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    ALFALAH SCHOOL OF ENGINEERING &TECHNOLOGY

    (An autonomous institution)

    SUMMER TRAINING REPORT

    AT

    From:

    Name : Atif Haider

    Class :B.tech(Me)-Vth sem

    Roll no. : M/09/19

    Submitted to:

    Mr. Gajender

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    Contents:

    S.no Topic

    1. About Reva Industries

    2. Facts about Reva

    3. Revas Products

    4. Machines used in RevaIndustries

    5. Manufacturing facilities

    6. Quality and Testing

    7. Companys contactinformation

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    About Reva Industries Ltd.

    Reva Industries Limited is a leading Manufacturer of Gearbox in Sector

    25 region of Faridabad. Reva Industries Limited manufacturers all

    types of Gearbox like Bevel Gearbox, Helical Gearbox, etc. Reva

    Industries Limited also takes large corporate orders for Gearboxand they can negotiate upon prices for large orders. Reva Industries

    Limited also provides good after sales service on sold Gearbox, if

    applicable.When you begin with this philosophy excellence becomes

    a way of life, and you achieve more than you aimed for.

    Exemplifying this spirit in all its operation is REVA INDUSTRIES

    LTD.A company that has been set on a dynamic track record ever

    since its inception, and has continued to move from one milestone to

    another. With an extremely dedicated team of enterprising

    engineers and self-dedicated workmen as it's main assets it

    manufactures EOT Cranes, Electric Wire Rope Hoists, Gear Boxes,Geared Couplings, Geared Motors & Thrustor Brakes.With a

    progressive outlook the company has been implementing the latest

    concepts in design, manufacturing, quality assurance, installation &

    servicing with the help of sophisticated machine tools such as CNC

    Machining & Turning Centers, Gear Hobbers, Gear Grinders etc.,

    ensuring not only dimensional control but also high repeatability.

    Up-to-date computer software's, statistical quality control

    techniques and effective training programmes for the personnel,

    product modularisation is another aspect where a lot of work has

    been done to modularise and standardise the equipment. The resultof these dedicated and sincere efforts has been extremely

    encouraging. The products have been very well accepted in the

    Indian market, making the company among one of the largest

    manufacturers of EOT Cranes & Electric Wire Rope Hoists. The

    sole aim of whole team is to achieve the delight of the customer.

    .

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    Facts about Reva Industries:

    WHAT WE GIVE

    WHAT YOU GET

    DESIGN

    Parametric 3d Solid ModellerFinite Element Analysis (Pro-Mechanical)In-House development Software's

    Virtual model, Quality products, Lighter weight, Saving on runway structure, Optimumsection with liberal safety margins, Accurate & faster designing.

    HOISTING GEAR BOX

    Hellical Gearing at all stagesBrake coupled with motorLow Carbon Alloy Steel Gears & Pinions case

    Hardened to 55-60 HRCProfile ground teethGround int./ext.Mounting Dimension

    Better strength and silent running.Longer life. No misalignmentBetter Physical Properties, Fine grain size, Minimal Wear, Reduced size, Low cost onshedes & allied equipments.- Less prone to cracks.- Minimal Wear. Increased impact strength.Fine surface finish, Reduced vibration, Low noise.Close tolerance, Less power consumption.Radial & facial runout eliminated, Properassembly.

    CT/LT DRIVE

    Helical Gearing at all stagesNo open gearing

    Better strength & silent runningDust Proof, Less wear, Compactness.Lubricated gear box.

    WHEELS

    Die Forged Medium Carbon Alloy Steel

    Fine grain size, Low friction, Better rollability.

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    CONTROL

    Cabin/Pendant/Remote

    Variable Frequency Drives

    Soft Starts

    FlexibilityState of the art controls.No jerks, no peak currents, no pendulum of load.

    QUALITY ASSURANCE

    An ISO: 90001 Company

    Design verification. Chemical, Physical and Ultrasonic testing of raw-materials.Inspection of Gears & Pinions on Gear Testers. Dimensional Controls, Load and

    Overload Testing at works, Erection, Commissioning & after sales service.

    OTHER SERVICES

    RevampingAnnual Maintenance Contracts

    You can use your very old equipment without any problems. Trouble free operationthrough the year.

    INPUT Purchased directly from manufacturers

    Steel - 98% from SAIL

    Bearings - 99% from SKF, NRB & NBC

    Motors - 99.5% from Crompton

    Brakes - 90% from EMCO-LENZE

    Switch Gears - 95% from BCH/SIEMENS

    Wire-Ropes - 100% from Usha Martin, Fort-Williams

    Ensures quality & timely Deliveries.

    MANUFACTURING FACILITY - 100% IN HOUSE

    CNC Horizontal Machining Centre

    CNC Turning Centres

    Gear Hobbers, Shapers

    Gear Grinders

    Sheet Metal Shop

    In-House Foundry

    Plano-Millers, VTLs

    Modem Fabrication Techniques

    Many more machines

    SERVICEABILITY

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    100% In-house manufacturing facility allows world class product in addition to quickDeliveries, Flexibility in Manufacturing and Competitive Prices.

    Revas Products :

    1. Electric Wire Rope Hoists

    2. Low Headroom crane

    3. E.O.T Cranes

    4. Crane Kit

    5. Curved tooth gearcouplings

    6. Helical Reduction gearboxes

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    7. Travelling block wheelassemblies

    8. Helical geared motors

    9. Reva Jib cranes

    10.Reva Thrustor brakes

    11.Flame proof Euipment

    Electric Wire Rope Hoists :

    250 kg to 25000 kg in six standard models consisting of minimum variants of ropes, Motors,Drums Reducers Coupled with reeving and control methods covering almost any hoistingapplication of speed load combinations.

    The square frame accessible from all sides easily adapts it to parellel, perpendicular trolley orsuspended by wheels on existing monorails. Hoists and its mechanism and other loadbearing structures are additionally protected by permanent mechanical load limiter or optionalelectrical load moniter and duration of use hour meter thus warranting the desired life withleast maintenance.

    The Hoists with different reeving arrangements augments additional capacities of the same unit upto 50000 kg.

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    Low Headroom Crane:

    REVA optimally designed & constructed Double Girder & Single Girder EOT Cranes are aresult of the most practical, intelligent, reliable, economical & balanced solution for today's

    Overhead Handling of loads in various applications. Be it a power house, a process industry,a machine shop, a scarp yard, a production/ maintenance shop, a godown or any other

    application where lifting & shifting is required, these cranes are the assembly of standardserially produced modules in our own shop.

    Each module has been specially designed and selected for rugged crane duty applications.Built tough, with a high level of standardization REVA OC Cranes ensure a thoroughlyreliable and economic package. These are available from one tonne to 25 tonne capacities.

    Reva designs / manufacturers S.G Cranes upto 25 Tonnes load & span upto 20 mtrs.confirming to IS 3177 & 807 and other international standards.

    E. O. T. Cranes:

    Reva designs / manufacturers D.G. E.O.T. Cranes upto 160 tonnes load & span to 35 mtrsconfirming to IS 3177 & 807 and other International standards.

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    These cranes are comprised of following serially produced assemblies & componentsoffering various modules to provide custom designed solutions.

    --- Hoisting frame including Gear Reducer, Coupling, Brake, Drum, Sheave & Motor etc. forvarious lifts & speed requirements further supplemented with electronic Controllers for safetyand speed.

    --- Maintenance free and readily accessible assemblies includingGeared Motor driven wheeldrive units to constitute flexibility in end carriage wheel bases.

    The box girders and other structural compact designs are due to vast experience supportedby FEM analysis by graphical and analytical simulation/software for this purpose.

    Reva's Double Girder EOT Cranes is a result of most practical and reliable solution fortodays Overhead Handling of loads in various applications. It is designed with state of artFEM analysis techniques, strict quality checks at various stage and final overload testingassures high reliability and safety. Moreover this all is backed by Reva's large experience.

    Tailor made solutions : These cranes are custom designed and built to suit the usersapplication. Reva is fully equipped in respect of design and manufacturing expertise requiredfor the same.

    Short Delivery Period : The basic components such as Gearboxes, Geared Couplings,Brakes and Wheels are pre-designed and are serially produced. High level of standardisationand modular design also reduces the delivery period.

    Double girder EOT cranes are available upto 160 tones capacity with different combination ofspan and lifts according to users application.

    Crane Kit :

    Reva's urge to have FAST & ECONOMICAL solutions for the customer, leads to the idea of'CRANE KIT'.

    A User can BUILD HIS OWN CRANE by buying readymade REVA Crane Kit, comprising of

    --- Hoisting equipment

    --- End carriages with traveling machineries

    --- Electrical panel

    --- and other accessories.

    All the possible help or on site deputation of engineers is available on request.

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    Reva Curved Tooth Flexible GearCouplings :

    Reva Curved Tooth Flexible Gear Couplings are manufactured as per IPSS :1-01-005-86.The design aims at achieving rationalization of sizes and numbers on basis of their torquetransmitting capacity and generally synchronizes Reva's modular gear boxes ratings, whichin turn are rated in increasing geometrical progression.

    Gear hubs and outer sleeves are manufactured from Carbon Steel conforming to IS:1030 forfirst three sizes and IS:1570 for remaining sizes. Teeth are generated by involute systemhaving 30 degree pressure angle instead of 20 degree to make a quantum breakthrough incoupling design and performance.

    Helical Reduction Gear Boxes:

    Reva offers Helical parallel shaft gear reducers upto 1000 center distance in two - fourstage, in C.I housings duty machined on CNC machining centers (with ATC and toolspresenter).

    The gears / pinions are gas carburised , hardened and profile ground skived to DINT7 fromforged blanks. The antifriction bearing supported on integral pinion shafts and gears are

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    splash oil lubricated which is prevented from leakage by narrow width wave rubber seal.Input/output, solid ,hollow splined and tapered shaft are available. The foot mounted gearreducers are rated from 250 Nm 5000Nm.

    Revas helical gearbox uses hardened and profile ground helical gears. Gearboxes areavailable in wide range of ratings with different configuration to select from.

    Design Features : Modular Concept Center distances, ratios, dimensions corresponding to R10, R 20, and R 40 series. Optimisation : Weight/Power optimised due to use of casehardened steels to high strength.

    Computer Aided Design : Based on Buckingham method resulting in compact and robust

    gearboxes with a factor of safety > 1.5 both in wear and strength. Low Running Noise : Use ofhardened and profile ground gears and cast iron housing reduces running noise and vibrations of

    the gearbox.

    Traveling Block Wheel Assemblies:

    Rail mounted travel units consisting of shrunk fitted/keyed/ splinted hollow axles toaccommodate geared motor solid/hollow /key or splied shaft or make a "made for each other"combination.

    The units can replace existing /obsolete /worn out wheels and travel gear boxes to makethese in line with current technology.Reva offers one of the finest available selection ofenergy

    efficient travelling Machineries with built in reliability, deriving product strength from makingall the key components IN-HOUSE, optimally engineered & manufactured using the latest indesigns, materials, manufacturing & quality assurance techniques.

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    WHEELS : Wheels are manufactured from forged medium carbon alloy steels and aremachined on up-to-date CNC turning centres. The wheels are hardened to a hardness of 36-42 HRC, axles shrunk fitted into the wheels have extended axle to fit into the hollow shaft ofthe travelling machinery with a key or shrink disc.

    WHEEL BLOCKS : Wheels Blocks are fabricated from IS 2062 steels. These Blocks areaccurately fabricated & machined to achieve required parallelism & perpendicularity of thewheels. An adapter plate is provided for welding of distance pieces to obtain required wheelbase. The distance pieces can be either standard rolled channel iron or fabricated box. Afterfixing the distance piece these wheel blocks become end-carriages for cranes or can be usedfor any other mechanical engineering usage. There is a mechanism by which mis-alignmentis taken care of.

    Helical Geared Motors:

    Reva's helical geared motors have shaft mounted gear boxes in model TM 06 to TM 16,to suitvarious motor ratings and output speed requirements. Dimensions,material of construction,

    tolerances confirms to national and international standards. Staggered and rationalized ceterdistances reduce the overall dimensions. Motors and rationalized center distances reduces the

    overall dimensions. Motors from ISO:9001 company and having CE marking are used for allgeared motor

    Reva Jib Cranes:

    Reva manufactures a range of jib cranes such as self supported, Pillar Mounted Wall / PillarMounted, Traveling cantilever wall cranes. These cranes relieve the overhead cranes forcarrying out more useful work on the shop floor. Being designed on FEA these are extremelyreliable & safe.

    These have standard 'REVA' Electric Wire Rope Hoist for lifting of loads.

    The cranes operate at lower height than the overhead crane with lift in the range of 3 to 5meters. The lifting capacity could be in the range of .5 Tonnes to 10 Tonnes (Higher lifts orcapacities can also be supplied).

    The jib cranes are very versatile in handling materials to and from machining bays, smallparts assembly shops, hammer/press shops, repair bays etc. Compared to overhead craneswhich are meant for handling heavier and bulky materials, the jib cranes are very useful for

    faster operation.

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    Jib cranes could be hand operated also but electrically operated cranes with electric wirerope hoists, are the order of the day for increasing the production.

    Jib cranes require much less investment as compared to overhead cranes .Leave aside thecapital cost, the running and maintenance cost are much less as the jib crane parameterscould be optimised as per job requirements.

    REVA is also manufacturing other version of jib cranes viz. Pillar cranes where materials arehandled within a circle. The rotation on the pillar is usually upto 270 degrees but 360 degreesrotation could be provided.

    Flame Proof Equipment:

    We manufacture Flame Proof Equipment for group IIA, IIB & IIC.

    Reva Thrustor Brakes :

    Reva thrustor brakes are suitable for operation an AC supplies on 3 Phase 415 volts and aredesigned particularly for use with heavy duly steel works on general duty overhead electrictravelling cranes and other drum brake applications. These are manufactured to suit Drumsizes 100 mm to 250mm in R-10 series. The construction is extremely simple and can bevery easily maintained.

    Machines used at Reva industries:

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    Lathe (metal)

    Center lathe with DRO and chuck guard. Size is 460 mm swing x 1000 mm between

    centers

    A metal lathe ormetalworking lathe is a large class oflathes designed for preciselymachining relatively hard materials. They were originally designed to machinemetals;

    however, with the advent ofplasticsand other materials, and with their inherent

    versatility, they are used in a wide range of applications, and a broad range of materials.

    In machiningjargon, where the larger context is already understood, they are usuallysimply called lathes, or else referred to by more-specific subtype names (toolroom lathe,

    turret lathe, etc.). These rigidmachine tools remove material from arotating workpiece

    via the (typically linear) movements of various cutting tools, such as tool bits and drillbits.

    Construction

    The design of lathes can vary greatly depending on the intended application; however,

    basic features are common to most types. These machines consist of (at the least) a

    headstock, bed, carriage, and tailstock. Better machines are solidly constructed withbroad bearing surfaces (slides orways) for stability, and manufactured with great

    precision. This helps ensure the components manufactured on the machines can meet the

    required tolerances and repeatability.

    Headstock

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    Headstock with legend, numbers and text within the description refer to those in theimage

    The headstock (H1) houses the main spindle (H4), speed change mechanism (H2,H3),

    and change gears (H10). The headstock is required to be made as robust as possible due

    to the cutting forces involved, which can distort a lightly built housing, and induceharmonicvibrations that will transfer through to the workpiece, reducing the quality of

    the finished workpiece.

    The main spindle is generally hollow to allow long bars to extend through to the work

    area. This reduces preparation and waste of material. The spindle runs in precisionbearings and is fitted with some means of attaching workholding devices such as chucks

    orfaceplates. This end of the spindle usually also has an includedtaper, frequently a

    Morse taper, to allow the insertion of tapers and centers. On older machines the spindlewas directly driven by a flat beltpulleywith lower speeds available by manipulating the

    bull gear. Later machines use a gear box driven by a dedicated electric motor. A fully

    geared head allows the operator to select speeds entirely through the gearbox.

    Bed

    The bed is a robust base that connects to the headstock and permits the carriage andtailstock to be aligned parallel with the axis of the spindle. This is facilitated by hardened

    and ground ways which restrain the carriage and tailstock in a set track. The carriage

    travels by means of a rack and pinion system, leadscrew of accurate pitch, or feedscrew.

    Types of beds include inverted "V" beds, flat beds, and combination "V" and flat beds."V" and combination beds are used for precision and light duty work, while flat beds are

    used for heavy duty work.

    [citation needed]

    When a lathe is installed, the first step is to levelit, which refers to making sure the bed is

    not twisted or bowed. There is no need to make the machine exactly horizontal, but itmust be entirely untwisted to achieve accurate cutting geometry. A precision level is a

    useful tool for identifying and removing any twist. It is advisable also to use such a level

    along the bed to detect bending, in the case of a lathe with more than four mountingpoints. In both instances the level is used as a comparator rather than an absolute

    reference.

    Feed and lead screws

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    The feedscrew (H8) is a long driveshaftthat allows a series of gears to drive the carriage

    mechanisms. These gears are located in the apron of the carriage. Both the feedscrew

    and leadscrew (H7) are driven by either the change gears (on the quadrant) or anintermediate gearbox known as a quick change gearbox(H6) orNorton gearbox. These

    intermediate gears allow the correct ratio and direction to be set for cutting threads or

    worm gears. Tumbler gears (operated by H5) are provided between the spindle and geartrain along with a quadrant plate that enables a gear train of the correct ratio and

    direction to be introduced. This provides a constant relationship between the number of

    turns the spindle makes, to the number of turns the leadscrew makes. This ratio allows

    screwthreads to be cut on the workpiece without the aid of a die.

    Some lathes have only one leadscrew that serves all carriage-moving purposes. For screw

    cutting, a half nut is engaged to be driven by the leadscrew's thread; and for general

    power feed, a key engages with a keyway cut into the leadscrew to drive a pinion along arack that is mounted along the lathe bed.

    The leadscrew will be manufactured to eitherimperialormetric standards and will

    require a conversion ratio to be introduced to create thread forms from a different family.

    To accurately convert from one thread form to the other requires a 127-tooth gear, or onlathes not large enough to mount one, an approximation may be used. Multiples of 3 and

    7 giving a ratio of 63:1 can be used to cut fairly loose threads. This conversion ratio isoften built into the quick change gearboxes.

    The precise ratio required to convert a lathe with an Imperial (inch) leadscrew to metric(millimeter) threading is 100 / 127 = 0.7874... . The best approximation with the fewest

    total teeth is very often 37 / 47 = 0.7872... . This transposition gives a constant -0.020

    percent error over all customary and model-maker's metric pitches (0.25, 0.30, 0.35, 0.40,0.45, 0.50, 0.60, 0.70, 0.75, 0.80, 1.00, 1.25, 1.50, 1.75, 2.00, 2.50, 3.00, 3.50, 4.00, 4.50,

    5.00, 5.50 and 6.00mm).

    Carriage

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    Carriage with legend, numbers and text within the description refer to those in the image

    In its simplest form the carriage holds the tool bit and moves it longitudinally (turning)

    or perpendicularly (facing) under the control of the operator. The operator moves the

    carriage manually via the handwheel(5a) or automatically by engaging the feed shaft

    with the carriage feed mechanism (5c). This provides some relief for the operator as themovement of the carriage becomes power assisted. The handwheels (2a, 3b, 5a) on the

    carriage and its related slides are usually calibrated, both for ease of use and to assist in

    making reproducible cuts. The carriage typically comprises a top casting, known as the

    saddle (4), and a side casting, known as the apron (5).

    Cross-slide

    The cross-slide(3) rides on the carriage and has a feedscrew that travels perpendicular to

    the main spindle axis. This permitsfacingoperations to be performed, and the depth ofcut to be adjusted. This feedscrew can be engaged, through a gear train, to the feed shaft

    (mentioned previously) to provide automated 'power feed' movement to the cross-slide.

    On most lathes, only one direction can be engaged at a time as an interlock mechanism

    will shut out the second gear train.

    Compound rest

    The compound rest (ortop slide) (2) is usually where the tool post is mounted. It

    provides a smaller amount of movement (less than the cross-slide) along its axis via

    another feedscrew. The compound rest axis can be adjusted independently of the carriageor cross-slide. It is used for turning tapers, to control depth of cut when screwcutting or

    precision facing, or to obtain finer feeds (under manual control) than the feed shaft

    permits. Usually, the compound rest has a protractor marked in its base (2b), enabling theoperator to adjust its axis to precise angles.

    The slide rest can be traced to the fifteenth century. In 1718 the tool-supporting slide rest

    with a set of gears was introduced by a Russian inventorAndrey Nartov and had limited

    usage in the Russian industry.[1] In the eighteenth century the slide rest was also used onFrench ornamental turning lathes. The suite of gun boring mills at the Royal Arsenal,

    Woolwich, in the 1780s by the Verbruggan family also had slide rests. The story has long

    circulated that Henry Maudslay invented it, but he did not (and never claimed so). Thelegend that Maudslay invented the slide rest originated with James Nasmyth, who wrote

    ambiguously about it in hisRemarks on the Introduction of the Slide Principle, 1841;

    later writers misunderstood, and propagated the error. However, Maudslay did help todisseminate the idea widely. It is highly probable that he saw it when he was working at

    the Arsenal as a boy. In 1794, whilst he was working forJoseph Bramah, he made one,

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    and when he had his own workshop used it extensively in the lathes he made and sold

    there. Coupled with the network of engineers he trained, this ensured the slide rest

    became widely known and copied by other lathe makers, and so diffused throughoutBritish engineering workshops. A practical and versatile screw-cutting lathe

    incorporating the trio of leadscrew, change gears, and slide rest was Maudslay's most

    important achievement.

    The first fully documented, all-metal slide rest lathe was invented by Jacques deVaucansonaround 1751. It was described in theEncyclopdie a long time before

    Maudslay invented and perfected his version. It is likely that Maudslay was not aware ofVaucanson's work, since his first versions of the slide rest had many errors that were notpresent in the Vaucanson lathe.

    Toolpost

    The tool bit is mounted in the toolpost(1) which may be of the American lantern style,

    traditional four-sided square style, or a quick-change style such as the multifixarrangement pictured. The advantage of a quick change set-up is to allow an unlimited

    number of tools to be used (up to the number of holders available) rather than being

    limited to one tool with the lantern style, or to four tools with the four-sided type.

    Interchangeable tool holders allow all tools to be preset to a centerheight that does notchange, even if the holder is removed from the machine.

    Tailstock

    Tailstock with legend, numbers and text within the description refer to those in the image

    The tailstockis a toolholder directly mounted on the spindle axis, opposite the

    headstock. The spindle (T5) does not rotate but does travel longitudinally under the

    action of a leadscrew and handwheel (T1). The spindle includes ataperto hold drill bits,

    centers and othertooling. The tailstock can be positioned along the bed and clamped (T6)in position as required. There is also provision to offset the tailstock(T4) from the

    spindles axis, this is useful for turning small tapers.

    The image shows a reduction gear box (T2) between the handwheel and spindle, this is afeature found only in the larger center lathes, where large drills may necessitate the extra

    leverage.

    Steady and follower rests

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    A steady rest

    Workpieces often need to be supported more than the chuck and/or centers can support

    them, because cutting metal produces tremendous forces that tend to vibrate or even bendthe workpiece. This extra support can be provided by a steady rest (also called a steady,

    a fixed steady, a center rest, or sometimes, confusingly, a center). It stands stationaryfrom a rigid mounting on the bed, and it supports the workpiece at the rest's center,

    typically with three contact points 120 apart. A follower rest (also called a follower or a

    travelling steady) is similar, but it is mounted to the carriage rather than the bed, whichmeans that as the tool bit moves, the follower rest "follows along" (because they are both

    rigidly connected to the same moving carriage).[2] Follower rests can provide support that

    directly counteracts the springing force of the tool bit, right at the region of the workpiecebeing cut at any moment. In this respect they are analogous to abox tool.

    A follower rest

    Types of metal lathes

    There are many variants of lathes within themetalworkingfield. Some variations are notall that obvious, and others are more a niche area. For example, a centering lathe is a

    dual head machine where the work remains fixed and the heads move towards the

    workpiece and machine a center drill hole into each end. The resulting workpiece maythen be used "between centers" in another operation. The usage of the term metal lathemay also be considered somewhat outdated these days, plastics and other composite

    materials are in wide use and with appropriate modifications, the same principles and

    techniques may be applied to their machining as that used for metal.

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    Center lathe / engine lathe / bench lathe

    Two-speed back gears in a cone-head lathe.

    A typical center lathe.

    The terms center lathe, engine lathe, and bench lathe all refer to a basic type of lathe

    that may be considered the archetypical class of metalworking lathe most often used by

    the general machinist or machining hobbyist. The name bench lathe implies a version ofthis class small enough to be mounted on a workbench (but still full-featured, and larger

    than mini-lathes or micro-lathes). The construction of a center lathe is detailed above, but

    depending on the year of manufacture, size, price range, or desired features, even theselathes can vary widely between models.

    Engine lathe is the name applied to a traditional late-19th-century or 20th-century lathe

    with automatic feed to the cutting tool, as opposed to early lathes which were used with

    hand-held tools, or lathes with manual feed only. The usage of "engine" here is in the

    mechanical-device sense, not the prime-mover sense, as in thesteam engineswhich werethe standard industrial power source for many years. The works would have one large

    steam engine which would provide power to all the machines via a line shaft system of

    belts. Therefore early engine lathes were generally 'cone heads', in that the spindleusually had attached to it a multi-step pulley called a cone pulley designed to accept a flat

    belt. Different spindle speeds could be obtained by moving the flat belt to different steps

    on the cone pulley. Cone-head lathes usually had a countershaft (layshaft) on the backside of the cone which could be engaged to provide a lower set of speeds than was

    obtainable by direct belt drive. These gears were called back gears. Larger lathes

    sometimes had two-speed back gears which could be shifted to provide a still lower set ofspeeds.

    When electric motors started to become common in the early 20th century, many cone-

    head lathes were converted to electric power. At the same time the state of the art in gear

    andbearing practice was advancing to the point that manufacturers began to make fullygeared headstocks, using gearboxes analogous to automobile transmissions to obtain

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    various spindle speeds and feed rates while transmitting the higher amounts ofpower

    needed to take full advantage ofhigh speed steeltools.

    The inexpensive availability of electronics has again changed the way speed control maybe applied by allowing continuously variable motor speed from the maximum down to

    almost zero RPM. (This had been tried in the late 19th century but was not found

    satisfactory at the time. Subsequent improvements have made it viable again.)

    Toolroom lathe

    A toolroom lathe is a lathe optimized fortoolroom work. It is essentially just a top-of-the-

    line center lathe, with all of the best optional features that may be omitted from lessexpensive models, such as a collet closer, taper attachment, and others. There has also

    been an implication over the years of selective assembly and extra fitting, with every care

    taken in the building of a toolroom model to make it the smoothest-running, most-accurate version of the machine that can be built. However, within one brand, the quality

    difference between a regular model and its corresponding toolroom model depends on the

    builder and in some cases has been partly marketing psychology. For name-brandmachine tool builders who made only high-quality tools, there wasn't necessarily any lack

    of quality in the base-model product for the "luxury model" to improve upon. In other

    cases, especially when comparing different brands, the quality differential between (1) anentry-level center lathe built to compete on price, and (2) a toolroom lathe meant tocompete only on quality and not on price, can be objectively demonstrated by measuring

    TIR, vibration, etc. In any case, because of their fully-ticked-off option list and (real or

    implied) higher quality, toolroom lathes are more expensive than entry-level centerlathes.

    Turret lathe and capstan lathe

    Main article: Turret lathe

    Turret lathes and capstan lathesare members of a class of lathes that are used for

    repetitive production of duplicate parts (which by the nature of their cutting process are

    usually interchangeable). It evolved from earlier lathes with the addition of the turret,which is an indexabletoolholder that allows multiple cutting operations to be performed,

    each with a different cutting tool, in easy, rapid succession, with no need for the operator

    to perform setup tasks in between (such as installing or uninstalling tools) nor to controlthe toolpath. (The latter is due to the toolpath's being controlled by the machine, either in

    jig-like fashion [via the mechanical limits placed on it by the turret's slide and stops] or

    via IT-directed servomechanisms [on computer numerical controlled (CNC) lathes].)

    There is a tremendous variety of turret lathe and capstan lathe designs, reflecting thevariety of work that they do.

    Gang-tool lathe

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    A gang-tool lathe is one that has a row of tools set up on its cross-slide, which is long and

    flat and is similar to a milling machine table. The idea is essentially the same as with

    turret lathes: to set up multiple tools and then easily index between them for each part-cutting cycle. Instead of being rotary like a turret, the indexable tool group is linear.

    Multispindle lathe

    Multispindle lathes have more than one spindle and automated control (whether viacams or CNC). They are production machines specializing in high-volume production.

    The smaller types are usually called screw machines, while the larger variants areusually called automatic chucking machines, automatic chuckers, or simply chuckers.

    Screw machines usually work from bar stock, while chuckers automatically chuck up

    individual blanks from a magazine. Typical minimum profitable production lot size on ascrew machine is in the thousands of parts due to the large setup time. Once set up, a

    screw machine can rapidly and efficiently produce thousands of parts on a continuous

    basis with high accuracy, low cycle time, and very little human intervention. (The lattertwo points drive down the unit cost per interchangeable part much lower than could be

    achieved without these machines.)

    Rotary transfer machines might also be included under the category of multispindle

    lathes, although they defy traditional classification. They are large, expensive, modularmachine tools with many CNC axes that combine the capabilities of lathes, milling

    machines, and pallet changers.

    CNC lathe / CNC turning center

    CNC lathe with milling capabilities

    An example turned vase and view of the tool turret

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    CNC lathes are rapidly replacing the older production lathes (multispindle, etc.) due to

    their ease of setting, operation, repeatability and accuracy. They are designed to use

    modern carbide tooling and fully use modern processes. The part may be designed andthe tool paths programmed by the CAD/CAM process or manually by the programmer,

    and the resulting file uploaded to the machine, and once set and trialled the machine will

    continue to turn out parts under the occasional supervision of an operator.

    The machine is controlled electronically via a computer menu style interface, theprogram may be modified and displayed at the machine, along with a simulated view of

    the process. The setter/operator needs a high level of skill to perform the process,however the knowledge base is broader compared to the older production machineswhere intimate knowledge of each machine was considered essential. These machines are

    often set and operated by the same person, where the operator will supervise a small

    number of machines (cell).

    The design of a CNC lathe varies with different manufacturers, but they all have somecommon elements. The turret holds the tool holders and indexes them as needed, the

    spindle holds the workpiece and there are slides that let the turret move in multiple axis

    simultaneously. The machines are often totally enclosed, due in large part toOccupational health and safety(OH&S) issues.

    With rapid growth in this industry, different CNC lathe manufacturers use different user

    interfaces which sometimes makes it difficult for operators as they have to be acquainted

    with them. With the advent of cheap computers, free operating systems such as Linux,andopen source CNC software, the entry price of CNC machines has plummeted.[citation

    needed]

    Hobbing Machine:

    Modern hobbing machines, also known as hobbers, are fully automated machines thatcome in many sizes, because they need to be able to produce anything from tiny

    instrument gears up to 10 ft (3.0 m) diameter marine gears. Each gear hobbing machine

    typically consists of a chuckand tailstock, to hold the workpiece or a spindle, a spindleon which the hob is mounted, and a drive motor.[3]

    For a tooth profile which is a theoretical involute, the fundamental rack is straight-sided,

    with sides inclined at the pressure angle of the tooth form, with flat top and bottom. Thenecessary addendum correctionto allow the use of small-numbered pinions can either be

    obtained by suitable modification of this rack to a cycloidal form at the tips, or by

    hobbing at other than the theoretical pitch circle diameter. Since thegear ratiobetween

    hob and blank is fixed, the resulting gear will have the correct pitch on the pitch circle,but the tooth thickness will not be equal to the space width.

    Hobbing machines are characterised by the largest module or pitch diameter it can

    generate. For example, a 10 in (250 mm) capacity machine can generate gears with a 10

    in pitch diameter and usually a maximum of a 10 in face width. Most hobbing machinesare vertical hobbers, which means the blank is mounted vertically. Horizontal hobbing

    machines are usually used for cutting longer workpieces; i.e. cutting splines on the end of

    a shaft.[6]

    Hob

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    A gear hob in a hobbing machine with a finished gear.

    The hob is the cutter used to cut the teeth into the workpiece. It is cylindrical in shapewith helical cutting teeth. These teeth have grooves that run the length of the hob, which

    aid in cutting and chipremoval. There are also special hobs designed for special gears

    such as the spline and sprocket gears.[3]

    The cross-sectional shape of the hob teeth are almost the same shape as teeth of a rack

    gearthat would be used with the finished product. There are slight changes to the shapefor generating purposes, such as extending the hob's tooth length to create a clearance in

    the gear's roots.[7]Each hob tooth is relieved on the back side to reduce friction.[8]

    Most hobs are single-thread hobs, but double-, and triple-thread hobs increase productionrates. The downside is that they are not as accurate as single-thread hobs.[9]

    This list outlines types of hobs:

    Roller chain sprocket hobs

    Worm wheel hobs

    Spline hobs Chamfer hobs

    Spur and helical gear hobs

    Straight side spline hobs

    Involute spline hobs

    Serration hobs

    Semitopping gear hobs

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    Gear Shaper :

    A gear shaper is a machine tool forcutting the teeth of internal or external gears. Thename shaper relates to the fact that the cutter engages the part on the forward stroke and

    pulls away from the part on the return stroke, just like the clapper box on aplanershaper.

    The cutting tool is also gear shaped having the same pitch as the gear to be cut. However

    number of cutting teeth must be less than that of the gear to be cut for internal gears. For

    external gears the number of teeth on the cutter is limited only by the size of the shapingmachine.

    For larger gears the blank is usually gashedto the rough shape to make shaping easier.

    Sheet metal shop:

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    Materials

    Stainless steel

    The three most common stainless steel grades available in sheet metal are 304, 316, and

    410.[1]

    Grade 304 is the most common of the three grades. It offers good corrosion resistancewhile maintaining formability andweldability. Available finishes are #2B, #3, and #4.

    Note that grade 303 is not available in sheet form.[1]

    Grade 316 offers more corrosion resistance and strength at elevated temperatures than

    304. It is commonly used forpumps, valves, chemical equipment, and marineapplications. Available finishes are #2B, #3, and #4.[1]

    Grade 410 is a heat treatable stainless steel, but does not offer as good corrosion

    resistance. It is commonly used in cutlery. The only available finish is dull.[1]

    Forming processes

    Bending

    Main article: Bending

    The equation for estimating the maximum bending force is,

    ,

    where kis a factor taking into account several parameters including friction. Tis the

    ultimate tensile strengthof the metal.L and tare Length and thickness of sheet metalrespectively. The variable Wis open width of a V-die or wiping die.

    Curling, Decambering, Deep drawing

    Example of deep drawn part

    Drawing is a forming process in which the metal is stretched over a form. In deepdrawing the depth of the part being made is more than half its diameter. Deep drawing is

    used for making automotive fuel tanks, kitchen sinks, 2 piece aluminum cans, etc. Deep

    drawing is generally done in multiple steps called draw reductions. The greater the depththe more reductions are required. Deep drawing may also be accomplished with fewer

    reductions by heating the workpiece, for example in sink manufacture.

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    In many cases, material is rolled at the mill in both directions to aid in deep drawing. This

    has a more uniform grain structure and is referred to as "draw quality" material which

    limits tearing.

    Incremental sheet forming, Ironing, Laser cutting:

    Cutting sheet metal can be done in various ways from hand tools called tin snips up tovery large powered shears. With the advances in technology, sheet metal cutting has

    turned to computers for precise cutting.

    Many sheet metal cutting operations are based on computer numerically controlled

    (CNC) lasers cutting or multi-tool CNC punch press.

    Perforating

    Perforating is a cutting process that punches multiple small holes close together in a flat

    workpiece. Perforated sheet metal is used to make a wide variety of surface cutting tools,such as the surform.

    Press brake forming

    Forming metal on a pressbrake

    This is a form of bending, used for long and thin sheet metal parts. The machine that

    bends the metal is called apress brake. The lower part of the press contains a V shapedgroove. This is called the die. The upper part of the press contains a punch that will press

    the sheet metal down into the v shaped die, causing it to bend. There are several

    techniques used here, but the most common modern method is "air bending". Here, thedie has a sharper angle than the required bend (typically 85 degrees for a 90 degree bend)

    and the upper tool is precisely controlled in its stroke to push the metal down the required

    amount to bend it through 90 degrees. Typically, a general purpose machine has a

    bending force available of around 25 tonnes per metre of length. The opening width ofthe lower die is typically 8 to 10 times the thickness of the metal to be bent (for example,

    5mm material could be bent in a 40mm die) the inner radius of the bend formed in the

    metal is determined not by the radius of the upper tool, but by the lower die width.Typically, the inner radius is equal to 1/6 of the V width used in the forming process.

    Punching:

    Punching is performed by placing the sheet of metal stock between a punch and a die

    mounted in a press. The punch and die are made of hardened steel and are the same

    shape. The punch just barely fits into the die. The press pushes the punch against and into

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    the die with enough force to cut a hole in the stock. In some cases the punch and die

    "nest" together to create a depression in the stock. Inprogressive stamping a coil of stock

    is feed into a long die/punch set with many stages.

    Foundry shop:

    Process:

    Melting

    Melting metal in a ladle for casting

    Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and

    alloying elements are used to charge the furnace. Virgin material refers to commercially

    pure forms of the primary metal used to form a particular alloy. Alloying elements areeither pure forms of an alloying element, like electrolytic nickel, or alloys of limited

    composition, such as ferroalloys or master alloys. External scrap is material from other

    forming processes such as punching, forging, or machining. Internal scrap consists of thegates, risers, or defective castings.

    The process includes melting the charge, refining the melt, adjusting the melt chemistry

    and tapping into a transport vessel. Refining is done to remove deleterious gases and

    elements from the molten metal to avoid casting defects. Material is added during themelting process to bring the final chemistry within a specific range specified by industry

    and/or internal standards. During the tap, final chemistry adjustments are made.

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    Furnace

    Several specialised furnaces are used to melt the metal. Furnaces are refractory lined

    vessels that contain the material to be melted and provide the energy to melt it. Modernfurnace types includeelectric arc furnaces(EAF), induction furnaces, cupolas,

    reverberatory, and crucible furnaces. Furnace choice is dependent on the alloy system and

    quantities produced. For ferrous materials, EAFs, cupolas, and induction furnaces are

    commonly used. Reverberatory and crucible furnaces are common for producingaluminum castings.

    Furnace design is a complex process, and the design can be optimized based on multiple

    factors. Furnaces in foundries can be any size, ranging from mere ounces to hundreds oftons, and they are designed according to the type of metals that are to be melted. Also,

    furnaces must be designed around the fuel being used to produce the desired temperature.

    For low temperature melting point alloys, such as zinc or tin, melting furnaces may reach

    around 327 Celsius. Electricity, propane, or natural gas are usually used for thesetemperatures. For high melting point alloys such as steel or nickel based alloys, the

    furnace must be designed for temperatures over 1600 Celsius. The fuel used to reach

    these high temperatures can be electricity orcoke.

    The majority of foundries specialize in a particular metal and have furnaces dedicated tothese metals. For example, an iron foundry (for cast iron) may use a cupola, induction

    furnace, or EAF, while a steel foundry will use an EAF or induction furnace. Bronzeor

    brass foundries use crucible furnaces or induction furnaces. Most aluminum foundries useeither an electric resistance or gas heatedcruciblefurnaces or reverberatory furnaces.

    A metal die casting robot in an industrial foundry

    Degassing

    In the case of aluminium alloys, a degassing step is usually necessary to reduce theamount of hydrogen in the liquid metal. If the hydrogen concentration in the melt is too

    high, the resulting casting will contain gas porosity that will deteriorate its mechanical

    properties.

    An efficient way of removing hydrogen from the melt is to bubble argon or nitrogen. To

    do that, several different types of equipment are used by foundries. When the bubbles go

    up in the melt, they catch the dissolved hydrogen and bring it to the top surface. There are

    various equipment which measure the amount of hydrogen present in it. Alternatively, thedensity of the aluminum sample is calculated to check amount of hydrogen dissolved in

    it.

    http://en.wikipedia.org/wiki/Electric_arc_furnacehttp://en.wikipedia.org/wiki/Electric_arc_furnacehttp://en.wikipedia.org/wiki/Electric_arc_furnacehttp://en.wikipedia.org/wiki/Induction_furnacehttp://en.wikipedia.org/wiki/Cupola_furnacehttp://en.wikipedia.org/wiki/Reverberatory_furnacehttp://en.wikipedia.org/wiki/Coke_(fuel)http://en.wikipedia.org/wiki/Cupola_furnacehttp://en.wikipedia.org/wiki/Bronzehttp://en.wikipedia.org/wiki/Bronzehttp://en.wikipedia.org/wiki/Bronzehttp://en.wikipedia.org/wiki/Brasshttp://en.wikipedia.org/wiki/Cruciblehttp://en.wikipedia.org/wiki/Cruciblehttp://en.wikipedia.org/wiki/Cruciblehttp://en.wikipedia.org/wiki/File:Automation_of_foundry_with_robot.jpghttp://en.wikipedia.org/wiki/File:Automation_of_foundry_with_robot.jpghttp://en.wikipedia.org/wiki/Electric_arc_furnacehttp://en.wikipedia.org/wiki/Induction_furnacehttp://en.wikipedia.org/wiki/Cupola_furnacehttp://en.wikipedia.org/wiki/Reverberatory_furnacehttp://en.wikipedia.org/wiki/Coke_(fuel)http://en.wikipedia.org/wiki/Cupola_furnacehttp://en.wikipedia.org/wiki/Bronzehttp://en.wikipedia.org/wiki/Brasshttp://en.wikipedia.org/wiki/Crucible
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    Mould making

    Many large foundries operate their own industrial railways

    In the casting process a pattern is made in the shape of the desired part. This pattern ismade out of wax, wood, plastic or metal. Simple designs can be made in a single piece or

    solid pattern. More complex designs are made in two parts, called split patterns. A split

    pattern has a top or upper section, called a cope, and a bottom or lower section called a

    drag. Both solid and split patterns can have cores inserted to complete the final partshape. Where the cope and drag separates is called theparting line.

    Plano Miller / Planner Miller:

    We offer our valuable clients with a gamut of Planner Machine, which are used in various

    industries for the purpose of creating flat and angular surfaces. Our machines features

    high operational efficiency, robust construction and high durability. Further, we welcome

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    customization of our machines as per clients requirements. We offer these machines at

    lucrative prices.

    Two Side Planner Machine

    We are the leading manufacturer and exporter of a highly efficient range of Two Side

    Planner Machine. Our machines have versatile uses in variety of industries. Our machinesare widely appreciated world wide for their high performance, sturdy construction and

    high tensile strength. Further, manufactured using high grade material, our range of Two

    Side Planner Machine is offered in various technical specifications to our clients.

    Moreover, We offer these two side planner machines at very reasonable rates.

    Features:

    The Bed

    Deep box section type

    Tied together at frequent intervals by double walled bridge pieces extending to thebottom of the bed

    The Uprights

    The uprights of planner machine are of rigid box section type

    Keyed firmly, bolted on to the bed and are capable of absorbing the heaviestshocks without vibration

    Extra pins are provided to re-fit the machine accurately after it has been

    dismantled

    The Table

    Box section type is streamlined with hand scraped 'V'

    Can bear heavy load

    Heavily ribbed

    Rack provided in it

    The Bearings

    Main bearings are cast solid with the bed

    Gear teeth hobbing machine cut except two gears which are helical

    Gun metal bearings have been provided for all shafts and loose pulleys. Taper roller bearings can also be provided instead of gun metal bushes

    The Cross Rail

    Box section type with large surface

    Suitable for both hand and mechanical drive

    The Drive

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    The planner machine is arranged for direct individual as well as two belt drive

    Tool Posts

    V-belt and Electric Motor & Starter

    advancedfabrication techniques:

    Fabrication comprises or overlaps with various metalworking specialties:

    Fabrication shops and machine shops have overlapping capabilities, but

    fabrication shops generally concentrate on metal preparation and assembly asdescribed above. By comparison, machine shops also cut metal, but they are more

    concerned with the machining of parts on machine tools. Firms that encompass

    both fab work and machining are also common.

    Blacksmithing has always involved fabrication, although it was not always calledby that name.

    The products produced by welders, which are often referred to as weldments, are

    an example of fabrication.

    Boilermakers originally specialized inboilers, leading to their trade's name, but

    the term as used today has a broader meaning.

    Similarly, millwrights originally specialized in setting up grain mills and sawmills, but today they may be called upon for a broad range of fabrication work.

    Ironworkers, also known as steel erectors, also engage in fabrication. Often the

    fabrications for structural work begin as prefabricated segments in a fab shop,

    then are moved to the site bytruck,rail, orbarge, and finally are installed byerectors.

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    Hoist machine :

    Construction Hoist Machine:

    Model

    Combinations

    Tensile

    Strength

    Cutting

    (No. of

    Bars)

    Bending

    (No. of

    Bars)

    RPM MotorApp.

    Weight

    App.

    Dimension

    1 2 3 1 2 3

    BMS -26/3245

    kg/sq.mm26 20 16 32 25 22 11 3 H.P 400 kg 88x105x90

    85

    kg/sq.mm20 14 11 26 20 16

    BMS-32/3645

    kg/sq.mm

    32 25 20 36 28 24 10 5 H.P 450 kg 90x105x90

    85

    kg/sq.mm25 18 14 28 22 16

    BMS-38/4545

    kg/sq.mm38 25 22 45 30 25 10

    5 H.P/7.5 H.P

    500 kg 90x100x92

    85

    kg/sq.mm32 22 18 36 25 20

    Double Brake systems - including grooved wooden Block and Brake-liners assure youof fool-proof speed control.

    Large dia winding drum not only ensures longer wire rope life, it curtails all

    dangers of snapping or breaking besides reducing strain on the drive (prime

    mover) system.

    The winch drum and friction pully on Taper Roller and Ball Bearing haveadditional gun metal bushes to avoid stoppage or breakdowns for efficient lasting

    operations.

    . An additional ratchet, locks the bucket carrier assembly at any point you want.The complete winch unit is mounted on a sturdy all channel frame.

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    The extremely smooth positive drive system of C.I. Drum coupled with a heavy

    friction pulley ensures low maintenance and safety at all times.

    Quality andinspection:

    Our quality control system, developed over the years, is implemented right from the inspection ofraw material to the final dispatch. Our testing lab is equipped with the necessary measurement

    and testing tools to enable stage-wise product testing while being put through the manufacturingprocess.

    The raw material is fully inspected dimensionally and metallurgically. It first goes through theprocess of crack detection. Before being released for gear cutting, turn blanks are checked indetail to ensure conformity to the drawing requirement. The contact pattern on the Gear andPinion is developed in the soft stage on the gear testing machine to suit the customersrequirement.

    During the heat treatment cycle, every batch is numberedand punched. Hardened components are then checked

    for hardness and micro structure. The metallurgical reportis maintained as per the heat code and test pieces arepreserved for counter checks. They are further checkedfor cracks on non-destructive type crack detectionequipment.

    Running quality i.e. noise, contact pattern and backlash variation of gear sets are determined by running matingGears & Pinions on the Hypoid gear tester. GearConcentricity and tooth spacing is measured on specialdevices. Finally, all the components are inspected toconform to the drawing dimension and released for packing.

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    Chemical Analysis Of raw materials:

    Chemical analysis is conducted for a wide range of purposes from material identification

    and characterization to quality control monitoring. In our extensive and well equipped

    laboratories most of the testing is conducted under our UKAS ISO 17025:2005

    accreditation (UKAS accredited testing laboratory No. 0013).

    Whilst many of our testing protocols are generally run according to standard

    methodologies (ISO, EN, BS, ASTM, DIN, etc), tailored analysis and testing can bedeveloped for specific applications. Some typical analytes are provided for information

    below. Determinations can be performed from 100% to sub ppm levels.

    We have extensive experience of analysing a wide range of materials including ceramics,

    raw materials, mortars, metals, polymers, natural materials, waste streams, gas and air

    monitoring, conformity to legislation, components and consumer products. Data iscollected using a combination of instrumental techniques including X-Ray Fluorescence

    Spectroscopy (XRF) and Inductively Coupled Plasma Spectrometry (ICP) with more

    traditional analytical techniques available.

    Typical applications for these analyses are:

    Quality control testing to ensure materials and products conform to aspecification

    Legislative checks e.g. toxic metals, ROHS, Waste Acceptance Criteria

    Identification re-engineering

    Occupational hygiene toxic metals

    Problem solving - contamination, discolouration, corrosion, investigation into

    abnormal behaviour.

    Typical Analytes

    SiO2, TiO2, Al2O3, Fe2O3, CaO, MgO, K2O, Na2O, P2O5, Cr2O3, Mn3O4, ZrO2, PbO

    Typical Materials

    Ceramics

    Tiles

    Clay sand rocks

    Mortars

    Screeds and plasters

    Electro ceramics

    Rubbers and plastics Investment castings

    Gas

    Electrical components

    Biomedical materials (including calcium phosphates)

    Tableware

    Sanitaryware

    Natural stone

    Concrete

    Building products

    Industrial ceramics

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    Metals

    Leachates and waters

    Soils

    Waste streams for disposal and recycling

    Physical & Thermal Testing

    Tests to determine a wide range of physical properties on raw materials, semi-finished or

    finished products are available. This may range from UKAS ISO 17025:2005 accredited(UKAS accredited testing laboratory No. 0013) to documented methods, national or

    international standards through to industrial or bespoke procedures. Whatever the

    specification, the testing is to the highest standards using transparent, traceable, calibratedapproaches by highly qualified and experienced technical staff.

    Thermal testing can range from measuring expansion at modest temperatures through to

    testing at high temperature to show fitness for purpose in harsh and corrosive

    environments. Bespoke testing regimes can be developed to proof test products in a wide

    range of industrial applications.

    Examples of some of Cerams physical tests and thermal tests are shown below.

    Physical Properties

    Whilst many of the tests conducted are specific to particular materials and applications,

    others are more general in nature. Most of the tests are conducted to specific testingregimes under ISO, EN, BS, ASTM and DIN methodologies.

    Refractories and Raw Materials

    Abrasion resistance

    Carbon monoxide attack

    Crushing strength

    Dimensions

    Fired shrinkage

    Modulus of Rupture Permanent Linear Change

    Plasticity

    Porosity

    Refractoriness

    Sieve grading Thermal shock

    Density

    Change in dimensions

    Creep

    Erosion of fibres

    Flexural strength

    Particle size

    Permeability

    Pore Size Distribution

    Pyrometric Cone Equivalent (PCE)

    Refractoriness-under-load

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    Surface area

    Vitrification.

    Testing of Thermal Properties

    Whilst many of the tests conducted are specific to particular materials and applications,others are more general in nature. Most of the tests are conducted to specific testing

    regimes under ISO, EN, BS, ASTM and DIN methodologies. Some of the available testsare listed below:

    Specific heat

    Specific heat capacity fibres

    Thermal conductivity

    Thermal expansion.

    Ultra sonic Testing:

    Ultrasonic methods of non destructive testing use beams of mechanical waves of short

    wavelength and high frequency, transmitted from a probe and detected by the same orother probes.

    Usually, pulsed beams of ultrasound are used and in the simplest instruments a single

    probe, hand held, is placed on the components surface. An oscilloscope display with a

    time base shows the time it takes for a ultrasonic pulse to travel to a reflector (a flaw, theback surface or other free surface) in terms of distance travelled across the oscilloscope

    screen.

    The height of the reflected pulse is related pulse is related to the flaw size as seen from

    the transmitter probe. The relationship of flaw size, distance and reflectivity arecomplex, and a considerable skill is required to interpret the display.

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    Ultrasonic examination has been utilised as a non-destructive testing method to carry out

    a wide variety of testing tasks enabling the equipment to conduct internal examination

    and make measurements of a component.

    It is also a commonly accepted method of checking the wall thickness of pipelines, tanks,

    silos and vessels, which are suspected of being eroded internally or where access is

    restricted to one side of the material.

    Ultrasonic testing equipment is small, lightweight, portable and presents no safety

    hazards, therefore it is ideal for carrying out examination of raw materials, components,welds etc.., together with corrosion monitoring and thickness measurements on

    components in service.

    Crane Load Testing

    Static Load TestingThis is comprised of a stationary overload load test, which is conducted to verify the structuraland mechanical integrity of the lifting equipment.

    Operational Load TestingThis consists of performing an overload test at 125% of equipment rated capacity, and testing thefollowing functions where applicable: hoisting and lowering of load, hoist brake hold, trolley and

    bridge operations.

    Dimensional Controls:

    Dimensional Controls. The features such as diameter, thickness and pipe length are

    checked and compared against the requisites.

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    Companys contactinformation:

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    CompanyName

    REVA INDUSTRIESLTD.

    Address

    PLOT NO. 28, SECTOR-25,Faridabad - 121004, HaryanaIndia

    Phone

    No 91-129-4069968/4069967/4185400

    Fax 91-129-4069969/4185414

    Contact

    Person

    Mr. Bal Raj Goel (Managing

    Director)

    Mobile

    +919810014144

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