Mini Project2

Industrial training ESampF VISAKHAPATNAM STEELPLANT

pg 1

ANDHRA UNIVERSITY

INDUSTRIAL TRANING REPORT OF A STUDY ON

ENGINEERING SHOPS AND FOUNDRY VISAKHAPATNAM STEEL PLANT

A mini project report submitted in partial fulfillment of the requirement for the award of

degree of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

Submitted by

B UDAY BASHKAR MURTHY ndash 311129520002 BMANOJ KUMARndash 311129520003

GLAKSHMAN LUMAR ndash 311129520012 K CHAITANAYAndash 311129520017

O HARI KIRAN ndash 311129520022

WELLFARE INSTITUTE OF SCIENCE TECHNOLOGY ampMANAGEMENT

Affiliated to ANDHRA UNIVERSITY

VISAKHAPATNAM


pg 2

AN OVER VIEW OF VISAKHAPATNAM STEEL PLANT Visakhapatnam is popularly called as the Steel City of India and credit

was because of the Vi zag Stee l P lant ndash a venture of Ispat Nigam

VSP i s the f i rs t coasta l based s tee l p lant o f India and i s located

16 km south west o f c i ty o f destiny VSP has an installed capacity of 3

million Tons per annum of liquid s tee l and 2 656 mi l l ion tons o f

sa leable s teel VSP products meet exa l t ing international quality

standards such as JIS DIN BIS BS etcVSP has the distinction to be the first

integrated steel plant in India to becomea ful l y ISO-

9002 cer t i f ied company The cer t i f i cate covers qual i ty systems tr

aining and marketing functions spreading over 4 regional marketing officer

20branch offices and 22 stockyards located all over the country VSP successfully

installing and operating efficiently Rs 460 cores worth of pollution

control and environment control equipment and converting the barren

land scape by planting more than 3 million plants has made the steel plant steel

township a greener cleaner place which can boas of 3 to 40C lesser temperature

even in the peak summer compared to Visakhapatnam City

Exports qual i ty p ig i ron and stee l pro jects to Sr i Lanka

Myanmar Nepal Middle East USA amp South East Asia (Pig Iron) RINL VSP was

awarded ldquoState Trading Houserdquo status during 1997-2000Besides these a captive

power plant with a capacity of 2475 MW Oxygen plant Acetylene plant

compressed iron plant extensive repair maintenance facilities form part of

facilities available at VSP VSP has sufficient infrastructure to expand the plant to

10 Million tons per annum of liquid steel capacity


pg 3

MAJOR PLANT FACILITIES VSP has the following major production facilities bull 4 coke oven batteries of 67 ovens each having 416 M3 Volume bull 2 Sinter machines of 312 M3 area bull 3 Blast furnace of 3200 M3 useful volume bull Steel Melts Shop with three LD converters of 150 Tons capacity each and 6 N0sof 4 standard continuous bloom casters bull Light and Medium Merchant Mill of 710000 Tons per year capacity bull Wire rod mill of 850000 tons per year capacity bull Medium Merchant amp Structural Mill of 850000 tons per year capacity Besides these a capacity power plant site a capacity of 2865 MW Oxygen Plant Acetylene plant with Air plant extensive repair maintenance facilities form Part of the facilities available at VSP Number of ovens in series one after the other form a coke oven Battery At VSP there Coke oven Batteries 7 Meter tall and having 67 Ovens each Each oven Is having a volume of 416 m3 amp can hold up 316 Tons of dry coal charge

MINOR DEPARTMENTS Power generation and distribution Water management

Traffic department

Engineering shops and foundry Utilities department

Quality assurance and technology development department

Calcining and refractory material plant


pg 4

ENGINEERING SHOPS amp FOUNDRY

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

Engineering shops amp foundry is set up to meet the requirements of Ferrous amp nonferrous spares of different departments Engineering shops amp Foundry is divided into 5 shops

1 Central Machine Shop 2 Forge Shop 3 Steel Structural Shop 4 Foundry 5 Utility equipment repair shop


pg 5

CENTRAL MACHINE SHOP

CMS is designed to carry the following manufacturing and repairing

activities

1) Manufacturing and finishing of castings forgings fabricated and

rolled sections

2) Heat treatment and reconditioning of parts

3) Tool room work including manufacturing and repair of jigs and

fixtures regrinding and sharpening of cutting tools

4) Dismantling repair and assembling of worn out machinery and

equipment

This shop has four longitudinal bays and one cross bay Heavy and medium

duty machines are located in the first two bays The third bay has light

machines for material preparation and tool room The forth bay houses the

heat treatment and thermal surfacing sections Cross bay connecting other

four bays is the fitting and assembly bay and also houses some of heavy

machine tools Each bay is provided with three EOT cranes with adequate

capacity

INPUTS Iron ampSteel castings forgings rolled sections repair and rectification

Parts nonferrous castings fabrication structures

PRODUCTS AND SERVICE shafts pinions Gears crane Wheels Rollers

Machining of various fabrication jobs done in SSS Repair ampreconditioning of

various assembly jobs like LampT housing To stands pulleys previsioning facing and

centering machines hacksaws and gas cutting facilities are provided The

machining section has over 100 major machine including lathes milling boring and

planning slotting shaping grinding and other machines The assembly section

undertakes medium repair and general overhauling of mechanical equipment

Horizontal and vertical presses washing tanks oil berths etc are provided The tool

room has facilities for manufacture of special tools jigs and fixtures re-grinding of

tools and brazing of tipped tools The heat treatment section is provided with

annealing normalizing heat treatment furnaces carbonizing furnaces heat


pg 6

treatment furnace with protective gas atmospheres high frequency hardening

machine quenching tanks with oil cooling arrangements welding generator and

transformers for normal welding sub-merged arc welding machine etc Facilities

for surface grinding pipe bending and threading are provided

MAJOR JOBS OF CMS

Repairing and reconditioning of TK stands of continuous casting

machine

Manufacturing and repairing of different types of gears and

couplings

Reconditioning of single roll crusher rotor assembly and spiral

classifier assembly

Repair of machining of cooling plates carbon blocks

Fitting amp assembly

section

Central Machine Shop

Machining Maintenance

Assembly amp repair

work

Reclamation

work

Machining Gear cutting

Heat

treatment


pg 7

EQUIPMENT IN CMS

Plano milling machine

Heavy lathes

Horizontal boring machine

Vertical turret boring machine

Grinding machine

Slotting machine

Milling machine

Planning machine

Drilling machine

Gear hobbing machine

Gear shaper

Bevel gear generator

Balancing machine

Shot blasting machine

Submerged arc welding

Induction gear hardening machine

HEAVY LATHE

The HEC LC 100 LC 125 type center lathes are heavy duty lathe machines

using in CMS These are fully satisfying the claims modern technology Their rigid

structure permits roughing and also precision finishing work It uses cemented

carbide tipped tools and high speed steel tools

Working range specifications LC100 LC125

Swing over bed mm 1000 1250


pg 8

Swing over carriage mm 710 900

Height of bed above carriage mm 500 630

Distance between centers mm 3000 12000

Max Torque kgm 2500 3150

Max Weight kg 10000 14000

Spindle speeds in 36 steps

First range rpm 18-90 14-71

second range rpm 8-400 63-315

Dia of taper in spindle mm 80110

Main motor speed rpm 1460 kW 40

Longitudinal feeds in 36 steps

First range mmrev 0125 to 6

Second range mmrev 1 to 48

Movement of

Cross slide mm 530 650

Compound rest mm 360

Tool post mm 110

Max Cross section of tool for 4way

Tool post mm 50times50

Long Rapid transverse mmmin 3600

Motor for Long Rapid transverse rpm 1400 kW 11

Dia of sleeve of tail stock mm 170

Dia of taper in sleeve mm 80110

Rate of travel tail stock mmmin 2150

Offsetting of tail stock mm +-10

Motor of tailstock rpm 1400 kW 005

Pitch of lead screw inch frac12 Motor for lubricating oil pump kW 018

The main parts of a lathe are

1) Bed

2) Head stock

3) Tail stock

4) Carriage


pg 9

BED It forms the base of the machine On the bed racks for carriage tail stock head

stock and bearings for feed rod and lead screw are fixed

The bed is provided with 3 transverse holes for lifting It also act as reservoir for

lubricating oil

HEADSTOCK It is on the left side of the lathe bed It contains the lathe spindle and

spindle driving mechanism The spindle is hollow throughout its length to allow bar

stock to pass through It is located and runs in precision anti friction bearings in head

stock housing The spur gear attached to the left end of the spindle drives the trains

gear to provide motion and direction to the feed rod quick change gear box and

thread cutting mechanism This lathe is driven by constant speed motor Change of

spindle speeds are obtained by a series of gear combinations by shifting two or three

levers in different positions The main motor is housed in head stock

CLUTCH and BRAKE The brake serves to reduce the costing of machine to the

maximum It 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 built up starting load

being less starting current of motor is less

CARRIAGE It controls the movement of cutting tool either parallel or

perpendicular to lathe axis It moves on the guide ways of the bed It 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 base of the compound rest can be swiveled to any angle between 0-360o

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 LC100125 lathes use the four way tool posts


pg 10

TAILSTOCK or loose head stock is located on right side of the bed It is used to

support work piece during rotation and to hold drill or reamer during drilling and

other operations It is provided with set over screw at its base for taper turning

alignment It has a cast iron body with bore to accommodate tail stock spindle and

top portion contains the feed screw hand wheel a spindle lock clamp It slides on

the guide ways of the bed and positioned according to the length of the work In case

of heavy lathes a special motor is provided to move the tailstock on the bed

Hydraulics

The head stock of the lathe houses two hydraulic clutches in the drive system

and one hydraulic brake The clutches and brake operate at pressure of 10kgcm2

The hydraulic system consists of an oil tank fixed to front leg of the machine a

suction strainer the gear pump driven by main motor a relief valve a pressure filter

and a rotary valve

In VSP central machine shop the lathes up to 17m length are belt driven and

lathes of bed length 3m 5m are all geared headstocks

Headstock of NH-22 lathe is designed to give spindle 16 forward speeds or 8 forward

and 8 reverse speeds


pg 11

HORIZONTAL BORING MACHINE

The table type of horizontal boring and milling machine has a wide range of

machining possibilities

The details of machine used in VSP CMS

Type BH 100

Version standardspecial

Overall length mm 6000

Overall width mm 2650

Overall height mm 3050

Total weight kg 13550

Supply voltage 4157 A 50 Hz 3Ph AC

The main assemblies of machine are

HEAD STOCK It houses the spindles and main drive The main and hollow

spindles are mounted in the radial two row roller bearings with a tapered hole and

inn the one row ball nearing The thrust bearings take up axial loads

The working spindle has the same revolutions as hollow spindle and is slide

able It is mounted in the bush and in taper bush This is slit alongside The torsion

movement is transferred from hollow spindle to working spindle by wedges The

feed of work spindle is delivered from thread shaft on the axis by means of feeding

nut over the plug to extension bearing of the lib

Die of spindle mm 100

Taper in spindle mm 6

Max boring dia mm 560


pg 12

Max boring depth mm 900

FACE PLATE The face plate is solid with main spindle the tool slide sliding nut

in a prismatic guide It is possible to take up the lateral clearance by a correct

setting of the adjusting screws When turning then the position of adjusting wedges

change in relation to prismatic guide in faces plate Thus the lateral clearance of

the tool slide increases or decreases

Dia of face plate mm 600

Centering dia mm 280

Depth of Centering dia mm 8

Max Distance between face plate and back rest mm 2800

COLUMN The cast iron column has a narrow guide on the right side when

viewing from front The position of column in relation to the bed is secured by

taper pins The space inside the stand serves for the counter weight hangs on a

chain leading over the pulleys on the top of the column

BED The sliding surfaces of beds are to be regularly lubricated inspected and

looked after the bed ways The bed must not be used for putting away tools etc

SLIDE and TABLE A lever engages different automatic feeds in the group ldquoslide

and tablerdquo

Clamping the work piece

Work pieces are clamped on the turn table with clamping T-slots The

medium slot intersects the rotation axis The centering dia for fixture centering is

turned on the clamping surface in the rotation axis It is possible to fix

simultaneously by the holder of cooling system with feed piping to this table

The table may be loaded with a work piece of the max weight of 4000kg on

condition of uniform distribution

Clamping surface mm 1250times1250



pg 13


Long Travel of table mm 1250 to 1750

Cross travel mm 1250

BACK REST the back rest is provided with an independent asynchronous electric

motor for the vertical adjustment of bearing The direction sense corresponds to the

position of the changeover switch The longitudinal movement of back rest is done

only by hand For this a crank put on the shaft is rotated The back rest is locked at

a particular position by tightening of screws

The working principle of machine consists of a coordinate travel of the

individual working groups vertical feed of head stock longitudinal feed of the slide

and cross feed of table

VERTICAL TURRET BORING MACHINE


pg 14

It is a special vertical type of lathe machine This is used for a large dia and small

depth jobs

CONSTRUCTION

Vertical turret lathe has a single turret head and a side on right hand upright

This turret head can be moved rightward and leftward on a cross slide ways The

cross slide can be raised and lowered on uprights by lever to accommodate

various depths of work by pulleys and suitable elevating screws In this machine

work is placed on a vertically mounted face plate and held in chuck The job must

be carefully balanced and run at a slow speed owing to vibration caused by the

wear in spindle bearings whereas with work mounted on vertical spindle all the

weight is evenly distributed downward on bearing s so that smooth running

results and heavy cutting is possible The main drive is by the electric motor to a

gear box giving 18 speeds operated by levers and then to a large ring gear fastened

to the table Feeds are available in all directions

OPERATION

The job is rotated on table and the turret head is lowered and set to the top of

the job and downward feed of turret is engaged Depth of cut is given by

rightward feed or leftward movement of tool head If outside of the job is doing

it is turning if inside of job it is boring if it is top of job it is facing the maximum

dia of job is 25m to 3m A pilot bush is fixed in a central hole of table It has a

series of drilled holes in order to facilitate the escape of cuttings down the hollow

spindle to the floor


pg 15

PLANO MILLING MACHINE

Plano milling machine is a milling machine but designed to execute certain work

formerly confined to the planer It is a multipurpose machine on which milling

planning drilling boring etc can be done It has a cross rail capable of being

raised or lowered carrying the cutters their heads and the saddles all supported

by stout uprights There may be multiple cutter heads on the rail as well as two

heads on the uprights Each cutter head in the Plano-miller is separately driven

The drive of the bed is through hydraulic system

The length of the bed is 8 m and the width of bed is 2 m so that 16 m length

jobs can be done easily This machine is safe on mechanical side using German

technology The electrical power to machine is immediately cut off when over

load or any other interruption like lack of lubricating oil etc is occurred

Therefore the mechanical breakdown doesnrsquot occur and this machine is running


pg 16

successfully from 20 years

HORIZONTAL MILLING MACHINE

In horizontal milling machines the cutter is mounted on horizontal arbor by

spacing collars and work is clamped on the table Horizontal milling machine is

generally used for cutting gears by using indexing and for cutting keyways

VERTICAL MILLING MACHINE

In vertical milling machine milling cutter is fixed to the vertical spindle and

work is clamped on the table It is generally employed for producing flat surfaces

Because of its multi-point cutter milling machine is mostly preferred than shaper in

producing flat surfaces

Coolant systems


pg 17

Correct cooling and lubrication of cutting tool faces is important Coolant

should have following properties

good cooling effect

good lubrication effect

protection against rust or other chemical influences

Depending upon the requirement of the specific milling operations coolants

may be used

Supply

The milling machine is provided with a coolant pump for the supply of

coolant The sump for the coolant of approximately 35 liters is arranged in the base

of the machine The coolant pump runs as long as spindle runs and is automatically

switched off when spindle stops A separate switch is provided to switch off coolant

independently to the spindle when not required

SHAPER

SHAPER is used for machining flat surfaces Machining on shaper is more

economical with better work setting and cheaper tooling In shaper work is held

stationary on the table and tool reciprocates across the work The tool used on shaper

is of single point cutting tool thus the work on shaper is transferred to milling

machine which is a multi-point cutting tool In shaper material is removed during

forward stroke and return stroke is an idle stroke The quick return mechanism is

employed in shaper to minimize the working time

SLOTTER

SLOTTING machine is used for cutting keyways grooves etc It consists of

ram reciprocates vertically and tool is fed to the work piece on the rotating table In

slotting machine material is removed only during forward stroke amp return is idle

stroke In slotter single point cutting tool is used for the operation Slotter is mainly

used for internal turning


pg 18

GEAR HOBBING MACHINE

It is used for machining gears from gear blank In this machine cutting is

carried out by a tool called hob The work is fixed on rotary table and the hob is

rotated by means of an electric motor and work is fed across the hob

Operation

Set the fixture and clamps in the T-slots provided on table Clamp the work

on the table and check the trueness using dial indicator Select the type of hob on the

arbor with a lock nut Set the required helix angle on the hob Start the machine to

cut the teeth on the gear blank


pg 19

BALANCING MACHINE

A balancing machine is a measuring tool used for balancing rotating machine

parts such as rotors for electric motors fans turbines disc brakes disc drives

propellers and pumps The machine usually consists of two rigid pedestals with

suspension and bearings on top As the part is rotated the vibration in the

suspension is detected with sensors and that information is used to determine the

amount of unbalance in the part Along with phase information the machine can

determine how much and where to add weights to balance the part

HARD-BEARING VS SOFT-BEARING

There are two main types of balancing machines hard-bearing and soft-bearing

The difference between them however is in the suspension and not the bearings

Hard- and soft-bearing machines can be automated to remove weight automatically

such as by drilling or milling but hard-bearing machines are more robust and

reliable Both machine principles can be integrated into a production line and loaded

by a robot arm or gantry requiring very little human control

Working of machine

With the rotating part resting on the bearings a vibration sensor is attached to the

suspension In most soft-bearing machines a velocity sensor is used This sensor

works by moving a magnet in relation to a fixed coil that generates voltage

proportional to the velocity of the vibration Accelerometers which measure

acceleration of the vibration can also be used

A photocell (sometimes called a phase) proximity sensor or encoder is used to

determine the rotational speed as well as the relative phase of the rotating part This

phase information is then used to filter the vibration information to determine the

amount of movement or force in one rotation of the part Also the time difference

between the phase and the vibration peak gives the angle at which the unbalance

exists Amount of unbalance and angle of unbalance give an unbalance vector

Calibration is performed by adding a known weight at a known angle In a soft-

bearing machine trial weights must be added in correction planes for each part This

is because the location of the correction planes along the rotational axis is unknown

and therefore it is unknown how much a given amount of weight will affect the

balance By using trial weights you are adding a known weight at a known angle

and getting the unbalance vector caused by it This vector is then compared to the


pg 20

original unbalance vector to find the resultant vector which gives the weight and

angles needed to bring the part into balance In a hard-bearing machine the location

of the correction plane must be given in advance so that the machine always knows

how much a given amount of weight will affect the balance

SUBMERGED ARC WELDING MACHINE

Submerged arc welding machine

Submerged arc welding (SAW) is a common arc welding process originally

devolved by the Linde - Union Carbide Company

It requires a continuously fed consumable solid or tubular (flux cored) electrode

The molten weld and the arc zone are protected from atmospheric contamination

by being ldquosubmergedrdquo under a blanket of granular fusible flux consisting of lime

silica manganese oxide calcium fluoride and other compounds When molten the

flux becomes conductive and provides a current path between the electrode and

the work This thick layer of flux completely covers the molten metal thus

preventing spatter and sparks as well as suppressing the intense ultraviolet

radiation and fumes that are a part of the SMAW (shielded metal arc welding)

process

SAW is normally operated in the automatic or mechanized mode however semi-

automatic (hand-held) SAW guns with pressurized or gravity flux feed delivery are

available The process is normally limited to the Flat or Horizontal-Fillet welding

positions (although Horizontal Groove position welds have been done with a


pg 21

special arrangement to support the flux) Deposition rates approaching 100 lb h

(45 kgh) have been reported mdash this compares to ~10 lb h (5 kgh) (max) for

shielded metal arc welding Although Currents ranging from 300 to 2000 an are

commonly utilized [1] currents of up to 5000 A have also been used (multiple arcs)

Single or multiple (2 to 5) electrode wire variations of the process exist SAW

strip-cladding utilizes a flat strip electrode (eg 60 mm wide x 05 mm thick) DC

or AC power can be used and combinations of DC and AC are common on

multiple electrode systems Constant Voltage welding power supplies are most

commonly used however Constant Current systems in combination with a voltage

sensing wire-feeder are available

Electrode

SAW filler material usually is a standard wire as well as other special forms This

wire normally has a thickness of 116 in to 14 in (16 mm to 6 mm) In certain

circumstances twisted wire can be used to give the arc an oscillating movement

This helps fuse the toe of the weld to the base metal

SHOT BLASTING MACHINE

The major operations of a blast machine are as follows

Cleaning of metals

Sand from the primary foundry process rust paint and powder epoxy or other

coatings may be removed from metals through the process of blast cleaning

Normally the metal is being prepared for another coating process so it is

important to remove all matter that would sacrifice the quality of the surface and

cause a poor finish

Descaling mill products

Mill scale produced in the primary process of manufacturing metals is removed by

blast machines Plate sheet strip wire bars billets and other products can be

descaled

Peening metals

In the peening process a stream of metal particles is applied at a high velocity via

a Rot oblast wheel against the surface of a metal part The contact alters the surface


pg 22

of the part and creates a rounded depression where the edges of the depression will

rise slightly above the original surface Aircraft components gears springs and

other critical parts undergo peening operations

BLAST MACHINE OPERATION IN 10 STEPS

Most wheel blast machine systems operate as follows

1 Steel abrasive is conveyed into a hopper which is located in a position that is

toward the middle of the system but higher than the Rot oblast Wheels

2 An abrasive gate located above the wheel controls the abrasive through a feed

spout toward the Rotoblast wheel

3 In the Rotoblast wheel is an impeller that rotates The feed spout directs the

abrasive toward the rotating impeller and the impeller directs the abrasive to an

opening in an impeller case

4 The impeller case then directs the abrasive towards the vanes The vanes are

connected to a runner head which is being driven by an electric motor system

Direct drive motors rotate the runner head at 1800 or 3600 RPM For bearing and

spindle drives the speeds can vary from 2100 to 3200 RPM

5 With the vanes rotating at a high speed by the runner head and the abrasive

being fed onto the vanes centrifugal force hurls the abrasive at high speeds toward

the work to be cleaned

6 The steel on steel contact cleans peens descales or performs other functions

designed into the system

7 After contacting the work the spent abrasive falls into a recovery hopper along

with other non-abrasive materials (sand scale etc) which has been removed from

the work The recovery hopper is located below the work that is being cleaned

8 The recovery hopper has a screw conveyor or oscillating conveyor that conveys

the material toward an elevator belt The elevator belt driven by another electric

motor is equipped with buckets that carry the material to the very top of the

system

9 At the top of the system is a scalping drum or another screw conveyor that

initiates a process where good abrasive is separated from foreign matter The

scalping drum detects larger contaminants compared to the size of the abrasive It


pg 23

directs the larger contaminants toward a scrap drum on the floor and sends the

balance of the abrasive toward a separator which detects abrasive that may be worn

due to use

10 The separator discharges the good abrasive into a storage bin and recycles to

the Rotoblastreg wheels The spent and broken abrasive is discharged out of the

system and into a refuse container

HEAT TREATMENT SECTION

It is a post machining operation and is carried out for changing the

structure and properties of metals and alloys by controlled heating and cooling

It is performed to relieve internal stresses refine grain size etc the heat treatment

section in VSP machine shop consists of

3 heating furnaces

Oil bath

Water bath

Induction hardening furnace

Carburizing furnace

Nit riding furnace

INDUCTION HARDENING FURNACE

Induction hardening is a form of heat treatment in which a metal part is heated by

induction heating and then quenched The quenched metal undergoes a martensitic

transformation increasing the hardness and brittleness of the part Induction


pg 24

hardening is used to selectively harden areas of a part or assembly without

affecting the properties of the part as a whole

Process

Induction heating is a non-contact heating process which utilizes the principle of

electromagnetic induction to produce heat inside the surface layer of a work-piece

By placing a conductive material into a strong alternating magnetic field electrical

current can be made to flow in the steel thereby creating heat due to the I2R losses

in the material In magnetic materials further heat is generated below the Curie point

due to hysteresis losses The current generated flows predominantly in the surface

layer the depth of this layer being dictated by the frequency of the alternating field

the surface power density the permeability of the material the heat time and the

diameter of the bar or material thickness By quenching this heated layer in water

oil or a polymer based quench the surface layer is altered to form a martensitic

structure which is harder than the base metal

Principal methods

Single shot hardening

In single shot systems the component is held statically or rotated in the coil and the

whole area to be treated is heated simultaneously for a pre-set time followed by

either a flood quench or a drop quench system Single shot is often used in cases

where no other method will achieve the desired result for example for flat face

hardening of hammers edge hardening complex shaped tools or the production of

small gears

Traverse hardening

In traverse hardening systems the work piece is passed through the induction coil

progressively and a following quench spray or ring is utilized Traverse hardening

is used extensively in the production of shaft type components such as axle shafts

excavator bucket pins steering components power tool shafts and drive shafts

The component is fed through a ring type inductor which normally features a

single turn The width of the turn is dictated by the traverse speed the available

power and frequency of the generator This creates a moving band of heat which

when quenched creates the hardened surface layer The quench ring can be either

integral a following arrangement or a combination of both subject to the

requirements of the application By varying speed power etc it is possible to create


pg 25

a shaft which is hardened along its whole length or just in specific areas and also to

harden shafts with steps in diameter or spines It is normal when hardening round

shafts to rotate the part during the process to ensure any variations due to

concentricity of the coil and the component are removed

Equipment

Power required

Power supplies for induction hardening vary in power from a few kilowatts to

hundreds of kilowatts dependent of the size of the component to be heated and the

production method employed ie single shot hardening traverse hardening or

submerged hardening

Frequency

Induction heating systems for hardening are available in a variety of different

operating frequencies typically from 1 kHz to 400 kHz Higher and lower

frequencies are available but typically these will be used for specialist applications

The relationship between operating frequency and current penetration depth and

therefore hardness depth is inversely proportional

CARBURISING FURNACE

It is used for case hardening of products are done In this process the heating

is carried out up to 600oC for 4 hours at 150oChr and then holding for half an hour

at 600oCtaken place again heating takes place at the rate of 61oChr to 875oC Thus

the heating cycle is completed and cooling is done by quenching them in the water

bath

The main components which are heat treated in this section are Bull head hammers

of flux crushing plant in the sinter plant gear blanks etc


pg 26

Horizontal Boring Machines-


pg 27

Radial Drilling Machines-

Universal Drilling Machines


pg 28

Milling Machines-


pg 29

FORGING SHOP

In forging shop the parts and objects which are needed high strength and hardness

that required to VSP

Forging is one of the oldest hot metal working processes It is defined as the

shaping of a heated metal by hammering and pressing In this process metals are

made plastic by heating them and deformed by hammering while they are hot The

components made b this are called forgings The process is carried out at

recrystallization temperature of metals

INPUTS Ingots from foundry blooms from SMS billets rods from mills etc

PRODUCTION AND SERVICES Raw material for shafts coupling gears pinions Flanges bull head hammers for plant hammer crusher drill rods for blast Furnace v-hooks for SMS straightening of pallet frames of sinter plant The shop is designed for production of shafts coupling - flanges Etc and also of forged shapes such as crusher hammer heads special bolts nuts Etc The repair and testing of chains are also carried out The annual production from the shop is about 2400 tons based On 300 working days per year and two Shifts per day These inputs consisting of ingots billets blooms and flats of various sizes In heavy forging section open die forging of long shafts gear blanks couplings etcis made with the help of 2-ton bridge type pneumatic hammers Each hammer will be provided with thin chamber heating furnaces Floor type manipulator and jib Crane are provided for handling heavy jobs In general forging section 1 ton 500 Kg and 200 Kg hammers with separate heating furnaces are provided A 2 ton drop stamp hammer with a heating furnace trimming press etc is provided for stamping For cutting them to size a cold saw a billet shear and gas cutting facilities are provided For stress relieving bogie type-annealing furnace is provided

HEAVY FORGING BAY


pg 30

In this bay the jobs which needed a large deformation and the large jobs

which required high forces to deform are done

General heavy forge jobs

Squares to rounds (shafts)

Round to hexagon

Gear blanks

Stepped shafts(bottom roll shafts)

Bull head hammers etc

Raw materials

Blooms (rectangle) rarr 240 320 mm

Squares rarr 240240 mm

Ingots rarr larger dia 350mm smaller dia 240 mm

Equipment in this bay

Heating furnaces ndash 4

Bogie furnace for heat treatment

2 ton amp 3 ton pneumatic hammers

Manipulators ndash 2 1 T amp 2 T capacity

LIGHT FORGING BAY

In this bay the jobs which need light deformation and smaller in size are done

General light forging jobs

Mud guns (4000 3500 2500 mm length)

Tongs

Squares etc

Equipment

Pneumatic hammers ndash 16 T


pg 31

500kg hammers ndash 2norsquos

250kg hammers ndash 1 no

Open hearth furnace ndash 1

Drop stamp hammer

Trimming press

TOOL ROOM

It is provided to cut the shafts billets making holes etc

Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine

Billet shearing machine

TYPES OF FORGING

There are many different kinds of forging processes available however they can be

grouped into three main classes

Drawn out length increases cross-section decreases

Upset Length decreases cross-section increases

Squeezed 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 forging and upsetting

OPEN-DIE DROP-HAMMER FORGING


pg 32

In open-die forging a hammer comes down and deforms the work piece which is

placed on a stationary anvil The dies (the working surfaces of the forge that contact

the work piece) do not enclose the work piece allowing it to flow except where

contacted by the dies Therefore the operator needs to orient and position the work

piece to get the desired shape

IMPRESSION-DIE DROP-HAMMER FORGING

Impression-die forging is also called closed-die forging In impression-die work

metal is placed in a die resembling a mold which is attached to the anvil The

hammer die is shaped as well The hammer is then dropped on the work piece

causing the metal to flow and fill the die cavities

PRESS FORGING

Press forging is variation of drop-hammer forging

Press forges work slowly by applying continuous pressure or force The amount of

time the dies are in contact with the work piece is measured in seconds (as compared

to the milliseconds of drop-hammer forges) The press forging operation can be done

either cold or hot

UPSET FORGING

Upset forging increases the diameter of the work piece by compressing its length

Engine valves couplings bolts screws and other fasteners

ROLL FORGING

Roll forging is a process where round or flat bar stock is reduced in thickness and

increased in length

HEATING FURNACE


pg 33

The furnace is equipment used to provide heat for a process Inn this type of

furnace a room type fixed hearth gas fired heating furnace is used

The pilot burner and main burner in two sets are at roof The coke oven gas is

supplied to burner and is burnt with the air provided from an air blower Different

valves are provided for air and gas controls

Operation of furnace

A starting procedure

2) Informing to gas control department indicating the starting of furnace

3) Observe the lsquowater over flowrsquo condition to ensure that lsquoUrsquo seal is full of water

or not

4) Ensure that there are no any defects in gas line fitting

5) Remove if any lsquoblanksrsquo in gas line

6) Keep the furnace door and damper open

7) Keep the main isolation switch of electrical panel in lsquoonrsquo position

8) Switch on the individual feeders

9) Start the blower after blower discharge valve close and then open the valve

ldquoUrdquo seal dewatering process

a Close the water inlet valve of u seal and open the drain

valve to escape water

b Close the over flow valve line and drain valve after

escaping of water

10) Open the gas valve and check the pressure whether it is 500-600 mm of

water column

11) Energize the solenoid and reset the annunciation

12) Set the required temperature in controller

B Lighting the burner

13) Keep the main burner air valve close while the pilot burner air valve is

partially opened

14) Lit the pilot burner by opening gas valve

15) Open the gas and air valves of main burner

16) Open pilot air valve completely while pilot gas valve is closed

17) Above same procedure is followed for second set of burners


pg 34

18) Close the furnace door and check the flame is stable or not

When the furnace room temperature is 900 deg C the jobs are introduced The

forging temperature is up to 1200 deg C

C

19) Inform the gas control dept that furnace is fired off

20) Close the main airline valve and accept the annunciation

21) Close the main burner gas line valves

HEAVY FORGING HAMMER

It is a bridge type pneumatic hammer

Construction

The machine supports on two columns Two columns are joined with an arch which

forms a multi prismatic guide of mono block type cylinder at center A ram is slide

inside the cylinder and the top die is fitted to the ram The bottom die is placed on

an anvil located below top die A stuffing box which houses valve controls is placed

before entrance and exhaust of the cylinder The machine and anvil are installed with

strong and deep basement ie 25to 35 feet to make the machine robust to absorb high

shocks

Operation

The top die is the actual tool which performs the hammering action The die

is operated upwards and downwards in cylinder by air pressure The inlet and

exhaust valves are controlled by a lever which is connected to stuffing box When

upper inlet valve is opened the highly pressurized air is supplied into the top of the

piston from lsquoAir Separation Plant Utilities deptrsquo Then the ram moves downwards

and blows on the job which is placed on the bottom die The air below the ram is

exhausted through lower exhaust valve There is a top pressure buffer cap in cylinder

which inserts the ram safely by an aid cushion at the end of its upward stroke The

cylinder and ram is lubricated with oil for free and smooth movement


pg 35

LIGHT FORGING HAMMER It is widely used for the manufacture of medium size forgings The ram is

directly connected to piston working in a steam or air cylinder The capacity of

column hammer is about 500kg

It operates with steam or compressed air As compared to pneumatic bridge

hammer column hammer does not possess built in compressor and therefore

requires additional arrangement for supplying high pressure steam or compressed

air

Pneumatic column hammer

DROP STAMP HAMMER

It is a closed die forging hammer Spanners nuts bolts etc are made by this

method The dies are made for these jobs they can produce at rapid rate

because as fast as the heated lumps of steel are taken out of furnace they can be

put into drop stamp pounded by it with dies to the required shape and then

removed to have the surplus metal cut off

Mechanism and operation of this hammer

This hammer is used the friction lift mechanism This consists of two multi

grooved friction drums fixed to the main shaft A one piece cast lifting arm is fitted

between these two drums and is mounted on anti-friction bearings are carried on

main shaft on the outside of each drum cast steel lifting levers are tied to the lifting


pg 36

arm by the tie plate and a cam spindle is carried through arm and levers Frodo-lined

Vee brakes operated on the cam spindle by means of a control lever at one end of

the lifter and engage with the friction drum which is fixed to the revolving main

shaft Thus by a pull on the control lever the stationary lifting arm levers and brakes

are locked with drum and the lifting mechanism is put into the operation The

hammer head is connected to the lifting arm by means of a belt which is guided by

a loosen pulley bushed on to the lifting arm The main shaft carries a fixed winch

around which is a control rope is worked by an operator who by a slight pull can lift

the hammer and hold it at any position in guide rods The drive is by means of an

electric motor placed in a suitable position on the floor engaging by a belt to a heavy

fly wheel driving the main shaft through a single train to accuracy machine cut gears

The process includes providing a super abundance of power over the live

weight which it has to control by lifting mechanism such that the forger can obtain

that sharp elastic lsquosnappyrsquo blow when it is left over the job that immediately the

instantaneously merged together


pg 37

MANIPULATORS-

Manipulators are used to hold the heated jobs while the forging operation is doing on heavy forging hammer It has two jaws which can be rotated around 360 deg When maximum flexibility in transport and handling capabilities during the forging process is important a Mobile Forging Manipulator is your first choice The compact design and maneuverability of manipulators from DANGO amp DIENENTHAL allow the transport of work pieces even when space is limited Whether small or very large handling capacities are needed DANGO amp DIENENTHAL offers both standard and customized solutions Our machines offer high reliability as well as great flexibility The sturdy and compact design is adapted to the special operating conditions Ergonomically aspects and hands-on experience are the decisive factors for selecting and arranging control levers switches and buttons Characteristics- Powerful tongs unit with large gripping range Multistage adjustment of closing force Spring systems acting both vertically and horizontally to absorb shock loads High maneuverability due to quick and flexible travelling behavior Semi-automatic working cycles at request Travel steering and tongs motions can be carried out at the same time excellent operators view in all directions air conditioned drivers cabin at requestpumpsdriven by electric motor or diesel engine Emergency functions

BOGIE FURNACE

A bogie furnace is used for heat treatment

of the forged jobs


pg 38

BILLET SHEARING MACHINE

Description

The shear is mechanically driven and provided with a fixed blade and vertically

moving top blade The drive is by electric motor via v-belts and fly wheel By the

switch able friction clutch the continuously rotating fly wheel can be connected

with the toothed gear The blade slide with the top blade is driven by the gear via

crank shaft and connecting rod With the clutch disengaged the toothed gear is

connected with shear frame by a single disc brake The blade slide moves in the

re-adjustable guides in the machine frame

The machine frame consists of mainly two steel plates and the blade frame from

cast steel which accommodates the bottom blade and the down holders Top blade

and bottom blade are mounted in special blade accommodations from cast steel

which holds the contact surfaces between machine and blade no wear on frame amp

blade slide is ensured

The down holder is arranged in the front of the shear over the bottom blade The

down holder stroke is made by means of a wedge shaped sliding member which

driving motion is taken off by 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 adjusted by means of a spindle gear

The required cutting gap between top amp bottom blades can be achieved by the


pg 39

Specifications horizontal displacement of the bottom blade accommodations by

means of a wedge

Operation

The billets are placed in the cradle in bundles or separately up to 10

tons It is important that the cradle must be completely lowered to avoid damages in

case of hard placing

An orderly and quantitatively regulated transfer of billets is performed by

lifting the cradle until the first billets are moved into the horizontally moved chute

If the billets are disorderly moved on to the chute it can be lifted until the billets are

arranged amp ejector is adjusted

If the cradle is lowered completely the ejector takes the bottom billet and

ejects it Then the billet in chute moves up to the required length stop regulated

manually and clutch is engaged which cuts the billet into required length Then the

clutch is disengaged

The forged jobs are dispatched to the customers after heat treatment is done


pg 40

STEEL STRUCTURAL SHOP

In sss the structural work and mainly fabrication work of steel is done The

repairs of huge parts are also done When used as industrial term fabrication

applies to the building of machine structures and other equipment by cutting

shaping and assembling components made from raw materials

Fabrication (steel structural) shop concentrated on the metal

preparation welding and assembling aspects

INPUTS Sheets of various sizes plates angles channels beams for fabrication

Of jobs PRODUCTION amp SERVICES All types of fabrication jobs repair of slag pots of SMS Mfg And repair of punishes for SMS Mfg Of scrap boxes for SMS for sinter Plant hot metal ladle for SMS 500 meters launder for SMS mfg of KAMAG Body for FMD Repairing of buckets for LMMM WRM The annual production of Fabricated structures are about 4500 tones and the input consisting of sheets Plates channels angles beams etc are about 5100 T For marking cutting to size forming and bending guillotine Shear circular saw plate bender gas cutting unit etc are provided for welding Transformer automatic and semi-automatic machines and submerged arc Welding machines are provided Painting is carried out partly with help of spray


pg 41

Guns and partly by hand Wire brush spray guns etc are provided A maintenance Section equipped with lathe shaper drill etc are provided for running Repair of shop equipment

DETAILS OF SHOP

Capacity annual production is 4500 tones and material needed is 5100 tones

Activities and work root

Marking the material on stock

Cutting to prepare material for object

Assembling various parts or plates prepared for an object

Welding the assembled parts to join them

Inspection for the defects

Dispatching to customer after ensuring no defects

Welding techniques used in this shop are

Arc welding

Metal in earth gas welding

Thermite welding

Maintenance of stores

A store is maintained for the new materials spare parts and tools etc

Raw materials for sss

Channels

Sheets

Plates

Beams

Billets

Angles

The raw materials are stored in open bay of the shop

Major and regular jobs

Hot metal ladle (BF)


pg 42

Tundishes Slag pot (SMS)

Coke bucket (Coke ovens)

Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press

Combination shearing machine

Radial drilling machine

CNC gas cutting machine

Tool room

This equipment is located in material preparation bay in shop

In material preparation bay the metal sheets and plates of required

dimensions are prepared by making and cutting on the various machines

Marking is done in required profile by developing the surfaces of final

shape of the object using micrometer steel rule compass etchellip tools

After marking material will be cut and shaped The operation of cutting

may be in the form of shearing bending punching pressing punching

notching etc

SHEARING MACHINE

Shearing (metalworking)

Shearing is a metalworking process which cuts stock without the formation of

chips or the use of burning or melting If the cutting blades are straight the

process is called shearing if the cutting blades are curved then they are

shearing-type operations The most commonly sheared materials are in the


pg 43

form of sheet metal or plates however rods can also be sheared Shearing-

type operations include blanking piercing roll slitting and trimming

Principle and working

A punch (or moving blade) is used to push the work piece against the die (or

fixed blade) which is fixed Usually the clearance between the two is 5 to

10 of the thickness of the material but dependent on the material

Clearance is defined as the separation between the blades measured at the

point where the cutting action takes place and perpendicular to the direction

of blade movement It affects the finish of the cut (burr) and the machines

power consumption

This causes the material to experience highly localized shear stresses between

the punch and die

The fracture will begin at the weakest point and progress to the next weakest

point until the entire work piece has been sheared this causes the rough edge

The material will then fail when the punch has moved 15 to 60 the thickness

of the material because the shear stresses are greater than the shear strength

of the material and the remainder of the material is torn

The rough edge can be reduced if the work piece is clamped from the top with

a die cushion Above a certain pressure the fracture zone can be completely

eliminated However the sheared edge of the work piece will usually

experience work hardening and cracking Two distinct sections can be seen

on a sheared work piece the first part being plastic deformation and the

second being fractured

Straight shearing


pg 44

Shearing machine 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 be foot powered (or less commonly hand powered) or

mechanically powered It works by first clamping the material with a ram

A moving blade then comes down across a fixed blade to shear the material

For larger shears the moving blade may be set on an angle or rocked in order

to shear the material progressively from one side to the other this angle is

referred to as the shear angle

This decreases the amount of force required but increases the stroke A 5

degree shear angle decreases the force by about 20 The amount of energy

used is still the same

The moving blade may also be inclined 05 to 25deg this angle is called the

rake angle to keep the material from becoming wedged between the blades

however it compromises the square ness of the edge[3] As far as equipment

is concerned the machine consists of a shear table work-holding device

upper and lower blades and a gauging device

The shear table is the part of the machinery that the work piece rests on while

being sheared The work-holding device is used to hold the work piece in

place and keep it from moving or buckling while under stress

The upper and lower blades are the piece of machinery that actually do the

cutting while the gauging device is used to ensure that the work piece is being

cut where it is supposed to be

The design of press tools is an engineering compromise A sharp edge

strength and durability are ideal however a sharp edge is not very strong or


pg 45

durable so blades for metal work tend to be square-edged rather than knife-

edged

Typical work piece materials include aluminum brass bronze and mild steel

because of their outstanding shear ability ratings however stainless steel is

not used as much due to its tendencies to work-harden

There are also other types of Geometrical Possibilities besides straight

shearing though These include the Squaring Shear the Angle Shear the Bow-

Tie Shear and the Bar Shear All of these have many different uses and are all

used pretty regularly in certain manufacturing fields

Tool Materials

Low alloy steel is used in low production of materials that range up to 14 in

thick

High-carbon high chromium steel is used in high production of materials that

also range up to 14 in in thickness

Shock-resistant steel is used in materials that are equal to 14 in thick or more

COMBINATION SHEARING MACHINE

It is a multi-purpose machine It is completely mechanically operated Five

types of operations can be done simultaneously on the machine

These operations are

2) Punching it is a purpose of making a desired hole by using a punch and

die (Oslash 35 Oslash32 sq 28 32 )

3) Notching it is a process of cutting out the edges of the strip to obtain the

desired outer contour of the work piece (dimensions of blade

180times180times18)

4) Cropping cutting the square bars and round bars (Oslash63 sq55)

5) Shearing cutting stocks without formation of chips


pg 46

The machine consists of individual units for each operation having punches

dies blades which are necessary for the above 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 At one side of the machine a fly wheel is located and connected to

motor to balance the machine and also drive all units This machine is used

crank lever mechanism to drive A gear train is mounted to fly wheel shaft

and all drives shafts When the lever of unit is engaged to this gear train that

unit is then starting working All the units of this machine can be operated

simultaneously thus it can be used for mass production

BENDING MACHINE

This is used to bend the plates or sheets in order to form into

cylindrical shape conical shape and other curved shapes as well as to

straighten the curved and abstracted plates or sheets and made them flat

Principle

The plates are fed between top roller and bottom rollers and pressure is

given from bottom to top of the plate and plate is fed to and fro so that it is

gradually bent into required shape

Construction and operation

Bending and straightening machine consists of five rollers one is

mounted at center of upper side of machine and four rollers are inserted in

radial slots at bottom can be lowered and raised radically A reversible

electric motor is connected to each bottom roller to drive them and the main

motor is connected to top roller

The plate is placed on the bottom rollers ensuring that the edges of the

plate and rollers are parallel When the machine is switched on the rollers start


pg 47

rotating and slowly raised Then the plate starts bending about the top roller

At the same time the plate is fed to and fro by reversing the motor and bending

progresses to the final shape

For conical sections the plate is bent in different sections a parted equal

space

Bending has to overcome both tensile and compressive stresses When

bending is done the residual stresses make it spring back towards its original

position therefore it should be over bend

For straightening process first two alternate rollers are raised and then

the passed through remaining bottom rollers The raised rollers are lowered

against plate and then the plate is straightened

The capacity of the machine is 25 mm thick ness and 2 m width of the

plate

HYDRAULIC PRESS

It is used to pressing large castings The ram is moved by the pressure of the

fluid Oil is mostly used fluid for this press The pressure of oil is increased

by 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 200 T

CNC GAS CUTTING MACHINE

CNC

In modern CNC systems end-to-end component design is highly automated

using CADCAM programs The programs produce a computer file that is

interpreted to extract the commands needed to operate a particular cutting

operation

The movement of the tool resulted in varying forces on the controls that would

mean a linear output would not result in linear motion of the tool The key

development in this area was the introduction of the servo which produced


pg 48

highly accurate measurement information Attaching two servos together

produced a selsyn where a remote servos motions was accurately matched

by another Using a variety of mechanical or electrical systems the output of

the selsyn could be read to ensure proper movement had occurred

MIT fit gears to the various hand wheel inputs and drove them with

roller chains connected to motors one for each of the machines three axes (X

Y and Z) The associated controller consisted of five refrigerator-sized

cabinets that together were almost as large as the mill they were connected

to Three of the cabinets contained the motor controllers one controller for

each motor the other two the digital reading system[7]

The MIT design used standard 7-track punch tape for input Three of the tracks

were used to control the different axes of the machine while the other four

encoded various control information[8] The tape was read in a cabinet that

also housed six relay-based hardware registers two for each axis With every

read operation the previously read point was copied into the starting point

register and the newly read one into the ending point[8] The tape was read

continually and the number in the register increased until a stop instruction

four holes in a line was encountered

The final cabinet held a clock that sent pulses through the registers compared

them and generated output pulses that interpolated between the points The

pulses are sent into a summing register in the motor controllers counting up

by the number of pulses every time they were received The summing registers

were connected to a digital to analog converter that output increasing power

to the motors

Once the second point was reached the pulses from the clock would stop and

the motors would eventually drive the mill to the encoded position The speed

of the cut by selecting points that was closer together for slow movements or

further apart for rapid ones

The system was terribly complex including 250 vacuum tubes 175 relays and

numerous moving parts reducing its reliability in a production setting Curves

are as easy to cut as straight lines complex 3-D structures are relatively easy

to produce and the number of machining steps that required human action has

been dramatically reduced


pg 49

The standard G-code was adapted for CNC use In turn G-code was

supplanted by STEP-NC a system that was deliberately designed for CNC

rather than grown from an existing plotter standard

G-Code or preparatory code or function are functions in the Numerical

control programming language The G-codes are the codes that position the

tool and do the actual work as opposed to M-codes that manages the

machine T for tool-related codes S and F are tool-Speed and tool-Feed and

finally D-codes for tool compensation

Partial list of M-Codes

M00=Program Stop (non-optional) M01=Optional Stop machine will only

stop if operator selects this option M02=End of Program M03=Spindle on

(CW rotation) M04=Spindle on (CCW rotation) M05=Spindle Stop

M06=Tool Change M07=Coolant on (flood) M08=Coolant on (mist)

M09=Coolant off M10=Pallet clamp on M11=Pallet clamp off

M30=End of programrewind tape (may still be required for older CNC

machines)

Common G Codes

G00 Rapid positioning G01 Linear interpolation G02 CW circular

interpolation G03 CCW circular interpolation G12 CW Circle Cutting G13

CCW Circle Cutting G17 X-Y plane selection G18 X-Z plane selection G19

Y-Z plane selection G20 Programming in inches G21 Programming in mm

G90 Absolute programming G91 Incremental programming

CNC gas cutting machinersquos main parts are

Control panel

Frame

Cutting torch

Nozzles

Gas cylinders

Control panel is the main part of the CNC gas cutting machine which

consists of various buttons to enter the data into the machine It consists of

various controls to regulate the speed of the torch to perform operation

Frame includes the bed for placing the sheet and mild steel frame


pg 50

which holds cutting torch and moves according to the given program to cut

the required structure

Torch is made of brass to with stand high temperatures It has two ends

To the one end nozzle is fixed and the other end has the provision to

connect two hoses for oxygen and acetylene

Nozzle in the part of the torch where flame comes out and the cutting

takes place Various sizes of nozzles are provided for various thicknesses

Gas cylinders of oxygen and acetylene are used for gas cutting In

this machine cutting is carried out by using oxy- acetylene

RADIAL DRILLING MACHINE

Radial drilling is used for drilling heavy works and especially for the

jobs where high degree of accuracy is required Its main parts are

Base

Column

Radial arm

Drill head

Spindle

BASE is a rigid cast iron casting which is designed to support column and table It

also contains fluid reservoir for coolant ampfor lubrication

COLUMN is mounted vertically on the base and supports radial arm It also houses

drive mechanism for spindle

RADIAL ARM is supported by column and rotates 360o to provide easy drilling in

heavier works

DRILL HEAD moves on the guide ways of the radial arm and it houses spindle and

speed and feed

SPINDLE is the main part which holds the drill and performs the operation Both

parallel shank and taper shank drills are used in drilling The standard taper of taper

shank drill is called MORSE TAPER

The prepared plates sections in material preparation bay they are transferred to

assembly may for assembling of various parts of a structure The plates are welded

to make a required structure

Welding is process of making a permanent joint by establishing inter atomic bonds

between two or more pieces of metal using heat or heat and pressure

In SSS three types of welding techniques are using They are


pg 51

i Arc welding

ii MIG welding

iii Thermite welding

FOUNDRY SHOP

Foundry work deals with manufacture of products from molten metal and obtained

products are called castings

The iron and steel foundry at VSP produces metal castings Meant for internal uses at different departments like SMS sinter plant continuous Casting blast furnace coke ovens etc The raw materials for the foundry are blast furnace pig iron and steel scrap This foundry has excellent facilities to produce Quality castings economically on a large scale The VSP foundry is mainly a captive Foundry because the castings produced by it are used only in VSP and is jobbing in Nature as variety of castings varying in chemistry and weight are being made Recently started executing outside orders for special steel ingots


pg 52

SEQUENCE OPERATIONS

1 Pattern Making

2 Mould and Core making

3 Melting and Pouring

4 Fettling

5 Inspection

PATTERN MAKING

Pattern is the replica or full size model of castings to be made It gives its

shape to the mould cavity in which the molten metal solidifies to that desired form

and size

PATTERN ALLOWANCES

A pattern differs from the casting dimensions The size of pattern is slightly larger

than the finished casting by an amount called lsquoallowancersquo

The allowances given to pattern are

1) Shrinkage allowance

When molten liquid metal solidifies the contraction or shrinkage will takes

place ie reduces its original size Therefore the pattern is made larger or

oversized than the required casting dimensions The correction for this is

expressed as a ratio

2) Machining allowance After casting is made machining is done in order to get smooth and clean

finishing Therefore the excess dimensions are given to the pattern

3) Draft allowance

When a pattern is removed from a mould the tendency to tear away the edges

of the mould is reduced if vertical surfaces of the pattern are tapered inwards

4) Rapping allowance


pg 53

Due to rapping of the pattern in the mould the size of the mould cavity

increases slightly Therefore lsquoshake or rappingrsquo allowances shall be given

to pattern making it smaller to compensate for rapping

Types of patterns

1) Solid pattern

In this type one side is made flat which serves as a parting surface The

mould cavity will be entirely in the drag

2) Split pattern It is used for intricate and complex shaped casting In two piece pattern one

part producing the mould in drag and the other in cope In three piece pattern

molding box is with these parts Center one is cheek box and remaining are

same

3) Gated pattern The pattern which includes gates and riser for producing castings are called

lsquogated patternrsquo

4) Sweep pattern

It is a template made of wood or metal revolving around a fixed axis in

mould shapes the sand to desired contour

5) Cope and Drag pattern This pattern is made up of two halves which are mounted on different

plates Cope and drag parts are made separately and then assembled

6) Skelton pattern It is used for making large castings in small number This is a wooden frame

out lining the shape of the casting The frame is filled with loam sand and

rammed

7) Segmental pattern It is form of a segment and used for molding circular objects such as rings

wheel rims etc This pattern revolves about center

PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics

In foundry shop the castings are made that is necessary to VSPrsquos needs

The sand is used for molding as it has high thermal shock absorption

Various types of sands used in Foundry are

Green sand Molding sand containing moisture is called lsquogreen sandrsquo It

consists of silica clay water (5) It can be reused by reconditioning

Dry sand Sand free from moisture is dry sand which is used for large

castings as it having high strength

Parting sand It is used to prevent the moulding sand from sticking to

surfaces It is free from clay

Core sand It is silicon sand mixed with organic compound like oils resins etc

It has high refractive ness used for core making

Silica sand It consists of 98 to 90 silica mixed with clay It is mixed with

coal powder and used for CO2 moulding process

MOULDING PROCESSES

According to method

Bench moulding In this moulding flasks are kept on bench used for small castings

Flour moulding The mould is made on flour It does not required cope box

Pit moulding Mould is made in pit and dug in flour It acts as drag box and the cope

box is used separately

According to material

CO2 process

In this process silica sand is mixed with a small amount of sodium silicate and is

placed in moulding box and rammed After moulding Co2 gas at certain pressure is


pg 55

flowed through mould by vent holes As the result of chemical reaction between

CO2 and sodium silicate sodium carbonate is formed Therefore the sand is made

harder and ready for pouring This sand can be used only once and not suitable for

reconditioning

Green sand moulding

It uses moist sand in which clay will be added to with stand the forces Drying is not

necessary and molten metal is poured as soon as the mould is prepared

MELTING

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

1) Direct Electric Arc Furnace

2) Induction Furnace

Direct Electric Arc Furnace-

This is used to melt steel and other metals

Charge Steel scrap Limestone Steel scrap is the metal which is used for casting

and lime stone is used as flux which eliminates impurities

Construction it consists of a roof which can be raised and lowered by hydraulic

system three electrodes and big cylinder which houses all these things and furnace

The cylinder is lined with refractory bricks to resist heat and melting of cylinder

Process In this the arc is struck between electrodes and steel scrap At the electrode

points the temperature is about 3600 degree centigrade The steel is heated gradually

and its temperature increases When it is reached to 1570 deg Centigrade oxygen is

injected into furnace This O2 is used to form slag by making oxides with impure

elements like MN O SO2 etc It forms slag and floats over the molten metal and

protects it from atmospheric contaminations and acts as a cover While melting the

metal piece sample is sent for the analysis of required additives and made the

required corrections in composition After sampling the reduction of metal is done

The additives required are added Here lime stone acts as a reducing agent


pg 56

After temperature is raised to 1640 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 level beside tap hole The cooling system is arranged in

furnace flows through pipes in order to cool the rotating parts of furnace Generally

water is used as coolant

Electric arc furnace details

Furnace capacity - 8-10tons

Transformer rating - 4000KVA

Secondary voltage - 125-250volts

Water pressure for electrode - 15kgcm2

Control and tilting

Water pressure for cooling - 3kgcm2

Max tilting angle at tapping - 40o

Slagging - 20o

Water for cooling - 6litsec

Power consumption - 492KWHton

Melt down period - 77min

INDUCTION FURNACE-

This furnace is used to melt cast iron

Charge pig iron scrap silica

Construction and process - The charge is placed in a crucible It is surrounded by

primary copper coils The space between the crucible and the coil is packed 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 by tilting the furnace


pg 57

The primary coil is cooled by water which flows through a separate pipe

surrounding the primary coil In this furnace the charge pig iron is refined in order

to get molten cast iron

Induction furnace details-

Capacity 53 tons

No Of crucibles 2 norsquos

Furnace voltage 1100 KV

Furnace power 1190 KW

Transformer 1350 KVA

Primary Voltage 11KW 3Oslash 50Hz

Secondary Voltage 1100KW max

Cooling water flow rate 1275 m3 hr

Pressure 4 kg cm2

Inlet temperature 45 deg cg

Outlet temperature 65 deg cg max

POURING

The molten metal from furnace is poured into ladle by tilting the furnace The

ladle is made from steel plate and is lined with fire clay Ladle is used to carry the

molten metal from furnace to mould and pouring the metal into mould The ladle is

kept as heat as in furnace so that the metal doesnrsquot loss heat in traveling These ladles

are carried by overhead cranes

The molten metal is poured into mould from ladle in two ways

1) The ladle is tilted by two hoists of overhead 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 In this slag inclusions may occur

2) Bottom pouring ladle is used for large castings The molten metal is poured

through bottom hole of ladle which is operated by a graphite stopper The

temperature in ladle is also controlled by the stopper As metal is poured from

bottom slag is not included and gives better pouring than top pouring


pg 58

SAND PLANT

Sand for moulding is brought from CHEERALA The sand is of 98 and also

of 90 silica The sand is stored in a pit The sand should be prepared before its use

in order to get required moulding properties

Sand handling equipment

1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator

5) Sand storage bins

6) Drier

7) Cooler

Sand preparation

The sand is poured into bunker from storage pit by a grab

This sand is dropped on the belt conveyor by a disc feeder which rotates and

drops the sand down by centripetal force

It is traveled up and passed in drier by screw feeder through another bunker

A blower forces the sand into drier and sand is heated by coke oven 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 bin by a bucket elevator There the sand is

stored when it is not required

When the gate of storage bin is opened the sand is dropped into mixer by a

vibrating feeder

In mixers the required additives are added and mixed thoroughly The

additives are for one ton of sand

Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59

Mixing cycle time is 6 minutes

The water is added for green sand only Then the sand is ready for moulding

The prepared sand is sent to small storage bins which are at moulding places

by bucket elevators and belt conveyors

A sand aerator is placed before each bin and it is used to crush the small sand

lumps (included in sand) and make it powder

Sand can be dropped in any storage bin in its traveling path with help of a

plough which diverts the sand to sides of conveyor

The used sand is also can be reconditioned as the similar way of sand preparation

and stored in separate bins

The sand plant is operated automatically by control panel in controlling room 10

ton of sand can be prepared in one hour

CORES Cores are specially made sand bodies intended to form holes and

cavities in castings Cores are placed in the mould cavity before pouring to form

interior surface of the casting

CORE MAKING

Cores are made in boxes Core boxes may be a simple solid type or split type made

of wood The two parts of core box is clamped together and kept in vertical position

Wires to provide venting and metal rods to strengthen are reinforced in core The

two halves of box are separated and the core is turned out Then the core is backed

in an oven about 230 deg C

CORE PRINTS

The core rest in the mould in recesses specially made for this purpose These

are made from pattern in the form of projections known as lsquocore printsrsquo

Horizontal Vertical Balanced Cover and hanging core etc types of cores are there

according to their position and orientation

FETTLING-

When the molten metal is completely solidified the casting is to be cleaned and

finished After they are removed from mould they have several unwanted projections

as the shape of runners risers fed gates etc And also sand is sticker to it These all


pg 60

waste material should be removed by some means This removal of material is called

lsquoFETTLINGrsquo

For iron these projections are removed by nicking them with a chisel and

snapping them off Nonferrous runners etc are sawn off Steel ones are removed by

oxy acetylene cutting process The core holes should be cleaned out and any fins are

removed with a cold chisel Cores are cleaned up by means of drifts The use of wire

brush on the exterior faces of a casting will remove any sands adhering to it and sand

blasting is also used for this purpose Castings that are not too delicate may be

cleaned by tumbling in rattler and fragile castings are properly filled

As per the norms of requirement for cast spares it was found That 12000 Tons of castings will be required for the steel plant comprising of 5400 T of cast iron spares 6240 T of steel spares and 360 T of non-ferrous spares Keeping the requirements in view various equipment were installed to meet the above targets The capacities of the shop are-

The maximum weight of single casting in steel ndash 10 T

The maximum weight of single casting in iron ndash 10 T

The maximum weight of single casting in non-ferrous ndash 1T Captive foundry was envisaged for the supply of consumables and spares for the Steel plant with an investment of 25 cores followed with the man power of 160 People

The foundry is divided into five bays AB Bay - Raw materials section BC Bay - sand preparation core making CD Bay - Melting mound making casting DE Bay - Fettling and cleaning EF Bay Heat treatment and non-ferrous section

UTILITY EQUIPMENT REPAIR SHOP (UERS)


pg 61

INPUTS Sheets Plates Channels Angles Beams Billets Rounds from Forge Shop for manufacturing Shafts Steel amp Iron castings

PRODUCTS AND SERVICES- Manufacturing of Impellers to various departments repair of GCP ID Fan Repair of Steam exhausters for SMS supply of Cones and Ducts of Various sizes build up amp machining of various components reclamation jobs like Valve repairs Conveyor Idlers PCM Rollers etc


pg 2

AN OVER VIEW OF VISAKHAPATNAM STEEL PLANT Visakhapatnam is popularly called as the Steel City of India and credit

was because of the Vi zag Stee l P lant ndash a venture of Ispat Nigam

VSP i s the f i rs t coasta l based s tee l p lant o f India and i s located

16 km south west o f c i ty o f destiny VSP has an installed capacity of 3

million Tons per annum of liquid s tee l and 2 656 mi l l ion tons o f

sa leable s teel VSP products meet exa l t ing international quality

standards such as JIS DIN BIS BS etcVSP has the distinction to be the first

integrated steel plant in India to becomea ful l y ISO-

9002 cer t i f ied company The cer t i f i cate covers qual i ty systems tr

aining and marketing functions spreading over 4 regional marketing officer

20branch offices and 22 stockyards located all over the country VSP successfully

installing and operating efficiently Rs 460 cores worth of pollution

control and environment control equipment and converting the barren

land scape by planting more than 3 million plants has made the steel plant steel

township a greener cleaner place which can boas of 3 to 40C lesser temperature

even in the peak summer compared to Visakhapatnam City

Exports qual i ty p ig i ron and stee l pro jects to Sr i Lanka

Myanmar Nepal Middle East USA amp South East Asia (Pig Iron) RINL VSP was

awarded ldquoState Trading Houserdquo status during 1997-2000Besides these a captive

power plant with a capacity of 2475 MW Oxygen plant Acetylene plant

compressed iron plant extensive repair maintenance facilities form part of

facilities available at VSP VSP has sufficient infrastructure to expand the plant to

10 Million tons per annum of liquid steel capacity


pg 3



Traffic department





pg 4


INTRODUCTION-








pg 5



activities


rolled sections





equipment







capacity















pg 6





MAJOR JOBS OF CMS


machine


couplings


classifier assembly



section



Assembly amp repair

work

Reclamation

work


Heat

treatment


pg 7

EQUIPMENT IN CMS


Heavy lathes



Grinding machine

Slotting machine

Milling machine

Planning machine

Drilling machine


Gear shaper


Balancing machine




HEAVY LATHE








pg 8














Movement of



Tool post mm 110












1) Bed

2) Head stock

3) Tail stock

4) Carriage


pg 9




lubricating oil
















of

saddle

compound rest

tool post






of tool posts

standard tool post

four way tool post



pg 10








Hydraulics





and a rotary valve






pg 11





Type BH 100




















pg 12


















and tablerdquo











pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 3



Traffic department





pg 4


INTRODUCTION-








pg 5



activities


rolled sections





equipment







capacity















pg 6





MAJOR JOBS OF CMS


machine


couplings


classifier assembly



section



Assembly amp repair

work

Reclamation

work


Heat

treatment


pg 7

EQUIPMENT IN CMS


Heavy lathes



Grinding machine

Slotting machine

Milling machine

Planning machine

Drilling machine


Gear shaper


Balancing machine




HEAVY LATHE








pg 8














Movement of



Tool post mm 110












1) Bed

2) Head stock

3) Tail stock

4) Carriage


pg 9




lubricating oil
















of

saddle

compound rest

tool post






of tool posts

standard tool post

four way tool post



pg 10








Hydraulics





and a rotary valve






pg 11





Type BH 100




















pg 12


















and tablerdquo











pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 4


INTRODUCTION-








pg 5



activities


rolled sections





equipment







capacity















pg 6





MAJOR JOBS OF CMS


machine


couplings


classifier assembly



section



Assembly amp repair

work

Reclamation

work


Heat

treatment


pg 7

EQUIPMENT IN CMS


Heavy lathes



Grinding machine

Slotting machine

Milling machine

Planning machine

Drilling machine


Gear shaper


Balancing machine




HEAVY LATHE








pg 8














Movement of



Tool post mm 110












1) Bed

2) Head stock

3) Tail stock

4) Carriage


pg 9




lubricating oil
















of

saddle

compound rest

tool post






of tool posts

standard tool post

four way tool post



pg 10








Hydraulics





and a rotary valve






pg 11





Type BH 100




















pg 12


















and tablerdquo











pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 5



activities


rolled sections





equipment







capacity















pg 6





MAJOR JOBS OF CMS


machine


couplings


classifier assembly



section



Assembly amp repair

work

Reclamation

work


Heat

treatment


pg 7

EQUIPMENT IN CMS


Heavy lathes



Grinding machine

Slotting machine

Milling machine

Planning machine

Drilling machine


Gear shaper


Balancing machine




HEAVY LATHE








pg 8














Movement of



Tool post mm 110












1) Bed

2) Head stock

3) Tail stock

4) Carriage


pg 9




lubricating oil
















of

saddle

compound rest

tool post






of tool posts

standard tool post

four way tool post



pg 10








Hydraulics





and a rotary valve






pg 11





Type BH 100




















pg 12


















and tablerdquo











pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 6





MAJOR JOBS OF CMS


machine


couplings


classifier assembly



section



Assembly amp repair

work

Reclamation

work


Heat

treatment


pg 7

EQUIPMENT IN CMS


Heavy lathes



Grinding machine

Slotting machine

Milling machine

Planning machine

Drilling machine


Gear shaper


Balancing machine




HEAVY LATHE








pg 8














Movement of



Tool post mm 110












1) Bed

2) Head stock

3) Tail stock

4) Carriage


pg 9




lubricating oil
















of

saddle

compound rest

tool post






of tool posts

standard tool post

four way tool post



pg 10








Hydraulics





and a rotary valve






pg 11





Type BH 100




















pg 12


















and tablerdquo











pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 7

EQUIPMENT IN CMS


Heavy lathes



Grinding machine

Slotting machine

Milling machine

Planning machine

Drilling machine


Gear shaper


Balancing machine




HEAVY LATHE








pg 8














Movement of



Tool post mm 110












1) Bed

2) Head stock

3) Tail stock

4) Carriage


pg 9




lubricating oil
















of

saddle

compound rest

tool post






of tool posts

standard tool post

four way tool post



pg 10








Hydraulics





and a rotary valve






pg 11





Type BH 100




















pg 12


















and tablerdquo











pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 8














Movement of



Tool post mm 110












1) Bed

2) Head stock

3) Tail stock

4) Carriage


pg 9




lubricating oil
















of

saddle

compound rest

tool post






of tool posts

standard tool post

four way tool post



pg 10








Hydraulics





and a rotary valve






pg 11





Type BH 100




















pg 12


















and tablerdquo











pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 9




lubricating oil
















of

saddle

compound rest

tool post






of tool posts

standard tool post

four way tool post



pg 10








Hydraulics





and a rotary valve






pg 11





Type BH 100




















pg 12


















and tablerdquo











pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 10








Hydraulics





and a rotary valve






pg 11





Type BH 100




















pg 12


















and tablerdquo











pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 11





Type BH 100




















pg 12


















and tablerdquo











pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 12


















and tablerdquo











pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 13














pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 14


depth jobs

CONSTRUCTION












OPERATION









pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 15















pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 16











Coolant systems


pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 17



good cooling effect




may be used

Supply






SHAPER








SLOTTER







pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 18





Operation






pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 19

BALANCING MACHINE















Working of machine



















pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 20

















process






pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 21











Electrode







Cleaning of metals





cause a poor finish




descaled

Peening metals




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 22




























system





pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 23



due to use









3 heating furnaces

Oil bath

Water bath


Carburizing furnace

Nit riding furnace






pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 24



Process












Principal methods







small gears

Traverse hardening












pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 25





Equipment

Power required




submerged hardening

Frequency






CARBURISING FURNACE





bath




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 26



pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 27




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 28

Milling Machines-


pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 29

FORGING SHOP










HEAVY FORGING BAY


pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 30





Round to hexagon

Gear blanks



Raw materials









LIGHT FORGING BAY




Tongs

Squares etc

Equipment



pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 31




Drop stamp hammer

Trimming press

TOOL ROOM


Equipment

Circular saw

Power hacksaw

Band saw

Drilling machine

Shaping machine

Grinding machine


TYPES OF FORGING










pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 32











PRESS FORGING





either cold or hot

UPSET FORGING



ROLL FORGING


increased in length

HEATING FURNACE


pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 33










or not











escaping of water


water column





partially opened






pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 34




C






Construction







shocks

Operation











pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 35







air


DROP STAMP HAMMER












pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 36

















pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 37

MANIPULATORS-


BOGIE FURNACE


of the forged jobs


pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 38


Description




















pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 39


means of a wedge

Operation














pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 40











pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 41


DETAILS OF SHOP










Arc welding


Thermite welding




Channels

Sheets

Plates

Beams

Billets

Angles





pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 42



Cones (SP)

Ducts (CRMP)

Rakes (Mills)

Hooks (for cranes)

Equipment in sss

Shearing machine

Bending machine

Hydraulic press




Tool room








notching etc

SHEARING MACHINE







pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 43










power consumption


the punch and die












Straight shearing


pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 44


























pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 45


edged








Tool Materials


thick












180times180times18)




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 46











BENDING MACHINE




Principle













pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 47





space








plate

HYDRAULIC PRESS






CNC




operation





pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 48
























to the motors











pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 49
















machines)

Common G Codes







Control panel

Frame

Cutting torch

Nozzles

Gas cylinders






pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 50













Base

Column

Radial arm

Drill head

Spindle






heavier works


speed and feed











pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 51

i Arc welding

ii MIG welding


FOUNDRY SHOP





pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 52

SEQUENCE OPERATIONS

1 Pattern Making



4 Fettling

5 Inspection

PATTERN MAKING



and size

PATTERN ALLOWANCES











3) Draft allowance





pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 53




Types of patterns

1) Solid pattern






same



4) Sweep pattern







rammed



PATTERN MATERIALS

1) Wood


pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 54

2) Metal

3) Steel

4) Thermo coal

5) Plaster of Paris

6) Ceramics














MOULDING PROCESSES

According to method






CO2 process




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 55




reconditioning

Green sand moulding



MELTING



casting





















pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 56











Control and tilting



Slagging - 20o




INDUCTION FURNACE-










pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 57





Capacity 53 tons








Pressure 4 kg cm2



POURING















pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 58

SAND PLANT





1) Sand mixer

2) Belt conveyor

3) Bucket elevator

4) Sand aerator


6) Drier

7) Cooler

Sand preparation











vibrating feeder



Bentonite ndash 6

Dextrin ndash 2

Molasses ndash 1

Moisture ndash 5


pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 59
















CORE MAKING






CORE PRINTS





FETTLING-





pg 60


lsquoFETTLINGrsquo















pg 61




pg 60


lsquoFETTLINGrsquo















pg 61




pg 61



Mini Project2

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Transcript of Mini Project2