Manhole cover manufacturing process consists of 6 steps. Each steps must be done sequentially. The following description of the 6 steps of manhole cover manufacturing process:
Manhole Cover Manufacturing Process
1. Design and Simulation
SolidWorks program can simulate the process of metal casting on foundry manufacturing. So that things can lead to defect could be prevented faster.
After it, we conducted Quality Control to the pattern. This is to ensure that the pattern dimensions are suitable with the technical drawing and decide that the pattern has been ready for moulding.
The composition of sand moulds:
- Quartz sand : 80-90%
- Bentonite Binder Materials : 8 %
- Water : 4-5 %
- Carbon Ash : 3-4%
Sand also conducted a test press, fracture test, sinter test, fineness grain of sand test, bent test as in laboratory of Manufacturing Polytechnic Ceper, Indonesia.
Melting is a crucial process. At this step there is a process of pouring metal liquid into mould. Speed and temperature must be measured and conducted by principle as soon as possible, as close as possible, and as smooth as possible.
We use induction furnace in melting process. This furnace have advantage in speed of production and material composition is quite good.
The liquid to be poured will be tested compositions using a spectrometer, so fluid composition can be known earlier.
After all of the parts are clean from the sand, manhole cover will be conducted assembling between frame and cover.
6. Quality Control
Quality control is the last steps of manhole cover manufacturing process before shipment. This process consist of:
- Dimension Control
- Chemical Composition Control
- Mechanical Properties Control
- Phsycal Properties Control
After qualifying at quality control step, manhole cover ready to pack and deliver to the customer.