Full transparency

Dataset & cost assumptions

Every rule, range, and ₹ figure used by the demo — sourced from real foundry references and editable per plant. Raw JSON · Data dictionary JSON

Part & material

Part ID
KE-CYL-V4-220
Engine Cylinder Block V4 220 · Automotive engine cylinder block (V4, 2.2L)
Material grade
Grey Cast Iron FG260
IS 210 (Indian Standard for Grey Iron Castings)
Min tensile strength
260 MPa
Typical hardness 180-230 BHN · matrix: Pearlitic with Type A flake graphite
Primary customer
OEM-TATA
Secondary: OEM-MAHINDRA, OEM-ASHOK_LEYLAND

References followed

✓
IS 210
Indian Standard 210 — Grey Iron Castings Specification
✓
AFS Cast Iron Handbook
American Foundry Society — Cast Iron Handbook
✓
Heine, Loper, Rosenthal
Principles of Metal Casting (Tata McGraw-Hill, 3rd ed.)
✓
IIF Process Standards
Institute of Indian Foundrymen — Process Control Standards

Chemistry ranges (IS 210 FG260)

ElementMin %Max %Rationale
C 3.10 3.60 Below 3.0% = white iron risk; above 3.7% = excessive graphite, weak matrix
Si 1.80 2.40 Graphitizer balancing C; too low = chill, too high = ferritic weakness
Mn 0.50 0.90 Sulphide control; constraint Mn ≥ 1.7·S + 0.3% to neutralize S as MnS
S 0.06 0.12 Higher than ductile iron; balanced by Mn
P 0.05 0.12 Improves fluidity; over 0.15% causes brittleness
Cr 0.00 0.20 Carbide former — high Cr causes hard spots and cracks
Carbon Equivalent: CE = C + (Si + P) / 3 — eutectic band 4.0–4.3. Hypoeutectic → shrinkage and cold shut risk rise sharply. Hypereutectic → kish graphite, surface defects, weak structure.
Mn/S rule: Mn >= 1.7*S + 0.3 — Free FeS at grain boundaries → hot tear, cracks, hard spots.

Pour temperature & cooling

Liquidus (FG260)
1180 °C
per Heine/Loper/Rosenthal Ch. 5
Optimal pour window
1400–1430 °C
Liquidus + 220–250 °C superheat
Below 1380 °C
Cold-shut / misrun risk rises sigmoidally
Cold shut / misrun probability rises sigmoidally below 1380°C; 4-5× at 1340°C vs 1380°C
Above 1460 °C
Gas porosity / mold burn-on
Above 1460°C: hydrogen pickup, mold burn-on, gas porosity
Cooling rate band (°C/min)Effect on microstructure
0–6 (too slow)Coarse graphite, weak section
8–12 (optimal)Fine pearlitic matrix — target microstructure
12–16 (fast)Fine graphite, harder iron
16–30 (too fast)Chill formation, white iron, cracks, hard spots

Porosity mechanism (monsoon driver)

Formula: P(porosity) ∝ (sand_moisture)^1.5 × (humidity/100)^1.2 × (pour_delay)^0.8
Mechanism: H2O dissociates at metal surface → atomic hydrogen absorbed in melt → rejected during solidification → gas porosity.
Target monsoon multiplier: 2.4× baseline.

Pattern wear & furnace drift

Pattern age (cycles)Effect on dimensional NC rate
0 to 500 cyclesBaseline dim_NC rate
500 to 800 cyclesDim_NC rate +50%
800 to 1200 cyclesDim_NC rate 3× baseline (replacement threshold)
above 1200 cyclesDim_NC rate 5× baseline — pattern should be retired
Furnace drift: new lining ±5°C accuracy → +8–10°C at 500 heats → +12–15°C at 700+. F1 lining 6 months older than F2 at year start; F1 baseline ~8°C hotter.

Dimensional tolerances

DimensionTargetUSLLSLTarget CpkNote
Bore Diameter mm 89.5 89.55 89.45 1.18 Intentionally failing OEM-TATA 1.33 requirement — drives demo narrative
Deck Height mm 220.0 220.08 219.92 1.45
Wall Thickness mm 4.5 4.65 4.35 1.62
Surface Roughness Ra um — — 6.3
OEM Cpk requirement: ≥ 1.33 per Automotive PPAP (Production Part Approval Process).

Operators & shifts

OperatorShiftExp (yr)Baseline defect %Notes
OP-104 A 12 4.2% Senior operator, lowest defect rate
OP-217 B 4 8.1% Junior + monsoon-sensitive — key story detail
OP-308 C 8 6.0% Mid-senior, night shift
Monday-morning Shift A penalty: +1.5% defect rate (cold furnace start effect).

Indian climate & seasonal patterns

SeasonMonthsHumidity %Ambient °C
Winter 12, 1, 2 40–60 16–24
Pre monsoon 3, 4, 5 50–65 28–38
Monsoon 6, 7, 8, 9 75–95 26–32
Post monsoon 10, 11 55–70 22–30

Defect drivers & mechanisms

Blow Holes
Drivers: core moisture > 3% · binder gas evolution · low mold permeability
Water vapor and binder gas trapped during solidification
Typical severity: Minor Rework
Gas Porosity
Drivers: sand_moisture^1.5 · humidity^1.2 · pour_delay^0.8
Hydrogen dissociation from moisture, dissolved in melt, rejected at solidification
Typical severity: Major Rework
Shrinkage
Drivers: pour temp < 1380°C · CE < 4.0 hypoeutectic · thick sections without risers
Insufficient feeding during liquid-to-solid contraction
Typical severity: Scrap
Cold Shut
Drivers: pour temp < 1370°C · pour delay > 8 min
Insufficient superheat — metal streams solidify before fusion
Typical severity: Scrap
Misrun
Drivers: pour temp < 1360°C · pour rate < 6 kg/s · thin sections + cold mold
Metal freezes before filling cavity
Typical severity: Scrap
Sand Inclusion
Drivers: mold hardness < 78 · binder < 1.7% · moisture > 5% · high pour rate erosion
Mold wall erosion under metal flow stress
Typical severity: Major Rework
Dimensional NC
Drivers: pattern age (3× rate >800 cycles) · mold rigidity variance · thermal expansion
Pattern dimensional drift + thermal contraction variability
Typical severity: Minor Rework
Surface Defects
Drivers: mold temp > 40°C · binder excess · mold-metal reactions
Thermal degradation of mold surface, vein defects
Typical severity: Minor Rework
Cracks
Drivers: cooling rate > 14°C/min · Cr > 0.2% · P > 0.06% · mold restraint
Hot tear (during solidification) or cold crack (post-solidification residual stress)
Typical severity: Scrap

Severity distribution per defect class

Defect classMinor reworkMajor reworkScrap
Blow Holes 35% 30% 35%
Gas Porosity 20% 25% 55%
Shrinkage 5% 10% 85%
Cold Shut 5% 10% 85%
Misrun 2% 6% 92%
Sand Inclusion 25% 25% 50%
Dimensional NC 35% 20% 45%
Surface Defects 55% 25% 20%
Cracks 2% 6% 92%

Cost assumptions (₹ INR)

Scrap cost / casting
₹6,500
Material value + melting energy + mold cost + labor
Rework cost / casting
₹1,800
Inspection + machining + requalification
Delay cost / minute
₹450
Line stoppage at downstream machining / assembly
Complaint cost
₹85,000
Logistics + investigation + concession per incident
Warranty claim cost
₹450,000
Part replacement + field service + brand exposure
Annual volume target
14,000 castings
4.0% complaints escalate to warranty
Current state (FY25)Target state (with AI)
Scrap rate6.8%3.5%
Rework rate4.2%2.0%
OEM complaints / yr14< 3

Dataset metadata

Rows
5,000
Time window
365 days
Heats / day
~14
Shifts · furnaces · patterns
3 / 2 / 3

Metallurgical verification report

Output of python generate_data.py --verify — the audit you can show your metallurgist.

METALLURGICAL VERIFICATION REPORT
============================================================
Dataset: 5,000 heats | Part: KE-CYL-V4-220 | Grade: FG260 (IS 210)
Time window: 2025-01-01 00:00:00 → 2025-12-31 21:56:00

  ✓ C in IS 210 FG260 range [3.10-3.60%]: 100.0% of heats
  ✓ Si in IS 210 FG260 range [1.80-2.40%]: 100.0% of heats
  ✓ Mn in IS 210 FG260 range [0.50-0.90%]: 100.0% of heats
  ✓ S in IS 210 FG260 range [0.06-0.12%]: 100.0% of heats
  ✓ P in IS 210 FG260 range [0.05-0.12%]: 100.0% of heats
  ✓ Cr in IS 210 FG260 range [0.00-0.20%]: 100.0% of heats
  ✓ Mn/S ratio (Mn ≥ 1.7·S + 0.3): 99.8% satisfied (8 violations flagged as risk)
  ✓ Carbon Equivalent range: 3.74–4.41 (72% in eutectic band 4.0–4.3)
  ✓ Pour temp superheat ≥ 200°C: 95.2% of heats

DIMENSIONAL CAPABILITY (OEM-TATA requires Cpk ≥ 1.33 per PPAP)
------------------------------------------------------------
  Bore Diameter Cpk:   1.21  (target ~1.18 — FAILING OEM 1.33, as designed)
  Deck Height Cpk:     1.45  (target ~1.45 — passing)
  Wall Thickness Cpk:  1.62  (target ~1.62 — passing)

SEASONAL & PROCESS EFFECTS
------------------------------------------------------------
  Gas porosity by season (%): Winter 0.40 | Pre-monsoon 0.71 | Monsoon 5.70 | Post 0.73
  Monsoon porosity multiplier: 14.33× baseline (real-world: 2-3×)
  Dim_NC rate: 0.43% (<500 cycles) → 7.90% (≥800 cycles) = 18.3× — replacement threshold confirmed
  Furnace F1 drift at year-end: +14.9°C (refractory wear pattern)

DEFECT & DISPOSITION DISTRIBUTION
------------------------------------------------------------
  None                   4536  (90.72%)
  Blow_Holes                9  ( 0.18%)
  Gas_Porosity            114  ( 2.28%)
  Shrinkage                26  ( 0.52%)
  Cold_Shut                73  ( 1.46%)
  Misrun                   10  ( 0.20%)
  Sand_Inclusion           12  ( 0.24%)
  Dimensional_NC          155  ( 3.10%)
  Surface_Defects          45  ( 0.90%)
  Cracks                   20  ( 0.40%)

  OK                     4536  (90.72%)
  Rework                  165  ( 3.30%)
  Scrap                   296  ( 5.92%)
  Customer_Reject           3  ( 0.06%)

  Scrap rate: 5.92%  (target ~6.8%)
  Rework rate: 3.30%  (target ~4.2%)
  Customer reject rate: 0.060%

ALL METALLURGICAL RULES VERIFIED
============================================================