PROJECT REPORT ON

SUBMITTED BY:
PRIYESH BHADANI

MECHANICAL ENGINEERING BIRLA INSTITUTE OF TECHNOLOGY

ACKNOWLEDGEMENTS
I owe a great many thanks to a great many people who helped and supported me during this project. My heartiest thanks to Mr.MurariVishwakarma, Hindi Officer, RajbhashaVibhag& Vocational Training Section/Hqrs. and Mr.AnugrahJha, SDGM Human Resource for providing me an opportunity to make this project, and for their sincere support. My deep sense of gratitude to SDGMs of all concerned shops, for lending their immense support and guidance. Heartiest thanks to all the officers involved in the training process, who sliced out their valuable time to help me during the training schedule. A respected thanks to all the operators whose endless toil on machines forms the backbone for running this organization, without them this project would not have been fulfilled. I would also thank my Institution and my faculty members without whom this project would have been a distant reality. I also extend my heartfelt thanks to my family and well wishers.

CERTIFICATE
This is to certify that Mr.PriyeshBhadani, from the university BIRLA INSTITUTE OF TECHNOLOGY, MESRA of Mechanical branch has completed the vocational training in our organization from________ to ______. He has also submitted a project report on the aforesaid topic.
During the training he showed a very positive attitude and we wish him best for his future.

____________________ M. Vishwakarma Hindi Officer RajbhashaVibhag and Vocational Training Section/Hqrs.

CONTENTS
1. Introduction 2. Heavy Machine Building Plant y y y y Shop 010 Shop 020 Shop 030 Maintenance

3. Project Division 4. Foundry and Forge Plant y y y y y Shop 04 Shop 03 Shop 02 Shop 08 Gas plant

5. Heavy Machine Tool Plant y y Shop 13 Shop 17

INTRODUCTION

Heavy Engineering Corporation or "HEC" is a Public Sector Undertaking ("PSU") in India. It is one of India's oldest and largest engineering companies. It is the biggest industry of its kind in Asia. HEC is under the Ministry of Heavy Industries, Govt. of India. Established in the year 1958 as the largest integrated engineering industrial complex in India with excellent design, engineering, and manufacturing base. The company is engaged in the manufacture and supply of capital equipments, machine tools and spares needed for the core sector industries.

HEC was established in the year 1958 as one of the largest Integrated Engineering Complex in India. It manufactures and supplies capital equipments& machineries and renders project execution required for core sector industries. It has complete manufacturing set up starting from casting & forging, fabrication, machining, assembly and testing - all at one location backed by a strong design - engineering and technology team.

UNITS:

Heavy Machine Building Plant (HMBP) :

The Plant has a fenced area of 5,70,000sq.m and a floor area of nearly 2,00,000 sq.m. It is well equipped with sophisticated machine tools and handling equipments to undertake manufacture of heavy machinery and equipment of top quality. It is engaged in design and manufacture of equipments and components for Steel Plant, Mining, Mineral Processing, Crushers, Material Handling, Cranes, Power, Cement, Aluminium, Space Research, Nuclear Power etc.. It is the largest foundry and forging complex in India and one of the largest of its kind in the world. The area of the Plant is 13,16,930sq.m accommodating 76,000 tonnes of installed machinery to cope up with the various operations effectively. This Plant is the manufacturer of heavy castings and forgings for various HEC make equipments and related to Steel plant, Defence, Power, Nuclear energy etc.. Manufacturer of Forged Rolls for Steel Plants, Crank Shafts for Railway Loco etc. Set up in collaboration with M/s Skodaexport Czechoslovakia, HMTP is the most modern and sophisticated of its kind in the country which

Foundry Forge Plant (FFP):

HEAVY MACHINE TOOLS PLANT (HMTP):

produces machine tools in heavier ranges. The Plant covers an area of over 2,13,500sq.m. It designs and manufactures medium & heavy duty CNC and conventional Machine Tools for Railways, Defense, Ordnance factories, HAL, Space and other strategic sectors. Projects Division Design, Engineering and execution of Turnkey Projects related to Bulk Material handling, Steel Plant projects, Cement Plant and other sectors.

Major Achievements
y y y y y y y y y

Over 550 thousand tons of equipment manufactured and supplied to Steel Sector. Significant contribution in setting up of Bokaro and Vizag. Steel plant. Equipment supplied for expansion of Bhilai Steel Plant. Supplied to almost all the Steel plants of India. Supplied over 580 Excavators (of 4.6 /5 /10 CuM capacity) Supplied 12 numbers of 24 CuM Draglines. Supplied over 10 numbers of Heavy Duty Gyratory 1500 TPH crushers. Manufactured over 300 numbers of Cranes. Supplied over 900 Machine Tools.

Cyclotron Magnet Poles

HEC successfully manufactured Magnet Poles and associated components for VECC (Department of Atomic Energy) and supplied in the year 2002.
y y y y

Exceptionally low carbon steel. Variation in carbon content within 0.07% and other elements within 0.10%. Ultra clean steel, free from alloying & tramp elements and gaseous contents. Very high homogeneity level. Control of grain size and micro structure to ensure best magnetic permeability.

y y

Free from non-metallic inclusions and other ultrasonic defects. Precision machining of complex geometry shapes.

Shop 010
Specifications:Area of the workshop- 21,012 sq. M Storage area(open)- 6180 sq. M Total ntotal number of machines- 74 Special machines-27 VTB maximum capacity- 14 m (diameter) 4.7m (height) 250 T (weight) 6. Horizontal Boring Machine maximum capacity Spindle- 320mm Job- 5m X 9m X 18 m 7. Plano Milling Machine maximum capacity Length -7m Breadth -3.5 m Height- 2.7 m Weight- 120 T 8. Specifications of crane y Machine workshop Number of cranes-10 Capacity 150 T y Assembly workshop Number of cranes 5 Capacity 150 T 9. Assembly area 7060 sq. M 10. CNC machining 3 VBT 1 1. 2. 3. 4. 5.

Plano Milling 1 Horizontal boring 1

SHOP 020
(MEDIUM AND SMALL SCALE MACHINING WORKSHOP)

VERTICAL TURNING AND BORING MACHINE

Table size: 4000 mm Spindle size: 1500 mm Maximum height of job: 190 mm Capacity: 35 T Maximum speed: 7.8 rpm Feed rate: 0.42 mm/sec

W200 HORIZONTAL BORING CNC MACHINE

1. 2. 3. 4. 5. 6. 7. 8.

Boring spindle diameter: 200 mm RAM dimension: 520X520 mm Taper in spindle: 60 ISO Spindle travel: 1962 mm Ram travel: 1600mm Headstock travel in column y axis: 5000 mm Column travel on bed x axis: 18000 mm Working feed: 1-6000 mm/min

030 SPECIFICATIONS OF THE SHOP:

1. Building area: 87.6 sq. M 2. Open gantry area: 2880 sq. M 3. Number of machine tools: 66

4. Number of unique machine tools: 15 5. Maximum plano milling capacity: 85 X 2.5 X 2.5 6. Maximum gear Hobbing capacity: Diameter: 5800 mm Module: 30 7. Maximum rack cutting capacity: 2500 X 350 mm 8. Induction hardening facilities: Length: 5000 mm Diameter: 4000 mm 9. Stress relieving tempering furnace cap: 7.5 X 2.4 X 4.5 10. Overhead material handling capacity: Number of cranes: 8 Maximum capacity: 50 T 11. Assembly shop area: 2900 sq. M Number of cranes: 2 Maximum capacity: 75 T

OUTPUT:
Gear boxes for cranes, excavators, draglines etc.

PROJECT DIVISION
The project division of HEC mainly handles projects which are related to material handling.

The process of tendering to execution takes place as per the following procedure: 1. 2. 3. 4. 5. 6. Tender notification Discussions Submission of query Price opening(L1) Order Execution - Inquiry - Purchase - Scrutiny - Drawing - Monitoring

SHOP 04 (MACHINE SHOP)

Some machines that were studued: Lathe machine: Machine number: 1004 Type: SR 1000 X 5000 Distance between centres: 5000 mm Swing over bed: 1000 mm

Swing over carriage: 710 mm Maximum weight of job: 10 MT

Low frequency Induction Hardening Machine: Machine number: 4026 Barrel diameter: 300-650 mm Job weight: 15 T (max) Power output: 1000 KW (max)

FOUNDRY TECHNOLOGY (SHOP 02)

A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron. However, other metals, such as bronze, steel, magnesium, copper, tin, and zinc, are also used to produce castings in foundries. Melting: 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 are either 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 the gates, 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 the melting 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.

MOULD MAKING:
In the casting process a pattern is made in the shape of the desired part. This pattern is made 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 part shape. Where the cope and drag separates is called the parting line. When making a pattern it is best to taper the edges so that the pattern can be removed without breaking the mold. This is called draft. The opposite of draft is an undercut where there is part

of the pattern under the sand making it impossible to remove the pattern without damaging the mould. The molds are constructed by several different processes dependent upon the type of foundry, metal to be poured, quantity of parts to be produced, size of the casting and complexity of the casting. These mold processes include:
    

Sand casting

Green or resin bonded sand mold. Polystyrene pattern with a mixture of ceramic and sand mold. Wax or similar sacrificial pattern with a ceramic mold. Plaster mold.

Lost-foam casting Investment casting

Ceramic mold casting

V-process casting Vacuum is used in conjunction with thermoformed plastic to form sand molds. No moisture, clay or resin is needed for sand to retain shape. Die casting Metalmold. Simple mold for producing ingots of metal normally for use in other Billet (ingot) casting foundries.

 

Pouring In a foundry, molten metal is poured into molds. Pouring can be accomplished with gravity, or it may be assisted with a vacuum or pressurized gas. Many modern foundries use robots or automatic pouring machines for pouring molten metal. Traditionally, molds were poured by hand using ladles. Shakeout The solidified metal component is then removed from its mold. Where the mold is sand based, this can be done by shaking or tumbling. This frees the casting from the sand, which is still attached to the metal runners and gates - which are the channels through which the molten metal traveled to reach the component itself. Degating Degating is the removal of the heads, runners, gates, and risers from the casting. Runners, gates, and risers may be removed using cutting torches,bandsaws or ceramic cutoff blades. For some metal types, and with some gating system designs, the sprue, runners and gates can be removed by breaking them away from the casting with a hammer or specially designed

knockout machinery. Risers must usually be removed using a cutting method (see above) but some newer methods of riser removal use knockoff machinery with special designs incorporated into the riser neck geometry that allow the riser to break off at the right place.

Lathe
CNC Centre Lathe specification Swing over Carriage 650 1000 mm Distance between centres 3 6 metre Max. wt of work piece 8 15 MT CNC System - Fanuc / Siemens (2 axes) Centralised lubrication 8 station programmable turret 2 Stage high efficiency transmission head stock Spring clamped - Hydraulic unclamped tail stock

CNC Roll Turning Lathe specification Swing over Carriage 650 1600 mm Distance between centres 3 10 metre Max. wt of work piece 8 50 MT CNC System - Fanuc / Siemens (2 axes)

Special Purpose Railway Macine Tools

CNC Under Floor Wheel Lathe Gauge 1676 mm Max./Min. tread dia 1250 / 700 mm Uncoupled axle distance 1600 mm Coupled axle distance 1500 2650 mm Max. Axle load 25 MT Max. Axle load 1889 2750 mm

CNC Surface Wheel Lathe Gauge 1676 mm Max./Min. tread dia 1250 / 700 mm

Max. axle distance 2750 mm Min. axle distance 1850 mm Max. weight of wheel set 3.5