Mechanical - Charu Gupta

8/4/2019 Mechanical - Charu Gupta

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PREFACE

Training in an industry is a dynamic tool to get feeling of practical aspect

of whatever has been learnt by us in the books. It greatly enhances knowledge

with the practical experience. Training in such great and well-managed company

is a great opportunity for the trainer as apart from the basic training. Also we get

a change to be familiar with certain other aspects of industry relations etc.

Our main objective of undergoing industrial training is to acquire

practical knowledge. Training enables us to get a clear-cut view of the subject

that we have read. Both theory and practical are essential. Hence we can say,

“The theory is blind without practical and practical without theory”. In fact, both

are complementary to each other.

As a part of three years of Degree with Industrial Engineering , I have

undergone for two month Industrial Training after the sixth Semester. I am

proud of receiving my Industrial Training in Tool Room at “INDIAN SUGAR &

GENERAL ENGINEERING CORPORATION (ISGEC)” Yamunanagar, Haryana

that is one of the top heaviest engineering industries of the country.

ACKNOWLEDGEMENT

During my training of two months as ISGEC ,whatever I learnt is going

to be of great practical importance in my future. For this I would like to express

my gratitude to Mr.Shiv Charan Sharma(Assistant Superivisor) so that under

his guidance I successfully completed my training.



I would also like to thanks the whole staff of Tool Room who’s friendly

and cooperative behaviour help me lot in learning various techniques and gave

me a never before experience in such reputed firm.

I would like to thanks to Mr. Mohinder Saini who gave me a chance to do

my training at ISGEC and to Mr.Shiv Charan Sharma for guiding me about my

training.

I convey my heartiest thanks to all those officers and employees of

ISGEC who have given me their full co-operation and devoted their valuable

time for rendering me their needy services, guidelines during the course of imparting me practical training and with whose sincere and precious helps, I

have been able to complete my practical training successfully.

ISGEC PROFILE

THE COMPANY

1. ISGEC the heavy engineering unit of Saraswati industrial ltd. was

established in 1946 and is located at yamunangar, Haryana about 200kms

from New Delhi.

2. The annual turnover of ISGEC is US $ 50 million and group turnover of the

Saraswati Industial Syndicate ltd.



APPROVALS

• ISGEC has been approved by Lloyds Register

Asia (LRA) of quality assurance as an ISO-9001: 2000 company.• The American Society of Mechanical Engineers

(ASME) approves ISGEC for the use of ASME ‘U’, ‘U2’, R & S code

stamps.

• Lloyds Register Asia as class-I Manufacturing of

Fusion welded pressure vessels approves ISGEC up to 200 mm

thickness.• Engineers India Ltd. (EIL) approves ISGEC for Manufacture of

vessels and columns in carbon and alloy steels up to 155mm thickness

and in clad steel up to 130mm thickness.

• Engineers India Ltd. approves ISGEC for

Manufacture of Heat Exchangers up to maximum tube sheet thickness of

300mm.

• China Safety Quality License

INFRASTUCTURE

1. ISGEC has a sprawling works covering an area of about 25 hectares

including covered production area of around 35,000 square meters.



2. It has the capacity to handle jobs weighing upto 100 tonnes (single

piece).

3. Extensive facilities for hot & cold rolling, machining, welding, heat

treatment and stringent quality controls to ensure strict compliance to

international standards.

4. More than 125 sophisticated machines and machine tools are installed in

various production bays. Apart from these, more than 100 welding

machines ( for various processes including SMAW, SAW, MIG, TIG

and flash butt welding and under operation).

5. ISGEC has own captive power generation of 3650 Kv through DG sets.

CORPORATE PROFILE

The Saraswati Industrial Syndicate Limited grew from the sugar mill

and the general Engineering group. The engineering group was launched in 1946with the establishment of the Indian Sugar And General Engineering

Corporation now it is famous as ISGEC. Today, ISGEC is ISO 9001:2000.

Company concentrates its production activities at Yamunanagar, Haryana about

200 km. North of Delhi, manufactures a variety of heavy Engineering

equipments such as Chlorine Containers, Boilers, Sugar Machineries, Cement

Machinery, Pressure Vessels, Mechanical and Hydraulic Presses, Plate Bending

Rolls and Iron Castings.



This flagship unit of group also maintains the process division at New

Delhi; responsible for the design, sales, contracting, and erection and

commissioning of turn key plants besides equipment for sugar and cement

industries.

In 1960 ISGEC collaborated with John Thompson, UK (now known as

NEI International Combustion Limited, UK). Located at New Delhi, ISGEC

John Thompson (IJT) designs, sales, erect a range of boilers and associated

equipments.

UP Steels was acquired in 1981 and latter merged with the parent

company. Established as a foundry in 1966 with the technical know how from

Japans Kobe steels, UP Steels, an ISO 9002 company at Muzaffar Nagar, UP

about 100 km. North of Delhi, manufactures sophisticated alloy steels and steel

casting, both hand and machine molded – as well as alloy iron castings steel

ingots.

Saraswati Sugar Mill (SSM) located at Yamuna Nagar, Haryana is

having crushing capacity of 9600 tones per day and has recorded best overall

recovering in India.

ISGEC COLLABORATIONS

Working continuously towards further excellence in technology, ISGEC entered

into technical collaborations with international well known companies.

To mention a few:-



1955 A.F. Cariag & Co. U.K. Sugar Machinery

1960 John Thompson, U.K. Industrial Boilers

1963 Kawasaki, Japan Cement Machinery

1964 Farrels, U.S.A. Sugar Mills

1966 John Shaw & Sons Hydraulic Presses

1968 Bronx, U.K. Plate Bending &

Leveling machine.

1979 NEI International Pulverized Fuel

Combustion, U.K. Boilers.

1980 Rovetta, Italy Mechanical Press.

PRODUCT RANGE

Diversity of ISGEC products range enables us to serve industry from

Automobile and ship building to oil & natural gas, defense, aeronautics and

nuclear power.

The group’s product range includes for:-

1. Hydraulic Presses, Mechanical Presses & Press brake. ISGEC has

successfully commissioned around 100 presses built include a 3700 tonnes

hydraulic presses for defense and a 2500 tonnes mechanical press.

2. Process plant equipments (pressure vessels, heat exchangers, columns,

storage and transport vessels, reactors etc.) from fertilizer refinery,

petrochemical and other industries.



3. Industrial & power boilers (including pulverized fuel boilers upto 60

MW size bubbling as well as circulating fluidized bed boilers up 200

TPH size).

4. Custom made equipments for India’s nuclear establishments. ISGEC has

supplied equipment during last 15 years to Bhabha Atomic Research

Center, Nuclear power corporation, center of advanced technology.

5. Chlorine, Ammonia and other gases containers. ISGEC are the largest

manufactures of chlorine in the world.

DIVISION OF ISGEC

ISGEC has been divided into three divisions as follows:-

1. PRESSURE VESSEL DIVISION (PVD)

Pressure vessel division is the oldest of ISGEC and it manufactures pressure

vessels such as boilers, heat exchangers etc. It is sub-divided into following

shops:-

a) PVD-I

b) PVD-II



c) PVD-III

d) PVD-IV

2. MACHINE BUILDING DIVISION (MBD)

Machine building division is very important division of ISGEC and it

manufactures sugar mill machinery. Press components and other Steel plant

machinery. It is sub-divided into following shops:-

a) FABRICATION SHOP-I,II

b) MACHINE SHOP-I,II

c) ASSEMBLY SHOP

d) QUALITY SHOP

3. FOUNDRY GROUP (FG)

Foundry group is the third important group of ISGEC and it is

responsible for casting of large castings for the big industries.

4.TUBE SHOP

Tube shop deals with tube manipulation and fabrication of tubing system

used in economizers and super-heaters.

5.CONTAINER SHOP

Container shop manufactures chlorine, ammonia and other gases

containers.



FABRICATION SHOP

Fabrication shop is one of the constituents of the machine-building department.

Almost all sort of fabrication work are done here. In this shop thick sheets of

mild steel are cut, welded and bent according to the required design. For the

cutting of plates and sheets CNC gas cutting techniques are made use of. Then

different cut parts are joined together with the help of welding.

Some of the welding techniques adopted in ISGEC are:-

• Gas Metal Arc Welding (GMAW)



• Submerged Arc Welding (SAW)

• Shielded Metal Arc Welding(SMAW)

• Semi Saw

• Plasma Arc Welding

Brief description of these welding techniques is given in the following pages.

The bending of sheets is preferred in hydraulic presses. For bending, a specific

type and size of the die is kept under the plate to be bent and then hydraulic

pressure is applied above the plate. Extent of bending depends upon the radiusof curvature of arc formed by bend plate. Gauging is used for cutting sheets.

WELDING TECHNIQUES

1. Shielding Metal Arc Welding (SMAW)

Principle:-

It is arc welding process in which coalescence if the metal is produced by

heat from an electric arc. That is maintained between tip of a covered electrode

and surface of base metal in joint being welded. The principal function of

covering on electrode is to provide arc stability and to shield molten metal from

oxidation with gases created as coating down from heat of the arc. For

generating arc there should be some difference between electrode and work-

piece. For better results length of the arc should be as small as possible.



Advantage:-

Auxiliary gas shielding or granular flux is not required any more.

Limitation:-

Due to high temperature are characteristics may change.

2. Submerged Arc Welding(SAW)

It produces the coalescence of metal by hating them with arc between

base metal electrode and work-piece. The arc and molten metal are

submerged in a blanket of granular fusible flux. The main role of the flux is

to control the chemical and mechanical properties of final weld. In the

welding end of a continuous bare wire electrode is inserted into the mould of

flux that covers area to be welded. An arc is initiated using one of the arc

initiation methods. A “wire feeding mechanism” begins to feed electrodewire. Additional flux is fed along with electrode. Heat evolved by electric

arc melts some of flux creating a pool of molten metal beneath layer of

molten slag. The flux blanket on the top surface of weld pool prevents the

atmospheric gases to mix.

Factors that usually effect SAW:-

• Chemical composition and final deposits of weld.

• Type of metal to be welded.

• Position in which weld is to be made.

• Volume of welding to be performed.



3. Gas Tungsten Arc Welding (GTAW)

It is technique that uses an arc between a tungsten electrode and weld

pool. The process is adopted with/without shielding gas. Shielding gas is fed

through torch to protect electrode, molten weld metal and shielding weld metal

from oxidation. The arc is produced by the passage of current through

conducting gas. The arc is established between the tip of electrode and work.

Heat generated by arc melts the joining surfaces. Filler wire is added to leading

edge to fill the joint.

4. Co2 Gas Welding/Metal Active Gas Welding (MGAW)

MGAW is so called because Co2 is an active gas. MS wire electrode is

fed automatically in the welding torch and Co2 gas is allowed to pass through

the torch pipes. It acts as a shielding gas because it protects the weld pool from

oxidation by atmospheric gases. If instead of Co2 we use helium/argon welding

technique is called MIG.

5. Plasma Arc Welding (PAW)

It is an arc welding process that produces coalescence of metals by

heating with a constricted arc between electrodes and constricted nozzle. It uses

a non consumable electrode. PAW torch has a nozzle that creates a gas in the

chamber surrounding the electrode. The arc heats the gas fed into chamber to a

particular temperature. It becomes ionized and conducts electricity. The ionized



gas is called ‘plasma’. It raises the gas temperature up to 30,000 degree F. It is

very expensive technique.

Principle:-

The gas is directed through the torch to surround the electrode. It bears

ionized un arc to form plasma. For most operations auxiliary shielding gas is

used. The arc construction nozzle is specified by nozzle diameter and throat

length.

Disadvantage:-

Major disadvantage of PAW is the relatively high expenses of equipment. Also

there are more control variables, more complex and expensive operator training.

ASSEMBLY SHOP

Study of liftable ladel turret assembly ;

A ladle rotating turret arrangement to be used in a continuous casting

plant. The central column can also be designed as a bushing and can serve for

accommodating a liftable and lowerable ladle support. A ladle turret has two

liftale forks, usually 180° apart. It has capacity of 300ton.

It is used in steel plant industry where molten material at high

temperature has to transfer from one place to other, where final shape has to be

given to the molten material. Firstly, this molten material is collected in

container and placed over the one end of the cradle for its movement.

Main parts of this assembly ;



Ladle turret rotation unit

Portal

Basement

Central body

Arms

Lever

Cradle

Hydrulaic cylinders

Bearings

Manuplating isulators

Manifold

Motor

Construction

In this assembly the main part is the basement. In the basement so

much type of piping is done. However, this piping is done to provide the

required force at different positions in the assembly. As in central part

hyduralic cylinders are provided, so for their movement required force

comes from piping of basement.



On the basement ladle turret unit is placed. There are no of bearings

system is also attached in between the central part and the basement.

Motor is also provided to give the motion to rotary unit (pinon). Bearing

gives the relative motion to central body.

In central body there is attachement of hydrulaic cylinders,which

gives the motion to cradle. There are two arms provided on the either side

of portal. On these arms cradles are attached. The motion of cradle is

controlled by the cylinders via levers. Portal is the vertical part, where all

these parts are assembled.

Surfaces of the cradles are tapered. It is because the containers

which has molten material in it has to place on this tapered part. In the

cradle pins and load cells are attached, which acts as shock absorber

during the movement of cradle. Around the load cells manifold pipe is

provided.

It is because when there is dissipation of heat during movement of

cradle, this pipe give cool air there.There are no. of holes on the manifold

for removal of cool air. Isulating plate is attached on the outer part of

cradle to maintain the temperature inside the assembly.

WORKING



As the simple working definition of this assembly is that the

transfer of molten material from one place to other where final shape has

to given to this molten material.

But each part in this assembly has its own and important role for carrying

out this process and the important parts are basement, central body,

arms and cradle;

• BASEMENT

It is the main part of the assembly. In this hydraulic and

pneumatic piping is done as per the require force in different

sections of the assembly. It is made up of such strong material so

that it can bear the whole load of the upper part and can absorb the

any type of shock observed during movement.

• CENTRAL BODY

In this part hydraulic cylinders are attached. The main

function of these cylinders is to control the motion of the cradles

via levers. To move these cylinders, we also require some force

which comes from the basement piping. The motion of the

cylinders with respect to cradle is opposite or relative i.e. when

cylinders move upward cradle moves downward and vice versa.

This central body also rotates relative to the basement due to

motion of rotary unit. Relative motion to the central body is



provided by bearing and motor attached in between the central

body and basement.

• ARMS

On the either side of portal arms are attached to give support

to the cradles. Cradles are attached to the bushes of arms, which

are self lubricating. It is because when cradle move up and down or

rotates then friction and wear tear losses will be there. So to

remove these effects lubrication is provided to bushes.

• CRADLE

This part of assembly attached to the arms. It has tapered

surface on which molten material carrier is placed. Its motion is

controlled by hydraulic cylinders. Levers of this cradle give it

require motion for movement. Pins are attached in this cradle

which acts as shock absorber. Load cells are also attached in this

cradle for the same function. However, these load cells have

springs to resist.

During the motion of cradle heat is generated, which is

controlled by manifold piping. It has so many holes for the exit of

cool air and is attached around the load cells in the cradle. This

cool air balances the temperature inside the cradle assembly.



Xeramic fiber insulator plate is attached on the outer

surface of the cradle. Once all the inner parts of cradle are well

assembled, then this plate is attached. This is placed like

plate/insulator/plate. As explained earlier function of inner plate to

control the inner temprature and function of outer plate is to resist

the outer temperature to come in contact with inside.

♦ This process of transfer is so rapid. It is because when one partof cradle takes the molten material, it moves to other position

and 2nd part of cradle comes nearer to the furnace of molten

material to move it away.

Now if this process of take and transfer is slow, then the

molten material will cool down. That’s why this process is so

rapid to keep the material hot. Because of this rapid process

there is attachment of load cells to absorb the shocks. Because

of this process every component plays an important role on

their specified positions. For e.g.

• Insulating plate

• Hydraulic cylinders

• Pins

• Bearings

• Motor

• Rotary unit



SOME OTHER COMPONENTS USED IN THIS ASSEBLY

• Washer

• Hex bolt phosphatized L40

• External serrated washer

• Pin

• Hex bolt L60

• Hex bolt L20

• Cover

• Plate

• SML pipe

• “U” bolt complete with nuts/washers

• MF UNION taper seat ZIN COAT

• Chain

• Door

• Mounting

• Latch housing

• Cam

• Bed plate



• Weld on number

• MAT.PER RETI DI TERRA #.45MT

• HEX SOCKET HEADCAP SCREW

• Slotted counters

So, these are also some helpful components used in this assembly to

support the large parts.

PLANNING AND SELECTION OF ASSEBLY

Now in any organisation basically there are three levels of management

Top level

Middle level

Bottom level

So in the top level of management managers and higher authorities set up

a project in an organisation. After discussion there is selection of best

method for achievement of the goal.

So it is set up for the next level of the organisation.



Now in the next level, executive engineers and other staff members

read this method properly and after removing any difficulties, it is

implemented.

So workers of organisation work as per scheduling and requirement of

the project. For this so many supervisors are provided to workers to ask

any difficult during working or carrying out the project.

Now selection of any assembly is done by BOM (bill of

material). In BOM specification of every part is given. With this

diagram of each component is also sent by that industry which

gives the order of assemblies to such companies.

By the study of BOM, it become easy to make decisions that

which kind of assembly shop is available or kind of assembly can

be done and what parts has to be purchased for the require

product.

After proper studying of BOM decisions are made for the

required assembly.

A layout of assembly;



Fabrication

Machining

Assembly

Quality

Dispatch

Firstly some parts which required welding etc send to

fabrication shop as per requirement. Then machining is done of some

parts to remove the sharp edges. After that finally machined parts

assembled to required positions. Quality is checked by the comparing

the final product with standard and then dispatched to the industry.

During assembly of pins in the cradle, chemphering is done. It can

be done by two ways by filler and grinder. By grinder it can be donefaster than the filler. It is done to make the radius of pin equal to that part

where it is going to attach. Because if there is any tolerance left, it may

make the assembly loose. That’s why proper oiling is done of the pins

and bolts are clamped tightly. It is done by so many workers so work rate

of each worker is checked out. Incentives are given as per there working

hours. By this time study we can also calculate the time taken by each

assembly and no of workers also.

•CONCLUSION



Hence it is a modern approach to carry out a process in short time to

keeping the material nearly at the same temperature at which we are

taking from the furnace. It is very rapid process by the help of which

productivity can be increased and also the efficiency of product.

MACHINE SHOP

Machine shop is the main work station of the organization. Here various

machining operations are carried out to produce different parts of hydraulic andmechanical presses.

There are two division of machine shop

a) Machine shop-I :- Heavy Work Division

b) Machine shop-II:- Light Word Division

Various Machine Employed at Machine Shop-I

1. SACEM CNC Horizontal Boring Machine. HB-9

2. WELDRICH COBURG plano-miller P-4

3. SWIFT LATHE L-14

4.H.M.T Radial Drilling Machine RD-4

5. SKODA Horizontal Boring Machine HB-1



6. HAURISTI Horizontal boring machine HB-8

7. WMW UNION Horizontal boring machine HB-5

8. SKODA Horizontal boring machine HB-3

PROCEDURE OF WORK:-

Every department or every work station works under planning department

of ISGEC. So the Machine-I planning Department prepare the design of the

press and any other job, to be manufactured. It prepares the drawing and route

card, which are directly obtained through the computers installed at shop floor

directly linked with the planning department. Route card is document at which

the whole process to be carried out and is printed in sequence i.e. operations to

be performed on the machine tool and after completion of work on job on one

machine then at which machine tool to be transferred and sequence of job on

one machine to be performed on that machine tool and operation observed.

FOUNDRY SHOP

Foundry shop is the main work station of the organization. Here various types

of difficult castings are to be cast, as required by the client. There is only one

division of casting in the ISGEC, rest of the work of casting is done at the U.P.

Steel plant of ISGEC group.

Pattern:- Pattern is the same or the original shape of the substance which we

have to cast.



Mould:- Whereas mould is the replica of the pattern which is used for giving

the proper shape to the casting as required and these moulds are made from the

sand.

Types of Sand used:-

There are two types of sand used in ISGEC for casting.

1. Cement Sand

2. Phenolic Sand

1. Cement Sand:- Cement sand contains two or three things i.e river Sand,

cement and molasses. These three things are mixed in fixed proportion

so that sand does not loose its adhesive nature. In Cement Sand there is

85% to 90% is river sand, 8% molasses and 4% cement. In this mixture

molasses act as binder, which binds the sand properly and its adhesive

nature. Cement sand is used only for filling the vacant area around the

mould. After the proper ramming of the cement, sand baked so that it

does not fatal by gaining moisture.

2. Phenolic Sand:- Phenolic sand is also the mixture of three things i.e

silica sand, resin and catalyst. The composition of Phenolic Sand is 90%

to 93% Silica Sand and 2% to 3% Catalyst. Here resin acts as chemical

which increases the properties of the sand and catalyst is used as binder

or hardener which helps in setting the sand. Silica sand is coarse sand, so

there is no need of baking it. After mixing all the things for making the

mixture of Phenolic sand, it is taken to the patterns where it is properly

rammed. After that it would be left for some time so that it becomes as

hard as stone.



Types of Materials Used for Making Patterns

1. Mostly the patterns used in ISGEC are made from thermocol sheets.

These thermocol sheets are cut in the shapes as per drawing given to

pattern making man. Pattern making man cut the big blocks of

thermocol in the pieces as per dimensions given in the drawing with the

help of cutters and element wire ( Element wire is that wire which is

used in heaters. This wire becomes hot and cuts the thermocol sheets

very smoothly without damaging the material).

2. Wooden patterns are also used for making the moulds .Wooden patterns

are used when more finishing is required.

3. Metal patterns are also used in castings. These patterns are used only for

taking the prints on the mould.

Direction for Moulding Work

⇒ On getting the patterns and moulding, understand the shape of

casting clearly.

⇒ Discuss the position of risers and setting clearly with the

supervisor.

⇒ Check the mixture poured from the mill.

⇒ Never use the set moulding and coarse sand.

⇒ Ram the sand in the moulds very well.

⇒ Always repair the moulds with the same sand, fix the repairing

portion with nails.

⇒ It is necessary to paint mould. Never use thinner for oily sand and

never use water paint for silicate sand.



⇒ Dry the core or mould of oil paint in the core oven or with the help

of burner.

⇒ Decide the thickness of mould and core assembly according to the

drawing.

⇒ Before closing the moulds provide passage for the release of the

gases.

⇒ Release the gases of core and moulds separately.

⇒ Clean the mould with air and brush before closing it.

⇒ Use thin sealing between mould boxes or between the cores before

closing it.

⇒ Place weight on the moulding boxes or tight them with the help of

bolts.

Procedure for Making a Mould

∗ Check clearly that the pattern is not wet from anywhere and it is not

damaged from anywhere.

∗ Always place the pattern on the plain surface.

∗ The handles used on the patterns should not be loose and always be

straight.

∗ Ramming in the pockets and contours should be properly done.

∗ After facing sand provide proper vents in the cement sand.

∗ Always check there is no alignment in the mould and the ramming of

upper box should be properly done.

∗ The height of the upper box should not less than 10” or it should be

according to pouring basin.



STUDY OF TIME CONSUMPTION

Types of time consumption:-

1. Manual Time

2. Machining Time

1. Manual Time:- Manual time is the time which is consumed during the

manual activity. Manual time is classified as:-

•Loading and Unloading

• Preparation Time study

• Setting Time Study

a. Loading and Unloading

This is the time which gets consumed during the loading and unloading

of the job from the machine. This involves operator involvement but it is

beyond limits to get it under control unless and until whose system is

computerized.

b. Preparation Time Study

Preparation time study is the study of all activities, which starts just after

unloading the finished job and halts before setting of the job in parallel and

perpendicular with the machine. Activities include in PTS are:-

1. Loading of the job

2. Clamping of the job



3. Search for the clamps

4. Instructions from supervisor

5. Getting route card

6. Setting tool on machine

7. Getting tool from tool room

c. Setting Time Study

Setting time study is carried out to record the time consumed during setting

of the job in parallel and perpendicular with bed and tool of the machine,

concentric with the chuck of the lathe and checking for circular run out on

lathe. As the machining operation involve lease operator interventions and it

has to work with the pace fed/set by the operator so to snatch time from this

part is difficult rather impossible. Now we are left only manual activities.

Mechanical - Charu Gupta

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Transcript of Mechanical - Charu Gupta