed for smooth, silent and trouble free continuous operation. An SS304 ‘U’ type baffle is fixed on the inner periphery of the vessel to ensure agitation.The rotating SS vessel is mounted on cast iron mounting flange - provided with a steel shaft, both precision machined & aligned. This is then mounted on sturdy bearings housed in precision machined cast iron bearing box. The machine is provided with a heavy, sturdy and stable cast iron base frame. An AC reduction geared motor is coupled with a belt drive arrangement to drive the rotating drum at a smooth preferred rpm.The geared motor is mounted on a cast iron mounting plate, which is located on the side of the cast iron machine base. The motor is safely encased in a cover to prevent any spillage onto the motor.The SS 304 vessel is bolted onto the cast flange of the rotating base. This allows for easy removal of the vessel when required for cleaning. Working Height is designed to maximize worker comfort, particularly while handling heavy trees.The vessel is provided with an SS304 Lid that fits snugly onto the lip ring.The rotating drum is covered on all sides with a heavy MS powder coated drum. The top of the drum is covered with a cast iron smooth precision machined – Lip ring. This prevents the worker from coming in contact with the rotating drum & further allows him to rest his arms on the wide smooth Lip ring while handling heavy clusters.

Applications :To formulate and thoroughly mix the ceramic Investment slurry before it is added to the slurry pot. The quality & consistency of the ceramic slurry decides the quality of the castings produced. Hence this is essential equipment in shell room of any IC foundry. This machine can also be used for storage of prepared slurry over a long period of time, without risk of deterioration of slurry quality.Available in 100lts., 150lts or larger capacities on request.All wetted parts are SS – 304, other structures in heavy MS construction, for rigidity & long life.An SS 304 Hopper hatch of Dia. 200mm with lid is provided to feed ceramic investment material.1½” Polypropylene gate valve is Slurry drain. Located 500mm from ground level for ease of operation during draining of prepared slurry.The rotating SS vessel is provided with cast steel support structure and shafts, precision machined & aligned, mounted on sturdy double ball bearings in bearing housings. This is designed for continuous trouble free operationAn AC, 3 phase, reduction geared motor coupled with a chain & sprocket arrangement with appropriate safety cover drives the mixer

Shell trolleys are generally used in entry level commercial foundries. Foundries where the no. of shells processed is usually less than 100 Nos./day. Properly designed route cards and good supervision are essential to ensure consistent quality and productivity.

Shell racks are generally used in tiny foundries or in R&D or educational institutes. Foundries where the no. of shells processed is so less that process control is easy.

Shell Room Equipment

Shell Room

Applications : The de-waxed shells are fired to burn out wax residues and pre-heat the shells for pouring.Electrical Furnaces or Gas fired or Oil fired furnaces are available for this application based on preference. Furnaces of Box design to support melt sizes of up to 100Kgs are available.The Rotary hearth furnace that support higher capacities with the same efficiency are available.Furnaces structures are of MS construction.Ceramic Fibre blocks are used for Insulation on all sides.Insulating bricks and hot-face fire bricks are used to form the Hearth.Automatic temperature and firing Control by way of Digital temperature indicator controller and suitable control panel. The rotary hearth furnace is optionally computer controlled with status display on a colour LCD screen.Temperature Accuracy : + / - 5 deg C. Max. Temp. : 1050 deg C. Power supply : 500 W, 230 V, 1 phase, A C. All the furnaces are provided with Pneumatic vertical swing - arm doors for smooth and quick operation. A foot-switch is provided to control door movement.

Application: In the shell building process, the slurry coated cluster is coated with sand or ‘stuccoed’. The machine produces a uniform sand rain in which the slurry dipped wax cluster is manipulated to obtain a uniform coating of the refractory particles on the cluster.Description: The Rainfall Type Sander is a sand coating unit with self loading rotary type elevator. The machine is noise and vibration free. It is provided with a cyclone type dust collector. The unique self loading rotary design of the elevator allows for an integral rain making chamber which is noise & vibration free. The RTS-SLR becomes fully operational with as less just 10 Kgs sand in the Rotary elevator.a)A steady and uniform rain is generated within the work area. Maximize covering efficiency with minimum quantity of sand is achieved. Perforated steel sheet provided below rain area sieves the unused sand before reloading into rotary type elevatorb)The refractory sand is automatically and continuously loaded into the sand raining box. c)A mechanical elevator system of the rotary drum design of appropriate size is provided.d)An excess sand collection chute with a collection bin is provided. The bin can be used to unload the machine or change coating sand also.e)M O C is MS. All parts of the machine are completely powder coated.f)There are very few moving parts in the design, hence minimal maintenance & no downtime. Zero noise and vibration free working.g)A uniformly distributed steady rain is generated with as little as 10Kgs. sand.h)The RTS has been ergonomically designed to maximize worker comfort.i)Designed for silent, smooth and trouble free operation.j)This design ensures that there is min or no wastage of expensive refractory sand.Equipment Model No:RTS - SLR‘Self Loading Rotary’ type. MS construction. SS on request.Corrosion resistant finish : All MS parts of the machine are completely powder coated.Work Area -900mm Dia x 600mm depth. Rain area - 350 mm. x 350 mm.1Hp, 3 phase, 440V, 50 Hz, AC reduction geared motor, coupled with a belt drive arrangement with appropriate safety cover.Power - 2 Kw, Designed for continuous run with min power usage.

Rain Type Stucco Applicater

Melting Area

Applications : The machine is used to Knockout the Ceramic shell after metal casting. The knock-out is done by an adjustable rate pneumatic hammer, provided with a variable position carriage for clamping IC poured trees. The whole is mounted within a acoustic enclosure to minimize noise. This is further provided with dust removal system.Knockout of Ceramic shell is by a pneumatically actuated hammer.Poured IC Shell is clamped and held in place by a pneumatic actuated variable position carriage.The cast shells are held in position under a Clamping pressure of 400Kgs max.Main carriage movement is about 250mm or higher if required.Tools such as cone anvil of amphitheatre design & appropriate hammer head is provided for securely clamping & hammering the job.The machine structure is M S – Powder coated.Compressed air at 65 cfm. and at 6 Kg / sq cm is required.An FRL unit is provided to ensure supply of clean and lubricated air to the cylinder. The machine is housed in an acoustically insulated cabinet lined with noise dampening materials to minimize noise. The door is provided with an inspection window fitted with double layered safety glass or transparent acrylic sheet for protection.A trolley mounted bin is provided for collection of the broken shell waste. An ergonomically placed control panel is provided to operate the machine. Provided with mains indicators, Power On/Off switch, Fuses, Neutral link. The panel is designed with separate power circuit and control circuitA timer allows accurate control of the cycle times. Controls for carriage movement, clamp – declamp, Hammering cycle On/Off, Cycle complete indication and Door-open safety is provided.Operation:The shell is to be manually placed and clamped between the stationary jaw and the moving carriage mounted hammer tool. The door closed and cycle initiated on the control panel. The air supply to the hammer will auto start for a preset time. The high frequency vibrations generated break and dislodge the shell from the castings. The door is then opened & job is de-clamped manually.Available in Medium duty and Heavy duty models.

Investments Casting Foundry

Shell Materials :(Premixed Slurries)Premixed primary coat slurries and secondary coat LNC-Slurries : slurries – possess the following properties to ensure smooth manufacturing :Long shelf lifeExcellent refractoriesHigh green strength.Easy collapsibility during knock-outHi-solubility for chemical deshelling are the of that Refractory sands and flours that are used in investable ceramic mixes such as Silliminite & Fused quartz are available. The materials are uniformly sized, dust free, impurities are within controlled levels, and possess good refractoriness. All the materials are calcined and tested to assure consistent results.LNC – slurries and refractories are reliable tested materials - an assurance of good, consistent cast components. Slurry additives that are periodically added to maintain properties of slurries under use, such as Colloidal silica, wetting agents and de-foamers are available.

Refactory Stuccos and Flours:-LNC Refractories cover a broad line of refractories that include fused silica, zircon, and alumino-silicate. Fused SilicaGood Rheology. Low thermal expansion. Resistance to thermal shock. Light weight. Easy knockout. Long slurry life. High permeabilityHigh Solubility. Good insulator For ferrous and non-ferrous applications. Zircon:-Very low reactivity (good for prime coats). Fine particle size for good surface quality. High strength. Excellent rheology. High solids loading capability. Alumino-silicate:-LNC alumino-silicate refractories have tight particle size distribution to minimize dust and maximize shell strength. Excellent refractoriness. Good strength. Wide range of stucco sizes. Relatively low thermal expansion. Economical. Available in 40% and 60% Alumina content.

Investment Casting and Sand Casting Foundry

The LNC Wax Injectors are Hydraulically actuated machines. The functions of the Press, Nozzle movements, Nozzle height adjustment, Injection, Injection shot size,Injection Pressure and Injection

The Press :The LNC Injectors are available in a variety of models in 4 - Pillar and C-Frame press designs. The total clamping force of the precision engineered press is calculated to accurately off-set the forces created during injection at maximum pressures.The press is provided with several standard features. These features are built-in to enhance productivity of the machine. Optional features that take efficiency to new highs are also available. Standard Press Features :The die clamping press has several features that are aimed at higher productivity, consistency and minimising operator fatigue. These are standard features for all models of LNC wax Injectors.M8 holes in a 50mm X 50mm grid are provided on the bottom & moving platens of the press for die mounting.Provision for platen cooling is provided as standard. The moving and Bottom platens of the press are provided with paths for coolant circulation. A die aligning jig is provided. This jig enables the operator to align the die correctly with the nozzle quickly. The jig is normally used when the dies are manually handled during short runs.Optional Features available :-LNC Injectors are offered with several optional features that further enhance productivity to new high. These options are normally available for the automatic models only. Three ‘T’ slots perpendicular to the nozzle may be chosen as the preferred die mounting facility in place of the M8- hole grid. Or a “quick-change die mounting” feature with hydraulic die-clamp facility may be chosen. This facility will bring the tool or die change time down to a few minutes further increasing productivity.Temperature is one of the most important control parameter of the injection machine. Platen temperature display is provided. Platen temperature display & control along with apparatus for cooling only or heating + cooling.Accelerated Press approach & return with soft clamping feature is provided to minimise cycle time & increase productivity.

Application: The FLUIDIZED BED types of stucco machines are meant for backup stucco. It is used for refractory sands of larger grain sizes like - 16 +30, -30 +40, or -60 +80. For the backup coats, the Fluidized Bed gives a uniform coating and high stucco efficiency. The Fluidised beds are available in Blower driven models and Compressed air driven models. Available in Powder coated MS construction or in SS304 construction on request. Driven by a blower supplied along with equipment or driven by Compressed air available at site.A cyclone type dust collector is supplied to uniformly remove the dust generated during operation.Alumina silicate refractory sands of -16 +30, -30 +40, or -60 +80 or similar mesh sizes are thoroughly fluidized.The Fluidised bed is designed to generate uniform fluidizing in the sand to maximize covering efficiency. A Bin – lid is provided to ensure that the major load of dust generated can be directed out through the Dust collection chute, keeping the work area as clean as possible.For Compressed air driven models, the Stucco bin is provided with a 11/4” dia. solenoid controlled Air shut-off valve. These valves are operated by a foot-switch. The operator activates the foot switch to fluidise the sand and deactivates it to shut the air & stop fluidising or agitation.The stucco bin is provided with a 11/2” dia. Drain port. If the sand is fluidised with the bin-lid closed and drain port open, all the refractory sand flows out of the bin through the drain port.The Fluidising drum has pneumatic operated tilt facility. This is to facilitate periodic cleaning of the drumEquipment Model No:FBS-5/7.5In case compressed air is not available, the fluidized beds can be driven by an appropriately designed blower. A blower with suction control valve will be supplied along with the fluidizing beds.

Shell drying conveyors is essential shell room equipment used in medium and large commercial foundries, where more than 150 shells are processed each day. Process control is computerised. Drying times for each shell is tracked by the PC. Operational instructions are continuously displayed on the LCD for each shell. The humidity and temperature of the shell room, air circulation, devices to create lamellar air flow around the shells to ensure uniform and quick drying of shells are all monitored, controlled and recorded by the conveyor computer.