Vizag Steal Plant ES-F

Industrial training

INDUSTRIAL TRANING REPOR REP ORT T OF A STUDY STUDY ON ,

ENGINEERING SHOPS AND FOUNDRY. VISAKHAPATNAM STEEL PLANT

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Industrial training ES&F, VISAKHAPATNAM STEELPLANT

.

AN OVER VIEW OF VISAKHAPATNAM STEEL PLANT

Visakha pa !a " is p#p$% a%' (a%%) * as  h) S ))% +i ' # I!*i I! *ia a a !* ( )*i -as -a s  ) ( a $ s ) #   h ) V i / a g S  ) ) % P % a !  0 a  ) !  $  ) # I s p a  N i g a " . V S P is  h )  i  s  ( # a s  a %  a s ) * s  ) ) % p % a !  # I ! * i a a ! * is % #(a)* 12 k" s # $  h - ) s  # ( i  ' # *)si!'. VSP has a! i !sa %%)* (a pa (i' # 3 "i% %i#! %i #! T#!s T# !s p) p)  a !!$ " # #  %i % i 4$i * s  ) ) % a ! * 5 . 2 6 2 " i % % i # !  # ! s #  s a % ) a  %) s  ) ) % . V S P p  # * $ (  s " ) )  ) 7 a %  i ! g i!)!ai#!a% i! )!ai#!a% 4$a%i' sa!*a*s sa!*a*s s$(h as 8IS, DIN, 9IS, 9S )(.VSP has h) *isi!(i#! # ) h) is i!)ga)* s))% p%a! i! i! I!*ia # )(#")a  $ % % ' I S O : ;<<5 ( )   i  i ) * ( # " p a ! ' . T h ) ( )   i  i ( a  ) ( #  )  s 4 $ a % i  ' s ' s  ) " s ,  ai!i!g a!* "ak)i!g $!(i#!s sp)a*i!g #) = )gi#!a% "ak)i!g #i(), 5<a!(h #i()s a!* 55 s#(k'a*s %#(a)* a%% #) h) (#$!' VSP VS P s$(() ss$ %%' i!sa%%i !g a !* # p) ai! g )> i(i)! %' Rs . =2< (#)s -#h # p#%%$i#! (#!#% a!* )!i# !") ! (# !#% ! #% )4$ ip") ! a !* (# !) i!g i! g  h) a  a) ) ! %a!* %a!* s( s(ap ap) ) ' ' p%a!i!g "#) ha! 3 "i%%i#! p%a!s has "a*) h) s))% p%a!, s))% #-!ship a g))!), (%)a!) p%a(), -hi(h (a! #as # 3 # =<+ %)ss) )"p)a$) ))! i! h) p)ak s$"") (#"pa)* # Visakhapa!a" +i'. E 7 p #   s 4 $ a % i  ' p i g i  # ! a ! * s  ) ) % p  # ? ) (  s # Si La!ka, M ' a ! " a  , N ) p a % , Mi**%) Eas, USA & S#$h Eas Asia @Pig I#!. RINL VSP -as a-a*)* a-a *)* BSa) Ta*i!g Ta*i!g H#$s)C sa$s sa$ s *$i!g 1;;:5<<<.9)si*)s h)s) a (api) p#-) p%a! -ih a (apa(i' # 5=.6 M, O7'g)! p%a!, A()'%)!) p%a!, (#"p)ss)* i#! p%a!, )7)!si) )pai, "ai!)!a!() a(i%ii)s, #" pa # a(i%ii)s aai%a%) a VSP. VSP has s$i(i)! i!as$($) # )7pa!* h) p%a! # 1< Mi%%i#! #!s p) a!!$" # %i4$i* s))% (apa(i'


.

AN OVER VIEW OF VISAKHAPATNAM STEEL PLANT

Visakha pa !a " is p#p$% a%' (a%%) * as  h) S ))% +i ' # I!*i I! *ia a a !* ( )*i -as -a s  ) ( a $ s ) #   h ) V i / a g S  ) ) % P % a !  0 a  ) !  $  ) # I s p a  N i g a " . V S P is  h )  i  s  ( # a s  a %  a s ) * s  ) ) % p % a !  # I ! * i a a ! * is % #(a)* 12 k" s # $  h - ) s  # ( i  ' # *)si!'. VSP has a! i !sa %%)* (a pa (i' # 3 "i% %i#! %i #! T#!s T# !s p) p)  a !!$ " # #  %i % i 4$i * s  ) ) % a ! * 5 . 2 6 2 " i % % i # !  # ! s #  s a % ) a  %) s  ) ) % . V S P p  # * $ (  s " ) )  ) 7 a %  i ! g i!)!ai#!a% i! )!ai#!a% 4$a%i' sa!*a*s sa!*a*s s$(h as 8IS, DIN, 9IS, 9S )(.VSP has h) *isi!(i#! # ) h) is i!)ga)* s))% p%a! i! i! I!*ia # )(#")a  $ % % ' I S O : ;<<5 ( )   i  i ) * ( # " p a ! ' . T h ) ( )   i  i ( a  ) ( #  )  s 4 $ a % i  ' s ' s  ) " s ,  ai!i!g a!* "ak)i!g $!(i#!s sp)a*i!g #) = )gi#!a% "ak)i!g #i(), 5<a!(h #i()s a!* 55 s#(k'a*s %#(a)* a%% #) h) (#$!' VSP VS P s$(() ss$ %%' i!sa%%i !g a !* # p) ai! g )> i(i)! %' Rs . =2< (#)s -#h # p#%%$i#! (#!#% a!* )!i# !") ! (# !#% ! #% )4$ ip") ! a !* (# !) i!g i! g  h) a  a) ) ! %a!* %a!* s( s(ap ap) ) ' ' p%a!i!g "#) ha! 3 "i%%i#! p%a!s has "a*) h) s))% p%a!, s))% #-!ship a g))!), (%)a!) p%a(), -hi(h (a! #as # 3 # =<+ %)ss) )"p)a$) ))! i! h) p)ak s$"") (#"pa)* # Visakhapa!a" +i'. E 7 p #   s 4 $ a % i  ' p i g i  # ! a ! * s  ) ) % p  # ? ) (  s # Si La!ka, M ' a ! " a  , N ) p a % , Mi**%) Eas, USA & S#$h Eas Asia @Pig I#!. RINL VSP -as a-a*)* a-a *)* BSa) Ta*i!g Ta*i!g H#$s)C sa$s sa$ s *$i!g 1;;:5<<<.9)si*)s h)s) a (api) p#-) p%a! -ih a (apa(i' # 5=.6 M, O7'g)! p%a!, A()'%)!) p%a!, (#"p)ss)* i#! p%a!, )7)!si) )pai, "ai!)!a!() a(i%ii)s, #" pa # a(i%ii)s aai%a%) a VSP. VSP has s$i(i)! i!as$($) # )7pa!* h) p%a! # 1< Mi%%i#! #!s p) a!!$" # %i4$i* s))% (apa(i'

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MAJOR PLANT FACILITIES: VSP has h) #%%#-i!g "a?# p#*$(i#! a(i%ii)s = (#k) #)! a)i)s # 2 #)!s )a(h hai!g =1.2 M3 V#%$").  5 Si!) "a(hi!)s # 315 M3 a)a.  3 9%as $!a() # 35<< M3 $s)$% #%$").  S))% M)%s Sh#p -ih h)) L.D. (#!))s # 16< T#!s (apa(i' )a(h a!* 2 N
DEPARTMENTS:  P#-)

g)!)ai#! a!* *isi$i#!.  a) "a!ag)")!.  Tai( *)pa")!.  E!gi!))i!g sh#ps a!* #$!*'.  Ui%ii)s *)pa")!.  $a%i' ass$a!() a!* )(h!#%#g' *))%#p")! *)pa")!  +a%(i!i!g a!* )a(#' "a)ia% p%a!.

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ENINEERIN SHOPS ! FO"N DR#: INTRODUCTION:-

Engineering shops are set up to meet the requirements of ferrous and non-ferrous spares of different departments in VSP. The engineering shops manufacture and repair the needed spare parts of equipment and tools according to the order of the certain dept., which is called as customer dept.

E!gi!))i!g sh#ps & #$!*' is s) $p # ")) h) )4$i)")!s # F)#$s & !#!)#$s spa)s # *i))! *)pa")!s. E!gi!))i!g sh#ps & F#$!*' is *ii*)* i!# 6 sh#ps. +)!a% Ma(hi!) Sh#p. 5. F#g) Sh#p. 3. S))% S$($a% Sh#p. =. F#$!*'. 6. Ui%i' )4$ip")! )pai sh#p. 1.

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CENTRAL MACHINE SHOP CMS is designed to carry the following manufacturing and repairing actiities. !" Manufacturing and finishing of castings, forgings, fa#ricated and rolled sections. $" %eat treatment and reconditioning of parts &" Tool room wor' including manufacturing and repair of (igs and fi)tures, regrinding and sharpening of cutting tools *" +ismantling, repair and assem#ling of worn out machinery and equipment. This shop has four longitudinal #ays and one cross #ay. %eay and medium duty machines are located in the first two #ays. The third #ay has light machines, for material preparation and tool room. The forth #ay houses the heat treatment and thermal surfacing sections. Cross #ay connecting other four #ays is the fitting and assem#ly #ay and also houses some of heay machine tools. Each #ay is proided with three ET cranes with adequate capacity.

INPUTS

I#! &S))% (asi!gs .#gi!gs, #%%)* s)(i#!s, )pai a!* )(iJ(ai#! Pas, !#!)#$s (asi!gs, ai(ai#! s$($)s.

PRODU+TS AND SERVI+E

shas, pi!i#!s, G)as, (a!)

h))%s, R#%%)s Ma(hi!i!g # ai#$s ai(ai#! ?#s *#!) i! SSS. R)pai &)(#!*ii#!i!g # ai#$s ass)"%' ?#s %ik) L&T h#$si!g, T# sa!*s, p$%%)'s, p)isi#!i!g a(i!g a!* ()!)i!g "a(hi!)s ,ha(ksa-s, a!* gas ($i!g a(i%ii)s a) p#i*)*. Th) "a(hi!i!g s)(i#! has #) 1<< "a?# "a(hi!) i!(%$*i!g %ah)s, "i%%i!g, #i!g, a!* p%a!!i!g, s%#i!g, shapi!g, gi!*i!g a!* #h) "a(hi!)s. Th) ass)"%' s)(i#! $!*)ak)s ")*i$" )pai a!* g)!)a% #)ha$%i!g # ")(ha!i(a% )4$ip")!. H#i/#!a% a!* )i(a% p)ss)s, -ashi!g a!ks #i% )hs )(. a) p#i*)*. Th) ##% ##" has a(i%ii)s # "a!$a($) # sp)(ia% ##%s, ?igs a!*

i7$)s, ):gi!*i!g # ##%s a!* a/i!g # ipp)* ##%s. Th) h)a )a")! s)(i#! is p#i*)* -ih a!!)a%i!g, !#"a%i/i!g , h)a )a")! $!a()s, (a#!i/i!g $!a()s, h)a pg. 6

Industrial training VISAKHAPATNAM STEELPLANT

ES&F,

)a")! $!a() -ih p#)(i) gas a"#sph))s, high )4$)!(' ha*)!i!g "a(hi!), 4$)!(hi!g a!ks -ih #i% (##%i!g aa!g)")!s, -)%*i!g g)!)a# a!* a!s#")s # !#"a% -)%*i!g, s$:")g)* a( -)%*i!g "a(hi!) )(. Fa(i%ii)s # s$a() gi!*i!g, pip) )!*i!g a!* h)a*i!g a) p#i*)*.

MAJOR JOBS OF CMS: •

•

•

epairing and reconditioning of T stands of continuous casting machine. Manufacturing and repairing of different types of gears and couplings. econditioning of single roll crusher rotor assem#ly and spiral classifier assem#ly.

R)pai # "a(hi!i!g # (##%i!g p%a)s (a#! %#(ks

+)!a% Ma(hi!) Sh#p

Fii!g & ass)"%' s)(i#!

Ass)"%' & )pai -#k

Ma(hi!i!g Mai!)!a!()

R)(%a"ai#!

Ma(hi!i!g ($i!g

G)a

H)a )a") !

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EQUIPMENT IN CMS: Plano milling machine • •

%eay lathes

•

%ori/ontal #oring machine

•

Vertical turret #oring machine

•

0rinding machine

•

Slotting machine

•

Milling machine

•

Planning machine

•

+rilling machine

•

0ear ho##ing machine

•

0ear shaper

•

1eel gear generator

•

1alancing machine

•

Shot #lasting machine

•

Su#merged arc welding

•

2nduction gear hardening machine



HEAVY LATHE ;

The %EC 3C !445 3C !$6 type center lathes are heay duty lathe machines using in CMS. These are fully satisfying the claims modern technology. Their rigid structure permits roughing and also precision finishing wor'. 2t uses cemented car#ide tipped tools and high speed steel tools. Workin r!n" #$"%i&i%!'ion#: LC()) LC(*+ Swing oer #ed mm !444 !$64

pg. 


Swing oer carriage %eight of #ed a#oe carriage +istance #etween centers Ma). Torque Ma). :eight Spindle speeds; in &9 steps
mm mm mm 'gm 'g rpm rpm mm rpm

Cross slide Compound rest Tool post Ma). Cross section of tool for *way Tool post 3ong. apid transerse Motor for 3ong. apid transerse +ia of sleee of tail stoc' +ia of taper in sleee ate of trael tail stoc' ffsetting of tail stoc' Motor of tailstoc'

rpm

Pitch of lead screw Motor for lu#ricating oil pump The main parts of a lathe are; !" 1ed $" %ead stoc' &" Tail stoc' *" Carriage

pg. 

7!4 644 &444 $644 !4444

844 9&4 !$444 &!64 !*444

!.=-84 !.*-7! =-*44 9.&-&!6 =45!;!4 !*94> ': *4

mm5re mm5re

4.!$6 to ! to

9 *=

mm mm mm

6&4

964 &94 !!4

mm 64?64 mm5min &944 rpm !*44> ': !.! mm !74 mm =45!;!4

mm5min mm !*44> ': 4.46 inch ':

$!64 @-!4

A 4.!=


1E+; 2t forms the #ase of the machine. n the #ed rac's for carriage, tail stoc', head stoc', and #earings for feed rod and lead screw are fi)ed. The #ed is proided with & transerse holes for lifting. 2t also act as reseroir for lu#ricating oil. %EB+STC; 2t is on the left side of the lathe #ed. 2t contains the lathe spindle and spindle driing mechanism. The spindle is hollow throughout its length to allow #ar stoc' to pass through. 2t is located and runs in precision anti friction #earings in head stoc' housing. The spur gear attached to the left end of the spindle dries the trains gear to proide motion and direction to the feed rod, quic' change gear #o) and thread cutting mechanism. This lathe is drien #y constant speed motor. Change of spindle speeds are o#tained #y a series of gear com#inations #y shifting two or three leers in different positions. The main motor is housed in head stoc'. C3TC% and 1BE; The #ra'e seres to reduce the costing of machine to the ma)imum. 2t applies automatically as soon as the main motor is switched off and is released again when the main motor is started. The clutch id of centrifugal type which permits a soft starting and the full torque is gradually #uilt up, starting load #eing less, starting current of motor is less. CB2B0E; 2t controls the moement of cutting tool either parallel or perpendicular to lathe a)is. 2t moes on the guide ways of the #ed. 2t again consists of; saddle • •

compound rest

•

tool post

Saddle is mounted on the guide ways carriage and supports the cross slide Compound rest is mounted on the guide ways of the saddle and supports the tool post. The #ase of the compound rest can #e swieled to any angle #etween 4-&94o and mainly used during taper turning operation. Tool post, its main purpose is to hold the tool during operation. There are two types of tool posts; standard tool post • four way tool post The 3C!445!$6 lathes use the four way tool posts. •

pg. ;


TB23STC; or loose head stoc' is located on right side of the #ed. 2t is used to support wor' piece during rotation and to hold drill or reamer during drilling and other operations. 2t is proided with set oer screw at its #ase for taper turning alignment. 2t has a cast iron #ody with #ore to accommodate tail stoc' spindle and top portion contains the feed screw hand wheel, a spindle loc' clamp. 2t slides on the guide ways of the #ed and positioned according to the length of the wor'. 2n case of heay lathes a special motor is proided to moe the tailstoc' on the #ed. %ydraulics; The head stoc' of the lathe houses two hydraulic clutches in the dr ie system and one hydraulic #ra'e. The clutches and #ra'e operate at pressure of !4'g5cm $. The hydraulic system consists of an oil tan' fi)ed to front leg of the machine, a suction strainer, the gear pump drien #y main motor, a relief ale, a pressure filter and a rotary ale. 2n VSP central machine shop the lathes up to !.7m length are #elt drien and lathes of #ed length &m, 6m are all geared headstoc's. %eadstoc' of D%-$$ lathe is designed to gie spindle !9 forward speeds or = forward and = reerse speeds.

pg. 1<


HORI,ONTAL BORIN MACHINE:

The ta#le type of hori/ontal #oring and milling machine has a wide range of machining possi#ilities. The details of machine used in VSP, CMS; Type; 1% !44 Version;

standard5special

erall length;

mm

9444

erall width;

mm

$964

erall height

mm

&464

Total weight

'g

!&664

Supply oltage

*!67 B> 64 %/> &Ph BC

The main assem#lies of machine are; %EB+ STC; 2t houses the spindles and main drie. The main and hollow spindles are mounted in the radial two row roller #earings with a tapered hole and inn the one row #all nearing. The thrust #earings ta'e up a)ial loads. The wor'ing spindle has the same reolutions as hollow spindle and is slide a#le. 2t is mounted in the #ush and in taper #ush. This is slit alongside. The torsion moement is transferred from hollow spindle to wor'ing spindle #y wedges. The feed of wor' spindle is deliered from thread shaft on the a)is #y means of feeding nut, oer the plug to e)tension #earing of the li#.

pg. 11

+ie of spindle;

mm

!44

Taper in spindle;

mm

9

Ma) #oring dia

mm

694


Ma) #oring depth mm

844

+ia of face plate;

mm

944

mm

$=4

+epth of Centering dia

mm

=

Ma). +istance #etween face plate and #ac' rest

mm

$=44

Centering dia;

C3MD; The cast iron column has a narrow guide on the right side when iewing from front. The position of column in relation to the #ed is secured, #y taper pins. The space inside the stand seres for the counter weight hangs on a chain leading oer the pulleys on the top of the column. 1E+; The sliding surfaces of #eds are to #e regularly lu#ricated, inspected and loo'ed after the #ed ways. The #ed must not #e used for putting away tools etc. S32+E and TB13E; B leer engages different automatic feeds in the group slide and ta#leF. Clamping the wor' piece; :or' pieces are clamped on the turn ta#le with clamping T-slots. The medium slot intersects the rotation a)is. The centering dia for fi)ture centering is turned on the clamping surface in the rotation a)is. 2t is possi#le to fi) simultaneously #y the holder of cooling system with feed piping to this ta#le. The ta#le may #e loaded with a wor' piece of the ma) weight of *444'g on condition of uniform distri#ution.

pg. 15

Clamping surface;

mm

!$64?!$64

Centering dia;

mm

!=4

Industrial training

ES&F, VISAKHAPATNAM STEELPLANT

+epth of Centering dia;

mm

9

3ong. Trael of ta#le

mm

!$64 to !764

Cross trael;

mm

!$64

1BC EST; the #ac' rest is proided with an independent asynchronous electric motor for the ertical ad(ustment of #earing. The direction sense corresponds to the position of the changeoer switch. The longitudinal moement of #ac' rest is done only #y hand. ertical feed of head stoc'> longitudinal feed of the slide and cross feed of ta#le.



pg. 13

VERTI CAL TURRET BORIN MACHINE:


2t is a special ertical type of lathe machine. This is used for a large dia and small depth (o#s. CONSTRUCTION: Vertical turret lathe has a single turret head and a side on right hand upright. This turret head can #e moed rightward and leftward on a cross slide ways. The cross slide can #e raised and lowered on uprights #y leer to accommodate arious depths of wor', #y pulleys and suita#le eleating screws. 2n this machine wor' is placed on a ertically mounted face plate and held in chuc'. The (o# must #e carefully #alanced and run at a slow speed, owing to i#ration caused #y the wear in spindle #earings, whereas with wor' mounted on ertical spindle, all the weight is eenly distri#uted downward on #earing s, so that smooth running results and heay cutting is possi#le. The main drie is #y the electric motor to a gear #o) giing != speeds operated #y leers and then to a large ring gear fastened to the ta#le. if inside of (o# it is #oring> if it is top of (o# it is facing> the ma)imum dia of (o# is $.6m to &m. B pilot #ush is fi)ed in a central hole of ta#le. 2t has a series of drilled holes in order to facilitate the escape of cuttings down the hollow spindle to the floor.

pg. 1=




PLANO

MILLIN

MACHINE:

Plano milling machine is a milling machine, #ut designed to e)ecute certain wor' formerly confined to the planer. 2t is a multipurpose machine on which milling, planning, drilling, #oring etc. can #e done. 2t has a cross rail, capa#le of #eing raised or lowered, carrying the cutters, their heads and the saddles, all supported #y stout uprights. There may #e multiple cutter heads on the rail, as well as two heads on the uprights. Each cutter head in the Plano-miller is separately drien. The drie of the #ed is through hydraulic system. The length of the #ed is = m and the width of #ed is $ m. so that !9 m length (o#s can #e done easily. This machine is safe on mechanical side using 0erman technology. The electrical power to machine is immediately cut off when oer load or any other interruption li'e lac' of lu#ricating oil etc. is occurred. Therefore the mechanical #rea'down doesnGt occur and this machine is running

pg. 16


successfully

from

$4

years.

 HORI,ONTAL MILLIN MACHINE:

2n hori/ontal milling machines the cutter is mounted on hori/ontal ar#or #y spacing collars and wor' is clamped on the ta#le. %ori/ontal milling machine is generally used for cutting gears #y using inde)ing and for cutting 'eyways.  VERTICAL MILLIN MACHINE;

2n ertical milling machine milling cutter is fi)ed to the ertical spindle and wor' is clamped on the ta#le. 2t is generally employed for producing flat surfaces. 1ecause of its multi-point cutter milling machine is mostly preferred than shaper in producing flat surfaces.

Coo.!n' #/#'"0#;

pg. 12


Correct cooling and lu#rication of cutting tool faces is important. Coolant should hae following properties; good cooling effect • •

good lu#rication effect

•

protection against rust or other chemical influences

+epending upon the requirement of the specific milling operations coolants may #e used. S1$$./ ; The milling machine is proided with a coolant pump for the supply of coolant. The sump for the coolant of appro)imately &6 liters is arranged in the #ase of the machine. The coolant pump runs as long as spindle runs and is automatically switched off when spindle stops. B separate switch is proided to switch off coolant independently to the spindle when not required. SHAPER ; S%BPE is used for machining flat surfaces. Machining on shaper is more economical with #etter wor' setting and cheaper tooling. 2n shaper wor' is held stationary on the ta#le and tool reciprocates across the wor'. The tool used on shaper is of single point cutting tool, thus the wor' on shaper is transferred to milling machine which is a multi-point cutting tool. 2n shaper material is remoed during forward stro'e and return stro'e is an idle stro'e. The quic' return mechanism is employed in shaper to minimi/e the wor'ing time.

SLOTTER ;

S3TT2D0 machine is used for cutting 'eyways, grooes etc., 2t consists of ram reciprocates ertically and tool is fed to the wor' piece on the rotating ta#le. 2n slotting machine material is remoed only during forward stro'e H return is idle stro'e. 2n slotter single point cutting tool is used for the operation. Slotter is mainly used for internal turning.

pg. 1


 EAR HOBBIN MACHINE;

2t is used for machining gears from gear #lan'. 2n this machine cutting is carried out #y a tool called ho#. The wor' is fi)ed on rotary ta#le and the ho# is rotated #y means of an electric motor and wor' is fed across the ho#. peration; Set the fi)ture and clamps in the T-slots proided on ta#le. Clamp the wor' on the ta#le and chec' the trueness using dial indicator. Select the type of ho# on the ar#or with a loc' nut. Set the required heli) angle on the ho#. Start the machine to cut the teeth on the gear #lan'.

pg. 1


 9ALAN+ING MA+HINE

B 2!.!n%in 0!%3in" is a measuring tool used for #alancing rotating machine parts such as rotors for electric motors, fans, tur #ines, di sc # ra 'e s, disc dries, propellers and pumps. The machine usually consists of two rigid pedestals, with suspension and #earings on top. Bs the part is rotated, the i#ration in the suspension is detected with sensors and that information is used to determine the amount of un#alance in the part. Blong with phase information, the machine can determine how much and where to add weights to #alance the part. HARD-BEARI NG VS SOFT-BEARING:

There are two main types of #alancing machines, 3!r4-2"!rin and #o&'-2"!rin. The difference #etween them, howeer, is in the suspension and not the #earings. %ard- and soft-#earing machines can #e automated to remoe weight automatically, such as #y drilling or milling, #ut hard-#earing machines are more ro#ust and relia#le. 1oth machine principles can #e integrated into a production line and loaded #y a ro#ot arm or gantry, requiring ery little human control.

Working of machine: :ith the rotating part resting on the #earings, a i#ration sensor is attached to the suspension. 2n most soft-#earing machines, a elocity sensor is used. This sensor wor's #y moing a magnet in relation to a fi)ed coil that generates oltage proportional to the elocity of the i#ration. Bccelerometers, which measure acceleration of the i#ration, can also #e used. B photocell Isometimes called a phase", pro)imity sensor, or encoder is used to determine the rotational speed, as well as the relatie phase of the rotating part. This phase information is then used to filter the i#ration information to determine the amount of moement, or force, in one rotation of the part. Blso, the time difference #etween the phase and the i#ration pea' gies the angle at which the un#alance e)ists. Bmount of un#alance and angle of un#alance gie an un#alance ector. Cali#ration is performed #y adding a 'nown weight at a 'nown angle. 2n a soft #earing machine, trial weights must #e added in correction planes for each part. This is #ecause the location of the correction planes along the rotational a)is is un'nown, and therefore it is un'nown how much a gien amount of weight will affect the #alance. 1y using trial weights, you are adding a 'nown weight at a 'nown angle and getting the un#alance ector caused #y it. This ector is then compared to the

pg. 1;


original un#alance ector to find the resultant ector, which gies the weight and angles needed to #ring the part into #alance. 2n a hard-#earing machine, the location of the correction plane must #e gien in adance so that the machine always 'nows how much a gien amount of weight will affect the #alance.



SU9MERGED AR+ ELDING MA+HINE

Su#merged arc welding machine

S120"r"4 !r% 5".4in ISAW" is a common arc w el di ng process, originally deoled #y the 3inde - nion Car#ide Company.

2t requires a continuously fed consuma#le solid or tu#ular I flu) cored" electrode. The molten weld and the arc /one are protected from atmospheric contamination #y #eing su#mergedF under a #lan'et of granular fusi#le flu) consisting of lime, s il ic a, manganese o)ide, calcium fluoride, and other compounds. :hen molten, the fl u) #ecomes conductie, and proides a current path #etween the electrode and the wor'. This thic' layer of fl u) completely coers the molten metal thus preenting spatter and spar's as well as suppressing the intense ultraiolet radiation and fumes that are a part of the SMB: I shielded metal arc welding" process.

SB: is normally operated in the automatic or mechani/ed mode, howeer, semiautomatic Ihand-held" SB: guns with pressuri/ed or graity flu) feed deliery are aaila#le. The process is normally limited to the
pg. 5<


special arrangement to support the flu)". +eposition rates approaching !44 l#. 5h I*6 'g5h" hae #een reported J this compares to K!4 l#. 5h I6 'g5h" Ima)" for shielded metal arc welding . Blthough Currents r anging from &44 to $444 an are commonly utili/ed, L! currents of up to 6444 B hae also #een used Imultiple arcs". Single or multiple I$ to 6" electrode wire ariations of the process e)ist. SB: strip-cladding utili/es a flat strip electrode Ie.g. 94 mm wide ) 4.6 mm thic'". +C or BC power can #e used, and com#inations of +C and BC are common on multiple electrode systems. Constant Voltage welding power supplies are most commonly used> howeer, Constant Current systems in com#ination with a oltage sensing wire-feeder are aaila#le. E."%'ro4"

SB: filler material usually is a standard wire as well as other special forms. This wire normally has a thic'ness of !5!9 in. to !5* in. I!.9 mm to 9 mm". 2n certain circumstances, twisted wire can #e used to gie the arc an oscillating moement. This helps fuse the toe of the weld to the #ase metal.



SHOT BLASTI N MACHINE:

The ma(or operations of a #last machine are as follows; C."!nin o& 0"'!.# Sand from the primary foundry process, rust, paint and powder, epo)y or other coatings may #e remoed from metals through the process of #last cleaning. Dormally, the metal is #eing prepared for another coating process, so it is important to remoe all matter that would sacrifice the quality of the surface and cause a poor finish. D"#%!.in 0i.. $ro41%'# Mill scale produced in the primary process of manufacturing metals is remoed #y #last machines. Plate, sheet, strip, wire, #ars, #illets and other products can #e descaled. P""nin 0"'!.# 2n the peening process, a stream of metal particles is applied at a high elocity ia a ot o#last wheel against the surface of a metal part. The contact alters the surface

pg. 51


of the part and creates a rounded depression where the edges of the depression will rise slightly a#oe the original surface. Bircraft components, gears, springs and other critical parts undergo peening operations. BLAST MACHINE OPERATION IN () STEPS

Most wheel #last machine systems operate as follows; !. Steel a#rasie is coneyed into a hopper which is located in a position that is toward the middle of the system #ut higher than the ot o#last :heels. $. Bn a#rasie gate located a#oe the wheel controls the a#rasie through a feed spout toward the oto#last wheel. &. 2n the oto#last wheel is an impeller that rotates. The feed spout directs the a#rasie toward the rotating impeller and the impeller directs the a#rasie to an opening in an impeller case. *. The impeller case then directs the a#rasie towards the anes. The anes are connected to a runner head, which is #eing drien #y an electric motor system. +irect drie motors rotate the runner head at !=44 or &944 PM.

directs the larger contaminants toward a scrap drum on the floor, and sends the #alance of the a#rasie toward a separator which detects a#rasie that may #e worn due to use. !4. The separator discharges the good a#rasie into a storage #in and recycles to the oto#lastN wheels. The spent and #ro'en a#rasie is discharged out of the system and into a refuse container .

•

HE AT T RE AT ME NT S EC TI ON;

2t is a post machining operation and is carried out for changing the structure and properties of metals and alloys #y controlled heating and cooling. 2t is performed to reliee internal stresses, refine grain si/e etc., the heat treatment section in VSP machine shop consists of; & heating furnaces • •

il #ath

•

:ater #ath

•

2nduction hardening furnace

•

Car#uri/ing furnace

•

Dit riding furnace



INDUCTION HARDENI N FURNACE:

In41%'ion 3!r4"nin is a form of heat treatment in which a metal part is heated #y induction heating and then quenched. The quenched metal undergoes a martensitic transformation, increasing the hardness and #rittleness of the part. 2nduction

pg. 53


hardening is used to selectiely harden areas of a part or assem#ly without affecting the properties of the part as a whole. Pro%"##:

2nduction heating is a non-contact heating process which utili/es the principle of electromagnetic induction to produce heat inside the surface layer of a wor'-piece. 1y placing a conductie material into a strong alternating magnetic field electrical current can #e made to flow in the steel there#y creating heat due to the 2$ losses in the material. 2n magnetic materials, further heat is generated #elow the Curie point due to hysteresis losses. The current generated flows predominantly in the surface layer, the depth of this layer #eing dictated #y the frequency of the alternating field, the surface power density, the permea#ility of the material, the heat time and the diameter of the #ar or material thic'ness. 1y quenching this heated layer in water, oil or a polymer #ased quench the surface layer is altered to form a martensitic structure which is harder than the #ase metal. Prin%i$!. 0"'3o4# ; Sin." #3o' 3!r4"nin:

2n single shot systems the component is held statically or rotated in the coil and the whole area to #e treated is heated simultaneously for a pre-set time followed #y either a flood quench or a drop quench system. Single shot is often used in cases where no other method will achiee the desired result for e)ample for flat face hardening of hammers, edge hardening comple) shaped tools or the production of small gears. Tr!6"r#" 3!r4"nin:

2n traerse hardening systems the wor' piece is passed through the induction coil progressiely and a following quench spray or ring is utili/ed. Traerse hardening is used e)tensiely in the production of shaft type components such as a)le shafts , e)caator #uc'et pins, steering components, power tool shafts and drie shafts. The component is fed through a ring type inductor which normally features a single turn. The width of the turn is dictated #y the traerse speed, the aaila#le power and frequency of the generator. This creates a moing #and of heat which when quenched creates the hardened surface layer. The quench ring can #e either integral a following arrangement or a com#ination of #oth su#(ect to the requirements of the application. 1y arying speed power etc. it is possi#le to create pg. 5=


a shaft which is hardened along its whole length or (ust in specific areas and also to harden shafts with steps in diameter or spines. 2t is normal when hardening round shafts to rotate the part during the process to ensure any ariations due to concentricity of the coil and the component are remoed.

E71i$0"n': Po5"r r"71ir"4:

Power supplies for induction hardening ary in power from a few 'ilowatts to hundreds of 'ilowatts dependent of the si/e of the component to #e heated and the production method employed i.e. single shot hardening, traerse hardening or su#merged hardening. Fr"71"n%/

2nduction heating systems for hardening are aaila#le in a ariety of different operating frequencies typically from ! '%/ to *44 '%/. %igher and lower frequencies are aaila#le #ut typically these will #e used for specialist applications. The relationship #etween operating frequency and current penetration depth and therefore hardness depth is inersely proportional.



CARBURI SIN FURNACE:

2t is used for case hardening of products are done. 2n this process the heating is carried out up to 944 oC for * hours at !64 oC5hr., and then holding for half an hour at 944 oCta'en place, again heating ta'es place at the rate of 9! oC5hr. to =76 oC. Thus the heating cycle is completed and cooling is done #y quenching them in the water #ath.

Th) "ai! (#"p#!)!s -hi(h a) h)a )a)* i! his s)(i#! a) 9$%% h)a* ha"")s # %$7 ($shi!g p%a! i! h) si!) p%a!, g)a %a!ks )(.

pg. 56


Ho riz ontal Boring Mach ines : -

pg. 52


Radial Drilling Machines:-

Universal Drilling Machines

pg. 5


Milling Machines:-

pg. 5


FORIN SHOP: 2n forging shop, the parts and o#(ects which are needed high strength and hardness that required to VSP.
INPUTS

I!g#s #" #$!*', %##"s #" SMS, i%%)s, #*s

#" "i%%s )(.

PROD"CTION AND SERVICES: Ra- "a)ia% # shas, (#$p%i!g, g)as, pi!i#!s, F%a!g)s $%% h)a* ha"")s # p%a! ha"") ($sh), *i%% #*s # %as F$!a(), :h##ks # SMS, saigh)!i!g # pa%%) a")s # si!) p%a!. Th) sh#p is *)sig!)* # p#*$(i#! # shas, (#$p%i!g : %a!g)s E(. a!* a%s# # #g)* shap)s s$(h as ($sh) ha"") h)a*s, sp)(ia% #%s, !$s, E(. Th) )pai a!* )si!g # (hai!s a) a%s# (ai)* #$. Th) a!!$a% p#*$(i#! #" h) sh#p is a#$ 5,=<< #!s as)* O! 3<< -#ki!g *a's p) ')a a!* -# Shis p) *a'. Th)s) i!p$s (#!sisi!g # i!g#s, i%%)s, %##"s a!* %as # ai#$s si/)s. I! h)a' #gi!g s)(i#!, #p)! *i) #gi!g # %#!g shas, g)a %a!ks, (#$p%i!gs )(.is "a*) -ih h) h)%p # 5:#! i*g) 'p) p!)$"ai( ha"")s. Ea(h ha"") -i%% ) p#i*)* -ih hi! (ha") h)ai!g $!a()s. F%## 'p) "a!ip$%a# a!* ?i +a!) a) p#i*)* # ha!*%i!g h)a' ?#s. I! g)!)a% #gi!g s)(i#!, 1 #!, 6<< Kg, a!* 5<< Kg ha"")s -ih s)paa) h)ai!g $!a()s a) p#i*)*. A 5 #! *#p sa"p ha"") -ih a h)ai!g $!a() i""i!g p)ss )(. is p#i*)* # sa"pi!g. F# ($i!g h)" # si/), a (#%* sa-, a i%%) sh)a a!* gas ($i!g a(i%ii)s a) p#i*)*. F# s)ss )%i)i!g, #gi) 'p):a!!)a%i!g $!a() is p#i*)*. HEAVY FORI N BAY:

pg. 5;


2n this #ay, the (o#s which needed a large deformation and the large (o#s which required high forces to deform are done. "n"r!. 3"!6/ &or" 8o2#; • • • • •

Squares to rounds Ishafts" ound to he)agon 0ear #lan's Stepped shaftsI#ottom roll shafts" 1ull head hammers etc.

R!5 0!'"ri!.#: • • •

1looms Irectangle" O $*4  &$4 mm Squares O $*4$*4 mm 2ngots O larger dia &64mm> smaller dia $*4 mm

E71i$0"n' in '3i# 2!/: • • • •

%eating furnaces Q * 1ogie furnace for heat treatment $ ton H & ton pneumatic hammers Manipulators Q $> ! T H $ T capacity

LIHT FORIN BAY:

2n this #ay the (o#s which need light deformation and smaller in si/e are done. "n"r!. .i3' &orin 8o2#:

Mud guns I*444> &644> $644 mm length" Tongs • Squares etc. • •

E71i$0"n': •

Pneumatic hammers Q !.9 T

pg. 3<


• • • • •

644'g hammers Q $noGs $64'g hammers Q ! no pen hearth furnace Q ! +rop stamp hammer Trimming press

TOOL ROOM:

2t is proided to cut the shafts, #illets, ma'ing holes etc. Equipment; • • • • • • •

Circular saw Power hac'saw 1and saw +rilling machine Shaping machine 0rinding machine 1illet shearing machine

TYPES OF FORIN:

There are many different 'inds of forging processes aaila#le, howeer they can #e grouped into three main classes.

+rawn out; length increases, cross-section decreases pset; 3ength decreases, cross-section increases Squee/ed in closed compression dies; produces multidirectional flow Common forging processes include; roll forging, swaging, cogging, open-die forging, impression-die forging, press forging, automatic hot forg ing and upsetting

OPEN-DI E DROP-HAMMER FORIN pg. 31


2n open-die forging a hammer comes down and deforms the wor' piece, which is placed on a stationary anil. The dies Ithe wor'ing surfaces of the forge that contact the wor' piece" do not enclose the wor' piece, allowing it to flow e)cept where contacted #y the dies. Therefore the operator needs to orient and position the wor' piece to get the desired shape.

IMPRESSION-DIE DROP-HAMMER FORIN

2mpression-die forging is also called closed-die forging. 2n impression-die wor' metal is placed in a die resem#ling a mold, which is attached to the anil. The hammer die is shaped as well. The hammer is then dropped on the wor' piece, causing the metal to flow and fill the die caities.

PRESS FORIN

Press forging is ariation of drop-hammer forging. Press forges wor' slowly #y applying continuous pressure or force. The amount of time the dies are in contact with the wor' piece is measured in seconds Ias compared to the milliseconds of drop-hammer forges". The press forging operation can #e done either cold or hot.

UPSET FORIN

pset forging increases the diameter of the wor' piece #y compressing its length. Engine ales, couplings, #olts, screws, and other fasteners.

ROLL FORIN

oll forging is a process where round or flat #ar stoc' is reduced in thic'ness and increased in length.

HEATI N FURNACE: pg. 35


The furnace is equipment used to proide heat for a process. 2nn this type of furnace, a room type fi)ed hearth gas fired heating furnace is used. The pilot #urner and main #urner in two sets are at roof. The co'e oen gas is supplied to #urner and is #urnt with the air proided from an air #lower. +ifferent ales are proided for air and gas controls. O$"r!'io n o& &1rn!%": A9 #'!r'in $ro%"41r":

$" 2nforming to gas control department indicating the starting of furnace. &" #sere the Rwater oer flowG condition to ensure that RG seal is full of water or not. *" Ensure that there are no any defects in gas line fitting. 6" emoe if any R#lan'sG in gas line 9" eep the furnace door and damper open. 7" eep the main isolation switch of electrical panel in RonG position. =" Switch on the indiidual feeders. 8" Start the #lower after #lower discharge ale close and then open the ale. F seal dewatering process; a. Close the water inlet ale of u seal and open the drain ale to escape water. #. Close the oer flow ale line and drain ale after escaping of water !4" pen the gas ale and chec' the pressure whether it is 644-944 mm of water column. !!" Energi/e the solenoid and reset the annunciation. !$" Set the required temperature in controller. B9 Li3'in '3" 21rn"r:

!&" eep the main #urner air ale close while the pilot #urner air ale is partially opened. !*" 3it the pilot #urner #y opening gas ale. !6" pen the gas and air ales of main #urner. !9" pen pilot air ale completely while pilot gas ale is closed. !7" B#oe same procedure is followed for second set of #urners.

pg. 33


!="

Close the furnace door and chec' the flame is sta#le or not.

:hen the furnace room temperature is 844 deg C the (o#s are introduced. The forging temperature is up to !$44 deg C. C9

!8" $4" $!"



2nform the gas control dept. that furnace is fired off. Close the main airline ale and accept the annunciation. Close the main #urner gas line ales.

HEAVY FORIN HAMMER:

2t is a #ridge type pneumatic hammer. Con#'r1%'ion:

The machine supports on two columns. Two columns are (oined with an arch which forms a multi prismatic guide of mono #loc' type cylinder at center. B ram is slide inside the cylinder and the top die is fitted to the ram. The #ottom die is placed on an anil located #elow top die. B stuffing #o) which houses ale controls is placed #efore entrance and e)haust of the cylinder. The machine and anil are installed with strong and deep #asement i.e. $6to &6 feet to ma'e the machine ro#ust to a#sor# high shoc's.

O$"r!'ion:

The top die is the actual tool which performs the hammering action. The die is operated upwards and downwards in cylinder #y air pressure. The inlet and e)haust ales are controlled #y a leer which is connected to stuffing #o). :hen upper inlet ale is opened, the highly pressuri/ed air is supplied into the top of the piston from RBir Separation Plant, tilities dept.G. Then the ram moes downwards and #lows on the (o#, which is placed on the #ottom die. The air #elow the ram is e)hausted through lower e)haust ale. There is a top pressure #uffer cap in cylinder which inserts the ram safely #y an aid cushion at the end of its upward stro'e. The cylinder and ram is lu#ricated with oil for free and smooth moement.

pg. 3=




LIHT FORIN HAMMER: 2t is widely used for the manufacture of medium si/e forgings. The ram is directly connected to piston wor'ing in a steam or air cylinder. The capacity of column hammer is a#out 644'g. 2t operates with steam or compressed air. Bs compared to pneumatic #ridge hammer, column hammer does not possess #uilt in compressor and therefore, requires additional arrangement for supplying high pressure steam or compressed air.

Pn"10!'i% %o.10n 3!00"r



DROP STAMP HAMMER:

2t is a closed die forging hammer. Spanners, nuts, #olts etc. are made #y this method. The dies are made for these (o#s, they can produce at rapid rate #ecause as fast as the heated lumps of steel are ta'en out of furnace they can #e put into drop stamp, pounded #y it with dies to the required shape and then remoed to hae the surplus metal cut off. M"%3!ni#0 !n4 o$"r!'ion o& '3i# 3!00"r:

This hammer is used the friction lift mechanism. This consists of two multi grooed friction drums fi)ed to the main shaft. B one piece cast lifting arm is fitted #etween these two drums and is mounted on anti-friction #earings are carried on main shaft on the outside of each drum cast steel lifting leers are tied to the lifting

pg. 36


arm #y the tie plate and a cam spindle is carried through arm and leers.
pg. 32




MANI PULATORS:-

Ma!ip$%a#s a) $s)* # h#%* h) h)a)* ?#s -hi%) h) #gi!g #p)ai#! is *#i!g #! h)a' #gi!g ha""). I has -# ?a-s -hi(h (a! ) #a)* a#$!* 32< *)g. h)! "a7i"$" %)7ii%i' i! a!sp# a!* ha!*%i!g (apai%ii)s *$i!g h) #gi!g p#()ss is i"p#a! a M#i%) F#gi!g Ma!ip$%a# is '#$ is (h#i(). Th) (#"pa( *)sig! a!* "a!)$)ai%i' # "a!ip$%a#s #" DANGO & DIENENTHAL a%%#- h) a!sp# # -#k pi)()s ))! -h)! spa() is %i"i)*. h)h) s"a%% # )' %ag) ha!*%i!g (apa(ii)s a) !))*)* DANGO & DIENENTHAL #)s #h sa!*a* a!* ($s#"i/)* s#%$i#!s. O$ "a(hi!)s #) high )%iai%i' as -)%% as g)a %)7ii%i'. Th) s$*' a!* (#"pa( *)sig! is a*ap)* # h) sp)(ia% #p)ai!g (#!*ii#!s. Eg#!#"i(a%%' asp)(s a!* ha!*s:#! )7p)i)!() a) h) *)(isi) a(#s # s)%)(i!g a!* aa!gi!g (#!#% %))s, s-i(h)s a!* $#!s. +haa()isi(s: P#-)$% #!gs $!i -ih %ag) gippi!g a!g) M$%isag) a*?$s")! # (%#si!g #() Spi!g s's)"s a(i!g #h )i(a%%' a!* h#i/#!a%%' # as# sh#(k %#a*s High "a!)$)ai%i' *$) # 4$i(k a!* %)7i%) a)%%i!g )hai# S)"i:a$#"ai( -#ki!g ('(%)s a )4$)s Ta)%, s))i!g, a!* #!gs "#i#!s (a! ) (ai)* #$ a h) sa") i") )7()%%)! #p)a#s i)- i! a%% *i)(i#!s ai (#!*ii#!)* *i)s (ai! a )4$)sp$"ps*i)! ' )%)(i( "## # *i)s)% )!gi!) E")g)!(' $!(i#!s



BOIE FURNACE: A #ogie furnace is used for heat treatment of the forged (o#s.

pg. 3




BILLET SHEARI N MACHINE; D"#%ri$'ion; The shear is mechanically drien and proided with a fi)ed #lade and ertically moing top #lade. The drie is #y electric motor ia -#elts and fly wheel. 1y the switch a#le friction clutch the continuously rotating fly wheel can #e connected with the toothed gear. The #lade slide with the top #lade is drien #y the gear ia cran' shaft and connecting rod. :ith the clutch disengaged the toothed gear is connected with shear frame #y a single disc #ra'e. The #lade slide moes in the re-ad(usta#le guides in the machine frame. The machine frame consists of mainly two steel plates and the #lade frame from cast steel which accommodates the #ottom #lade and the down holders. Top #lade and #ottom #lade are mounted in special #lade accommodations from cast steel which holds the contact surfaces #etween machine and #lade no wear on frame H #lade slide is ensured. The down holder is arranged in the front of the shear oer the #ottom #lade. The down holder stro'e is made #y means of a wedge shaped sliding mem#er which driing motion is ta'en off #y the eccentric shaft. The down holder seats on the cutting material prior to cutting and clamp during the total cutting operation. The height for adaptation to the cross section is ad(usted #y means of a spindle gear. The required cutting gap #etween top H #ottom #lades can #e achieed #y the

pg. 3


Specifications; hori/ontal displacement of the #ottom #lade accommodations #y means of a wedge. O$"r!'ion;

The #illets are placed in the cradle in #undles or separately up to !4 tons. 2t is important that the cradle must #e completely lowered to aoid damages in case of hard placing. Bn orderly and quantitatiely regulated transfer of #illets is performed #y lifting the cradle until the first #illets are moed into the hori/ontally moed chute. 2f the #illets are disorderly moed on to the chute, it can #e lifted until the #illets are arranged H e(ector is ad(usted. 2f the cradle is lowered completely the e(ector ta'es the #ottom #illet and e(ects it. Then the #illet in chute moes up to the required length stop regulated manually and clutch is engaged which cuts the #illet into required length. Then the clutch is disengaged. The forged (o#s are dispatched to the customers after heat treatment is done.

pg. 3;


STEEL STRUCTURAL SHOP 2n sss, the structural wor' and mainly fa#rication wor' of steel is done. The repairs of huge parts are also done. :hen used as industrial term, fa#rication applies to the #uilding of machine, structures and other equipment, #y cutting, shaping and assem#ling components made from raw materials.
INP"TS: Sh))s # ai#$s si/)s, p%a)s a!g%)s, (ha!!)%s, )a"s # ai(ai#! O ?#s. PROD"CTION ! SERVICES: A%% 'p)s # ai(ai#! ?#s, )pai # s%ag p#s # SMS, Mg. A!* )pai # p$!ish)s # SMS, Mg. O s(ap #7)s # SMS # si!) P%a!, h# ")a% %a*%) # SMS, 6<< "))s %a$!*) # SMS, "g. # KAMAG 9#*' # FMD. R)paii!g # $(k)s # LMMM, RM. Th) a!!$a% p#*$(i#! # Fai(a)* s$($)s a) a#$ =,6<< #!)s a!* h) i!p$ (#!sisi!g # sh))s, P%a)s, (ha!!)%s, a!g%)s, )a"s, )(. a) a#$ 6,1<< T. F# "aki!g, ($i!g # si/), #"i!g a!* )!*i!g, g$i%%#i!) Sh)a, (i($%a sa- p%a) )!*), gas ($i!g $!i )(. a) p#i*)*, # -)%*i!g Ta!s#"), a$#"ai( a!* s)"i:a$#"ai( "a(hi!)s a!* s$")g)* a( )%*i!g "a(hi!)s a) p#i*)*. Pai!i!g is (ai)* #$ pa%' -ih h)%p # spa' G$!s a!* pa%' ' ha!* .i) $sh, spa' g$!s )(. a) p#i*)*. A "ai!)!a!() S)(i#! )4$ipp)* -ih %ah), shap), *i%% )(. a) p#i*)* # $!!i!g R)pai # sh#p )4$ip")!. +ETB23S < S%P; Capacity; annual production is *644 tones and material needed is 6!44 tones. Bctiities and wor' root; • • •

Mar'ing the material on stoc' Cutting to prepare material for o#(ect Bssem#ling arious parts or plates prepared for an o#(ect

• • •

pg. =<

:elding the assem#led parts to (oin them 2nspection for the defects +ispatching to customer after ensuring no defects.


:elding techniques used in this shop are; • • •

Brc welding Metal in earth gas welding Thermite welding

•

Maintenance of stores; B store is maintained for the new materials, spare parts and tools etc. aw materials for sss; Channels Sheets • Plates • 1eams • 1illets • • Bngles The raw materials are stored in open #ay of the shop. •

Ma(or and regular (o#s; • • • • • • •

%ot metal ladle I1<" Tundishes, Slag pot ISMS" Co'e #uc'et ICo'e oens" Cones ISP" +ucts ICMP" a'es IMills" %oo's Ifor cranes"

Equipment in sss; • • • • • •

Shearing machine 1ending machine %ydraulic press Com#ination shearing machine adial drilling machine CDC gas cutting machine

pg. =1


Tool room This equipment is located in material preparation #ay in shop. •

2n material preparation #ay the metal sheets and plates of required dimensions are prepared #y ma'ing and cutting on the arious machines. Mar'ing is done in required profile #y deeloping the surfaces of final shape of the o#(ect using micrometer, steel rule, compass etc tools. Bfter mar'ing, material will #e cut and shaped. The operation of cutting may #e in the form of shearing, #ending, punching, pressing, punching, notching etc.



SHEARI N MACHINE:

S3" !r in 0"' !.5 ork in:

Shearing is a metalwor'ing process which cuts stoc' without the formation of chips or the use of #urning or melting. 2f the cutting #lades are straight the process is called shearing> if the cutting #lades are cured then they are shearing-type operations. The most commonly sheared materials are in the form of sheet metal or plates> howeer rods can also #e sheared. Shearingtype operations include; #lan'ing, piercing, roll slitting, and trimming. Prin%i$. " !n4 5orki n :

B punch Ior moing #lade" is used to push the wor' piece against the die Ior fi)ed #lade", which is fi)ed. sually the clearance #etween the two is 6 to !4 of the thic'ness of the material, #ut dependent on the material. Clearance is defined as the separation #etween the #lades, measured at the point where the cutting action ta'es place and perpendicular to the direction of #lade moement. 2t affects the finish of the cut I#urr" and the machineUs power consumption. This causes the material to e)perience highly locali/ed shear stresses #etween the punch and die. The fracture will #egin at the wea'est point and progress to the ne)t wea'est point until the entire wor' piece has #een sheared> this causes the rough edge.

pg. =5


The material will then fail when the punch has moed !6 to 94 the thic'ness of the material, #ecause the shear stresses are greater than the shear strength of the material and the remainder of the material is torn. The rough edge can #e reduced if the wor' piece is clamped from the top with a die cushion. B#oe a certain pressure the fracture /one can #e completely eliminated. %oweer, the sheared edge of the wor' piece will usually e)perience wor' hardening and crac'ing. Two distinct sections can #e seen on a sheared wor' piece, the first part #eing plastic deformation and the second #eing fractured. S'r!i3' #3"!rin :

S3"!rin 0!%3in"

Straight shearing is done on sheet metal, coils, and plates. The machine used is called a squaring shear, power shear, or guillotine. The machine may #e foot powered Ior less commonly hand powered", or mechanically powered. 2t wor's #y first clamping the material with a ram. B moing #lade then comes down across a fi)ed #lade to shear the material. this angle is referred to as the shear angle. This decreases the amount of force required, #ut increases the stro'e. B 6 degree shear angle decreases the force #y a#out $4. The amount of energy used is still the same. The moing #lade may also #e inclined 4.6 to $.6W, this angle is called the ra'e angle, to 'eep the material from #ecoming wedged #etween the #lades, howeer it compromises the square ness of the edge.L& Bs far as equipment pg. =3


is concerned, the machine consists of a shear ta#le, wor'-holding deice, upper and lower #lades, and a gauging deice. The shear ta#le is the part of the machinery that the wor' piece rests on while #eing sheared. The wor'-holding deice is used to hold the wor' piece in place and 'eep it from moing or #uc'ling while under stress. The upper and lower #lades are the piece of machinery that actually do the cutting, while the gauging deice is used to ensure that the wor' piece is #eing cut where it is supposed to #e. The design of press tools is an engineering compromise. B sharp edge, strength and dura#ility are ideal> howeer a sharp edge is not ery strong or dura#le so #lades for metal wor' tend to #e square-edged rather than 'nifeedged. Typical wor' piece materials include aluminum, #rass, #ron/e, and mild steel #ecause of their outstanding shear a#ility ratings, howeer, stainless steel is not used as much due to its tendencies to wor'-harden. There are also other types of 0eometrical Possi#ilities #esides straight shearing though; These include the Squaring Shear, the Bngle Shear, the 1ow- Tie Shear and the 1ar Shear. Bll of these hae many different uses and are all used pretty regularly in certain manufacturing fields.

Too. M!'"ri!. #:

3ow alloy steel is used in low production of materials that range up to !5* in. thic' %igh-car#on, high chromium steel is used in high production of materials that also range up to !5* in. in thic'ness Shoc'-resistant steel is used in materials that are equal to !5* in. thic' or more



pg. ==

COMBI NATION SHEARI N MACHINE:


2t is a multi-purpose machine. 2t is completely mechanically operated. sq. $=, &$ >". &" No'%3in; it is a process of cutting out the edges of the strip to o#tain the desired outer contour of the wor' piece Idimensions of #lade; !=4?!=4?!=". *" Cro$$in: cutting the square #ars and round #ars IX9&, sq66". 6" S3"!rin: cutting stoc's without formation of chips. The machine consists of indiidual units for each operation haing punches, dies, #lades which are necessary for the a#oe operations. The punching unit is located in the front of the machine. Shearing and cropping units in the rear side and notching unit is in the middle of the machine. Bt one side of the machine a fly wheel is located and connected to motor to #alance the machine and also drie all units. This machine is used cran' leer mechanism to drie. B gear train is mounted to fly wheel shaft and all dries shafts. :hen the leer of unit is engaged to this gear train, that unit is then starting wor'ing. Bll the units of this machine can #e operated simultaneously, thus it can #e used for mass production.



BENDI N MACHINE:

This is used to #end the plates or sheets in order to form into cylindrical shape, conical shape and other cured shapes as well as to straighten the cured and a#stracted plates or sheets and made them flat.

Principle;

pg. =6


The plates are fed #etween top roller and #ottom rollers and pressure is gien from #ottom to top of the plate and plate is fed to and fro so that it is gradually #ent into required shape.

C on st ru ctio n a nd op era ti on; 1ending and straightening machine consists of fie rollers one is mounted at center of upper side of machine and four rollers are inserted in radial slots at #ottom, can #e lowered and raised radically. B reersi#le electric motor is connected to each #ottom roller to drie them and the main motor is connected to top roller. The plate is placed on the #ottom rollers ensuring that the edges of the plate and rollers are parallel. :hen the machine is switched on the rollers start rotating and slowly raised. Then the plate starts #ending a#out the top roller. Bt the same time the plate is fed to and fro #y reersing the motor and #ending progresses to the final shape.


HYDRAULI C PRESS:

2t is used to pressing large castings. The ram is moed #y the pressure of the fluid. il is mostly used fluid for this press. The pressure of oil is increased #y pump and is transmitted to the cylinder in order to lift the ram of or to force the ram downwards. The capacity of machine is $44 T.

pg. =2




CNC AS CUTTIN MACHINE:

CNC:

2n modern CDC systems, end-to-end component design is highly automated using CB+5CBM programs. The programs produce a computer file that is interpreted to e)tract the commands needed to operate a particular cutting operation. The moement of the tool resulted in arying forces on the controls that would mean a linear output would not result in linear motion of the tool. The 'ey deelopment in this area was the introduction of the sero, which produced highly accurate measurement information. Bttaching two seros together produced a selsyn, where a remote seroUs motions was accurately matched #y another. sing a ariety of mechanical or electrical systems, the output of the selsyn could #e read to ensure proper moement had occurred. M2T fit gears to the arious hand wheel inputs and droe them with roller chains connected to motors, one for each of the machineUs three a)es IY, Z, and [". The associated controller consisted of fie refrigerator-si/ed ca#inets that, together, were almost as large as the mill they were connected to. Three of the ca#inets contained the motor controllers, one controller for each motor, the other two the digital reading system. L7 The M2T design used standard 7-trac' punch tape f or input. Three of the trac's were used to control the different a)es of the machine, while the other four encoded arious control information. L= The tape was read in a ca#inet that also housed si) relay- #ased hardware registers, two for each a)is. :ith eery read operation the preiously read point was copied into the starting point register, and the newly read one into the ending point. L= The tape was read continually and the num#er in the register increased until a stop instruction, four holes in a line, was encountered. The final ca#inet held a cloc' that sent pulses through the registers, compared them, and generated output pulses that interpolated #etween the points. The pulses are sent into a summing register in the motor controllers, counting up #y the num#er of pulses eery time they were receied. The summing registers

pg. =


were connec connected ted to to a power to the motors.

digital to analog conerter that output increasing

nce the second point was reached the pulses from the cloc' would stop, and the motors would eentually drie the mill to the encoded position. The speed of the cut #y selecting points that was closer together for slow moements, or further apart for rapid ones. The system was terri#ly comple), including $64 acuum tu#es , !76 relays and numerous moing parts, reducing its relia#ility in a production setting. Cures are as easy to cut as straight lines, comple) comple) &-+ structures structures are relatiely easy to produce, and the num#er of machining steps that required human action has #een dramatically reduced. The standard 0  0-code e was adapted for CDC use. 2n turn, 0-code was suppla supplante nted d #y S TE TE P- DC, a system that was deli#erately designed for CDC, rather than grown from an e)isting plotter standard. -Co4", or preparatory code or function, are functions in the Dumerical control programming language . The 0-codes are the codes that position the tool and do the actual wor', as opposed to M-codes, that manages the machine> T for tool-related codes. S and < are tool-Speed and tool-
Partial list of M-Codes M44\Program Stop Inon-optional", M4!\ptional Stop, machine will only stop if operator operator selects this option, option, M4$\End M4$\End of Program, Program, M4&\Spindle M4&\Spindle on IC: rotation", M4*\Spindle M4*\Spindle on ICC: rotation", rotation", M46\Spindle M46\Spindle Stop, M49\Tool M49\Tool Change, M47\Coolant on Iflood", M4=\Coolant on Imist", M48\Coolant off, M!4\Pallet clamp on, M!!\Pallet clamp off, M&4\End of program5rewind tape Imay still #e required for older CDC machines". Common 0 Codes; 044 apid positioning> 04! 3inear interpolation> 04$ C: circular interpolation> 04& CC: circular interpolation> 0!$ C: Circle Cutting> 0!& CC: Circle Cutting> 0!7 Y-Z plane selection> 0!= Y-[ plane selection> 0!8

pg. =


Z-[ plane selection> 0$4 Programming in inches> 0$! Programming in mm> 084 B#solute programming> 08! 2ncremental programming> CDC gas cutting machineGs main parts are; •

Control panel

• •

Cutting torch

Do//les

• •

0as cylinders

Con'ro. $!n". is the main part of the CDC gas cutting machine which consists of arious #uttons to enter the data into the machine. 2t consists of arious controls to regulate the speed of the torch to perform operation. includes the #ed for placing placing the sheet and mild steel frame Fr!0" includes which holds cutting torch and moes according to the gien program to cut the required structure. Tor%3 is made of #rass to with stand high temperatures. 2t has two ends. To the one end no//le is fi)ed and the other end has the proision to connect two hoses for o)ygen and acetylene. No<<." in the part of the torch where flame comes out and the cutting ta'es place. Various si/es of no//les are proided for arious thic'nesses. !# %/.in4"r# of o)ygen and acetylene are used for gas cutting. 2n this machine cutting is carried out #y using o)y- acetylene. 

RADIAL DRILLIN MACHINE; adial drilling is used for drilling heay wor's and especially for the (o#s where high degree of accuracy is required. 2ts main parts are; 1ase •

Column

• •

adial arm

•

+rill head

Spindle

•

1BSE is a rigid cast iron casting which is designed to support column and ta#le. 2t also contains fluid reseroir for coolant Hfor lu#rication. C3MD is mounted ertically on the #ase and supports radial arm. 2t also houses drie mechanism for spindle. B+2B3 BM is supported #y column and rotates &94 o to proide easy drilling in

pg. =;


heaier wor's. +233 %EB+ moes on the guide ways of the radial arm and it houses spindle and speed and feed. SP2D+3E is the main part which holds the drill and performs the operation. 1oth parallel shan' and taper shan' drills are used in drilling. The standard taper of taper shan' drill is called MSE TBPE. The prepared plates, sections in material preparation #ay, they are transferred to assem#ly may for assem#ling of arious parts of a structure. The plates are welded to ma'e a required structure. :elding is process of ma'ing a permanent (oint #y esta#lishing inter atomic #onds #etween two or more pieces of metal using heat or heat and pressure. 2n SSS, three types of welding techniques are using. They are; i. Brc welding ii. M20 welding iii. Thermite welding

pg. 6<


FOUNDRY SHOP
Th) i#! a!* s))% #$!*' a VSP p#*$()s ")a% (asi!gs M)a! # i!)!a% $s)s a *i))! *)pa")!s %ik) SMS, si!) p%a!, (#!i!$#$s +asi!g, %as $!a(), (#k) #)!s )(. Th) a"a)ia%s # h) #$!*' a) %as $!a() pig i#! a!* s))% s(ap. This #$!*' has )7()%%)! a(i%ii)s # p#*$() $a%i' (asi!gs )(#!#"i(a%%' #! a %ag) s(a%). Th) VSP #$!*' is "ai!%' a (api) F#$!*' )(a$s) h) (asi!gs p#*$()* ' i a) $s)* #!%' i! VSP a!* is ?#i!g i! Na$) as ai)' # (asi!gs a'i!g i! (h)"is' a!* -)igh a) )i!g "a*). R)()!%' sa)* )7)($i!g #$si*) #*)s # sp)(ia% s))% i!g#s. SEQUENCE OPERATIONS:

!. $. &. *. 6.

Pattern Ma'ing Mould and Core ma'ing Melting and Pouring
PATTERN MA=IN;

Pattern is the replica or full si/e model of castings to #e made. 2t gies its shape to the mould caity in which the molten metal solidifies to that desired form and si/e. PATTERN ALLOWANCES:

B pattern differs from the casting dimensions. The si/e of pattern is slightly larger than the finished casting #y an amount called RallowanceG.

•

The allowances gien to pattern are; !" S3rink!" !..o5!n%";

pg. 61


:hen molten liquid metal solidifies, the contraction or shrin'age will ta'es place i.e. reduces its original si/e. Therefore the pattern is made larger or oersi/ed than the required casting dimensions. The correction for this is e)pressed as a ratio. $" M!%3inin !..o5!n%": Bfter casting is made machining is done in order to get smooth and clean finishing. Therefore the e)cess dimensions are gien to the pattern. &" Dr!&' !..o5!n%": :hen a pattern is remoed from a mould the tendency to tear away the edges of the mould is reduced if ertical surfaces of the pattern are tapered inwards. *" R!$$in !..o5!n%"; +ue to rapping of the pattern in the mould, the si/e of the mould caity increases slightly. Therefore Rsha'e or rappingG allowances shall #e gien to pattern ma'ing it smaller to compensate for rapping.

T/$"# o& $!''"rn#: !" So.i4 $!''"rn; 2n this type one side is made flat which seres as a parting surface. The mould caity will #e entirely in the drag. $" S$.i' $!''"rn: 2t is used for intricate and comple) shaped casting. 2n two piece pattern one part producing the mould in drag and the other in cope. 2n three piece pattern molding #o) is with these parts. Center one is chee' #o) and remaining are same. &" !'"4 $!''"rn: The pattern which includes gates and riser for producing castings are called Rgated patternG. *" S5""$ $!''"rn; 2t is a template made of wood or metal reoling around a fi)ed a)is in mould, shapes the sand to desired contour. 6" Co$" !n4 Dr! $!''"rn: This pattern is made up of two hales, which are mounted on different plates. Cope and drag parts are made separately and then assem#led.

pg. 65


9" Sk".'on $!''"rn: 2t is used for ma'ing large castings in small num#er. This is a wooden frame out lining the shape of the casting. The frame is filled with loam sand and rammed. 7" S"0"n'!. $!''"rn: 2t is form of a segment and used for molding circular o#(ects such as rings, wheel rims etc. This pattern reoles a#out center.

PATTERN MATERIALS:

!" $" &" *" 6" 9"

:ood Metal Steel Thermo coal Plaster of Paris Ceramics 2n foundry shop the castings are made that is necessary to VSPGs needs. The sand is used for molding as it has high thermal shoc' a#sorption. Various types of sands used in
r""n #!n4: Molding sand containing moisture is called Rgreen sandG. 2t consists of silica, clay, water I6". 2t can #e reused #y reconditioning.

Dr/ #!n4: Sand free from moisture is dry sand, which is used for large castings as it haing high strength...

P!r'in #!n4:

2t is used to preent the moulding sand from stic'ing to surfaces. 2t is free from clay. Cor" #!n4: 2t is silicon sand mi)ed with organic compound li'e oils, resins etc. 2t has high refractie ness used for core ma'ing. Si.i%! #!n4: 2t consists of 8= to 84 silica mi)ed with clay. 2t is mi)ed with coal powder and used for C$ moulding process.

pg. 63


MOULDIN PROCESSES: Bccording to method; B"n%3 0o1.4in; 2n this moulding flas's are 'ept on #ench used for small castings. F.o1r 0o1.4in ; The mould is made on flour. 2t does not required cope #o). Pi' 0o1.4in; Mould is made in pit and dug in flour. 2t acts as drag #o) and the cope #o) is used separately.

Bccording to material; CO* $ro%"##;

2n this process silica sand is mi)ed with a small amount of sodium silicate and is placed in moulding #o) and rammed. Bfter moulding Co$ gas at certain pressure is flowed through mould #y ent holes. Bs the result of chemical reaction #etween C$ and sodium silicate, sodium car#onate is formed. Therefore the sand is made harder and ready for pouring. This sand can #e used only once and not suita#le for reconditioning. r""n #!n4 0o1.4in:

2t uses moist sand in which clay will #e added to with stand the forces. +rying is not necessary and molten metal is poured as soon as the mould is prepared.

M EL TI N : Melting is a process of changing the solid state of iron or steel to liquid state. The molten metal is poured into the mould and then solidifies in order to get required casting. The furnaces used in this shop are; !" +irect Electric Brc
Dir"%' E."%'ri% Ar% F1rn!%":This is used to melt steel and other metals. C3!r"; Steel scrap, 3imestone. Steel scrap is the metal which is used for casting and lime stone is used as flu) which eliminates impurities.

pg. 6=


Con#'r1%'ion; it consists of a roof which can #e raised and lowered #y hydraulic system> three electrodes and #ig cylinder which houses all these things and f urnace. The cylinder is lined with refractory #ric's to resist heat and melting of cylinder. Pro%"##: 2n this the arc is struc' #etween electrodes and steel scrap. Bt the electrode points the temperature is a#out &944 degree centigrade. The s teel is heated gradually and its temperature increases. :hen it is reached to !674 deg. Centigrade o)ygen is in(ected into furnace. This $ is used to form slag #y ma'ing o)ides with impure elements li'e MD, , S$ etc. 2t forms slag and floats oer the molten metal and protects it from atmospheric contaminations and acts as a coer. :hile melting the metal piece, sample is sent for the analysis of required addities and made the required corrections in composition. Bfter sampling the reduction of metal is done. The addities required are added. %ere lime stone acts as a reducing agent.

Bfter temperature is raised to !9*4 deg centigrade, the metal is tapped off through tap hole. The furnace is tilted and molten metal is poured into ladle which is placed underground leel #eside tap hole. The cooling system is arranged in furnace flows through pipes in order to cool the rotating parts of furnace. 0enerally water is used as coolant. Electric arc furnace details;
-

=-!4tons

Transformer rating

-

*444VB

Secondary oltage

-

!$6-$64olts

:ater pressure for electrode

-

!6'g5cm $

:ater pressure for cooling

-

&'g5cm $

Ma) tilting angle at tapping

-

*4 o

Slagging

-

$4 o

:ater for cooling

-

9lit5sec

Power consumption

-

*8$:%5ton

Melt down period

-

77min

Control and tilting

pg. 66


INDUCTION FURNACE;-

This furnace is used to melt cast iron. C3!r": pig iron scrap, silica. Con#'r1%'ion !n4 $ro%"##: - The charge is placed in a cruci#le. 2t is surrounded #y primary copper coils. The space #etween the cruci#le and the coil is pac'ed with sand or any insulating material. The high frequency electric current is passed through coil, and this current produces an intense heat in metal charge. This heat is enough to melt the charge. The molten cast iron is tapped off through tap hole and poured into ladle #y tilting the furnace.

The primary coil is cooled #y water which flows through a separate pipe surrounding the primary coil. 2n this furnace the charge pig iron is refined in order to get molten cast iron. In41%'ion &1rn!%" 4"'!i.#;-

Capacity;

6.& tons

Do. f cruci#les;

$ noGs

!!44 V

!!84 :

Transformer;

!&64 VB

Primary Voltage;

!!:, &X, 64%/

Secondary Voltage;

!!44: ma)

Cooling water flow rate;

!$.76 m& 5hr.

Pressure;

* 'g5 cm$

2nlet temperature;

*6 deg cg

utlet temperature;

96 deg cg ma)

P OU RI N : The molten metal from furnace is poured into ladle #y tilting the furnace. The ladle is made from steel plate and is lined with fire clay. 3adle is used to carry the molten metal from furnace to mould and pouring the metal into mould. The ladle is

pg. 62


'ept as heat as in furnace so that the metal doesnGt loss heat in traeling. These ladles are carried #y oerhead cranes. The molten metal is poured into mould from ladle in two ways; !" The ladle is tilted #y two hoists of oerhead crane and molten metal is poured from top of ladle into the mould using pouring cups. This type of pouring is used for small and medium castings. 2n this slag inclusions may occur. $" 1ottom pouring ladle is used for large castings. The molten metal is poured through #ottom hole of ladle which is operated #y a graphite stopper. The temperature in ladle is also controlled #y the stopper. Bs metal is poured from #ottom, slag is not included and gies #etter pouring than top pouring.

SAND PLANT: Sand for moulding is #rought from C%EEB3B. The sand is of 8= and also of 84 silica. The sand is stored in a pit. The sand should #e prepared #efore its use in order to get required moulding properties. S!n4 3!n4.in "71i$0"n': ( * > ? + @ 7"

Sand mi)er 1elt coneyor 1uc'et eleator Sand aerator Sand storage #ins +rier Cooler

S!n4 $r"$!r!'ion: • •

• •

• •

The sand is poured into #un'er from storage pit #y a gra#. This sand is dropped on the #elt coneyor #y a disc feeder which rotates and drops the sand down #y centripetal force. 2t is traeled up and passed in drier #y screw feeder through another #un'er. B #lower forces the sand into drier and sand is heated #y co'e oen gas to eliminate moisture in it. Then it is passed through cooler to cool the sand to room temperature. Then the sand is passed to storage #in #y a #uc'et eleator. There the sand is stored when it is not required.

pg. 6


•

•

:hen the gate of storage #in is opened the sand is dropped into mi)er #y a i#rating feeder. 2n mi)ers the required addities are added and mi)ed thoroughly. The addities are; for one ton of sand; 1entonite Q 9 +e)trin Q $ Molasses Q ! Moisture Q 6.

Mi)ing cycle time is 9 minutes. • •

•

•

The water is added for green sand only. Then the sand is ready for moulding. The prepared sand is sent to small storage #ins which are at moulding places #y #uc'et eleators and #elt coneyors. B sand aerator is placed #efore each #in and it is used to crush the small sand lumps Iincluded in sand" and ma'e it powder. Sand can #e dropped in any storage #in in its traeling path with help of a plough which dierts the sand to sides of coneyor.

The used sand is also can #e reconditioned as the similar way of sand preparation and stored in separate #ins. The sand plant is operated automatically #y control panel in controlling room. !4 ton of sand can #e prepared in one hour.

CO RE S; Cores are specially made sand #odies intended to form holes and caities in castings. Cores are placed in the mould caity #efore pouring to form interior surface of the casting. C OR E M A= IN :

Cores are made in #o)es. Core #o)es may #e a simple solid type or split type made of wood. The two parts of core #o) is clamped together and 'ept in ertical position. :ires to proide enting and metal rods to strengthen are reinforced in core. The two hales of #o) are separated and the core is turned out. Then the core is #ac'ed in an oen a#out $&4 deg C.

pg. 6


CORE PRI NTS:

The core rest in the mould in recesses specially made for this purpose. These are made from pattern in the form of pro(ections 'nown as Rcore printsG. %ori/ontal> Vertical> 1alanced> Coer and hanging core> etc. types of cores are there according to their position and orientation.

FETTLIN::hen the molten metal is completely solidified, the casting is to #e cleaned and finished. Bfter they are remoed from mould they hae seeral unwanted pro(ections as the shape of runners, risers, fed gates etc. Bnd also sand is stic'er to it. These all waste material should #e remoed #y some means. This remoal of material is called R
As p) h) !#"s # )4$i)")! # (as spa)s, i -as #$!* Tha 15<<< T#!s # (asi!gs -i%% ) )4$i)* # h) s))% p%a! (#"pisi!g # 6=<< T # (as i#! spa)s, 25=< T # s))% spa)s a!* 32< T # !#!: )#$s spa)s. K))pi!g h) )4$i)")!s i! i)- ai#$s )4$ip")! -)) i!sa%%)* # ")) h) a#) ag)s. Th) (apa(ii)s # h) sh#p a):  Th) "a7i"$" -)igh # si!g%) (asi!g i! s))% 0 1< T.  Th) "a7i"$" -)igh # si!g%) (asi!g i! i#! 0 1< T.  Th) "a7i"$" -)igh # si!g%) (asi!g i! !#!:)#$s 0 1T. +api) #$!*' -as )!isag)* # h) s$pp%' # (#!s$"a%)s a!* spa)s # h)

S))% p%a! -ih a! i!)s")! # 56 (#)s, #%%#-)* -ih h) "a! p#-) # 12<

pg. 6;


P)#p%).

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"TILIT# E+"IPMENT REPAIR SHOP "ERSINP"TS: Sh))s, P%a)s, +ha!!)%s, A!g%)s, 9)a"s, 9i%%)s, R#$!*s #" F#g) Sh#p # "a!$a($i!g Shas, S))% & I#! (asi!gs. PROD"CTS AND SERVICES:. Ma!$a($i!g # I"p)%%)s # ai#$s *)pa")!s, )pai # G+P ID Fa!, R)pai # S)a" )7ha$s)s # SMS, s$pp%' # +#!)s a!* D$(s # Vai#$s si/)s, $i%* $p & "a(hi!i!g # ai#$s (#"p#!)!s, )(%a"ai#! ?#s %ik) Va%) )pais, +#!)'# I*%)s, P+M R#%%)s )(.

Vizag Steal Plant ES-F

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