Consumables in Wheel Manufacturing

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Questions and Answers

What is the primary function of an asbestos gasket in the casting of railway cast steel wheels?

To retain the ingate sleeve in position

To enhance the durability of the pouring tube

To provide structural support to the mold

To seal between the drag and pouring tube (correct)

What specific pressure is required to fix the Clay Graphite Tapered Ingate Sleeve in the graphite drag?

40-42 kg/cm2

60-62 kg/cm2

52-56 kg/cm2 (correct)

30-32 kg/cm2

What is the purpose of the pouring tube glaze?

To increase the pouring speed of molten metal

To enhance the aesthetic appearance of the tube

To ensure the pouring tube is air tight (correct)

To improve the thermal insulation of the pouring tube

Which consumable is primarily responsible for preventing the back flow of molten metal in the mold during casting?

Clay Graphite Stopper Signup and view all the answers

During the firing of Clay Graphite Tapered Ingate Sleeves, they must be encased in which of the following?

Graphite or calcined petroleum coke Signup and view all the answers

What role does the ceramic pouring tube serve in the casting process?

To direct the flow of molten metal into the mold Signup and view all the answers

What happens to the ingate sleeve after each casting in terms of its maintenance?

It is cleaned and reused after reaming Signup and view all the answers

In which atmosphere should the Clay Graphite Tapered Ingate Sleeve be fired?

In a controlled reducing atmosphere Signup and view all the answers

What is the maximum pressure allowed for the molten metal to rise through the ceramic pouring tube?

35 psi Signup and view all the answers

What material is required for proper sealing in the pouring tube assembly?

Clay graphite glaze Signup and view all the answers

What is the primary application of steel shots mentioned?

Cleaning and peening of cast steel wheels Signup and view all the answers

What is the hardness range of the cast steel wheels that steel shots are used on?

255 to 363 BHN Signup and view all the answers

In the data showing the average wheels cast per day, which year has the lowest average?

2015-2016 Signup and view all the answers

What was the average number of heats per day in 2014-2015?

22.62 Signup and view all the answers

What is the percentage of wheel rejection noted for the year 2015-2016?

7.31 % Signup and view all the answers

Which of the following figures represents the highest good wheels per day?

670 Signup and view all the answers

What was the change in average wheels cast per day from 2013-2014 to 2014-2015?

Increase of about 10 wheels Signup and view all the answers

Which month recorded the highest wheel rejection percentage?

May Signup and view all the answers

How many heats per day were recorded in 2013-2014?

22.75 Signup and view all the answers

What is the significance of steel shots in the wheel shop's operations?

To ensure the strength and durability of the wheels Signup and view all the answers

What is the primary purpose of Calcined Lime in the steel making process?

As a flux for making slag Signup and view all the answers

How does Ferro Silicon contribute to the steel casting process?

It acts as a ladle addition to achieve final silicon chemistry Signup and view all the answers

What role does Silico Manganese play in the context of steel production?

It is a ladle addition for achieving manganese and silicon chemistry Signup and view all the answers

What is the key function of Graphite Powder/Granules in steel production?

To maintain carbon content in the molten steel Signup and view all the answers

What is Magnaglo Powder primarily used for?

To locate surface and subsurface discontinuities in cast steel wheels Signup and view all the answers

What additive is used alongside Fused Silica Powder to prepare mould spray?

Veegum Signup and view all the answers

Which of the following is true regarding Ferro Manganese?

It serves as a furnace addition in steel-making practices Signup and view all the answers

Which property is NOT associated with Magnaglo Powder?

Used as a flux in steel melting Signup and view all the answers

What characteristic of Ferro Silicon is crucial for casting railway steel wheels?

Providing the final chemistry with respect to silicon Signup and view all the answers

What is not a function of Graphite Powder/Granules in the Electric Arc Furnace?

Reducing the temperature during melting Signup and view all the answers

Study Notes

Consumables for Wheel Shop

Consumables are used directly for wheel manufacturing (e.g., coke, graphite, ferro-silicon) or indirectly
Asbestos gasket: a sealant between drag and pouring tube in railway cast steel wheel casting, to prevent liquid steel bleeding; one gasket per wheel
Ingate sleeves: clay graphite tapered sleeves; fired/baked in a controlled reducing atmosphere; encased in graphite, calcined petroleum coke or similar during firing to prevent oxidation; fixed in graphite drag against taper for position using 52-56 kg/cm2 pressure
Ceramic pouring tube: assembled with pressure pouring tank cover; molten metal rises through the tube to the mold using controlled pressure (35 psi max) pouring technique
Pouring tube glaze: a coating for ceramic pouring tubes, applied by dipping; makes the tube air tight
Clay graphite stopper: made of clay graphite; prevents molten metal backflow after pouring in the mold; used for cast steel wheel manufacture
Calcined lime: a flux for slag in steel-making process using electric arc furnance melting practice
Ferro silicon: added to liquid steel tapped from electric arc furnace to achieve suitable silicon chemistry for railway steel wheel casting
Silico Manganese: added to liquid steel for achieving suitable manganese and partial silicon chemistry for railway steel wheel casting.
Ferro Manganese: used as a furnace addition in the making of steel from electric arc furnaces for railway steel wheel casting

Wheel Shop Specifications

Average Wheels Cast Per Day: data presented in a bar graph (13-14, 14-15, 15-16 periods shown)
Average Heats Per Day: data as a pie chart showing 2013-2014 to 2015-2016 periods. Numerical data given for each period:

-22.75,20.79, 22.62
Good Wheels Per Day: data in a bar graph (13-14, 14-15, 15-16 periods shown)
Wheel Rejection %: data shown in a pie chart, with breakdown of rejection percentages across different time periods (15-Apr, 15-May, 15-Jun, 15-Jul, 15-Aug)

Additional Consumables

Fused silica powder: used for preparing a spray for graphite molds, acting as stabilizer, suspending agent, binder, organic gum modifier ,and with additives of CMC and veegum for mold spray
Steel shots: used for cleaning and peening cast steel wheels (hardness 255-363BHN) - Sizes of shots are provided with ranges shown.

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Description

This quiz covers essential consumables used in the wheel manufacturing process. You'll learn about the various materials and their specific applications, including asbestos gaskets, ingate sleeves, and ceramic pouring tubes. Test your knowledge on how these components contribute to efficient and safe wheel production.