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CERTIFICATE
INTERNAL GUIDE:
Mr. kodanda Rama Rao,
Asst professor,
Dept. of mechanical engineering,
Gudlavalleru engineering college.
EXTERNAL GUIDE:
Mr.T.V.Rama Gopal
DCM (sinter plant)
RINL-VSP
2
By
1. Sk Rahaman Basha
2. K Stephen small
3. K. Pavan Kumar
4. Sampath Anne.
OBJECTIVES:
PERIOD OF STUDY:
THE PROJECT WORK HAS BEEN CARRIED OUT FROM
2-12-2007 TO 22-12-2007.
CERTIFICATE
Mr.A.Sampath
Mr.k.Stephen Small
Mr.k.Pavan Kumar
Has satisfactorily
completed the project work entitled “LIFE IMPROVEMENT OF DOLOMITE
CRUSHNING HAMMERS” in partial fulfillment of the requirement for the degree of
Bachelor of technical in mechanical engineering during the academic year 2007-2008.
ABSTRACT:
Introduction:
Visakhapatnam Steel Plant, the first coastal based steel plant of India is
located, 16km south west of Visakhapatnam. Bestowed with modern technologies,
VSP has an installed capacity of 3 Million tones per annum if liquid steel and 2.656
Million tones of saleable steel. VSP Products meet exalting International Quality
Standards such as JIS, DIN, BIS, BS etc...
VSP has the distinction to be the first integrated steel plant in India to become
an ISO-9001, EMS-14001&OHSAS-18001 certified company. These certificates
cover quality systems of all operational, maintainance, services units besides purchase
system, environmental management systems and occupational healthy safety
measures.
VSP by successfully installing and operating efficiently Rs 460 crores worth
of pollution control systems and converting the barren landscapes by planting more
than 3Million plants has made the steel plant, steel township and surrounding areas
into a heaven of lush greenery.
Having a total manpower of about 17250 VSP has envisaged a labor
productivity of not less than 270 tones per man-year of liquid steel, which is the best
in the country when compared with international levels.
VSP exports quality pig iron and steel products to srilanka, Myanmar, Nepal,
Middle East, USA& South East Asia(pig iron).RINL-VSP was awarded “Star Trading
House” status during 1997-2000. It is also awarded with “Energy Conservation
Award” at national level successively for three consecutive year’s viz., 2002, 2003,
and 2004.
7
MAJOR FACILITIES:
PLANT LAYOUT:
BLAST FURNACE
STEEL MELTING
SHOP
CONTINUOUS
CASTING SHOP
P
LMMM
R
O
D MILLS
MMSM
U
C
T WRM
Sinter Plant:
WHAT IS SINTER?
RMHP
BLAST
FURNACE RMB
BELT
CONVERYS SINTER MACHINE
STRAIGHT LINE
COOLER CRUSHERS
10
Armour plates
Grate bars
Impact plates
Bore beams
Rotor
Hammers etc. are the some of the main components of crushing
equipment.
Among the above mentioned, Bull head hammers are the critical components which
are subjected to high impact loads and are prone to greater wear. So these hammers
play a key role in assessing the performance of crushing plant.
12
HAMMER CRUSHER
HAMMERS
COUPLING
BEARING
BEARING
X X X X X X X X X
X X X X X X X X X
X X X X X X X X X
X X X X X X X X X
X X X X X X X X X
X Hammer
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NECK
AREA
120 mm
100 mm 100 mm
Dolomite and Limestone. These hammers are made in Forge shop and Central
machine shop. In Forge shop, raw materials is forged to the required shape, stress
relieved/annealed and send to CMS for further operations like drilling and heat
treatment .The raw material for bull head hammer is being procured from M/s
VSNL, BHADRAWATI, and the material specification is 50CrMO4. Average life of
Bull-head hammer is 60 hrs
Technical specifications OF BULL HEAD HAMMERS as per
drawing:
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C : 0.46-0.54,
Cr : 0 .9-0.12,
Mo: 0.25-0.3,
Hotrolled, spherodoisedannealed
Si : 0.15-0.4,
Mn : 0.5-.8,
P : 0.03 max,
S : 0.03 max,
TEMPERING - When a steel specimen has been fully hardened, it is very hard and
brittle and has high residual stresses. The steel is unstable and tends to contract on
aging. The internal stress can be relieved by an additional heating process. This
heating process is called tempering. After specimen has been fully hardened by
quenching from above critical temp, it is reheated to some temp below the critical
temp for a certain period of time and then allowed to cool in still air. The temp to
which it is reheated depends upon the composition and the degree of hardness or
toughness desired.
Tempering reduces the elastic limit and ultimate strength lightly but
they are still higher than they were before drawing. Hardening with subsequent
tempering serves the following purposes for bullhead hammer. It develops high
hardness to resist wear and to enable it to cut another metals. It also improves
strength, elasticity, and ductility.
Tempering is a term historically associated with the heat treatment of martensite in
steels. It describes how the microstructure and mechanical properties change as the
metastable sample is held isothermally at a temperature where austenite cannot form.
The changes during the tempering of martensite can be categorized in to stages.
During the first stage, excess carbon in solid solution segregates to defects or forms
clusters within the solid solution.
It then precipitates, either as cementite in low-carbon
steels, or as transition iron-carbides in high-carbon alloys. The carbon concentration
that remains in solid solution may be quite large if the precipitate is transition carbide.
Further annealing leads to stage 2, in which almost all
of the excess carbon is precipitated, and the carbides all convert into more stable
cementite. Any retained austenite may decompose during this stage. Continued
tempering then leads to the coarsening of carbides, extensive recovery of the
dislocation structure, and finally to the recrystallisation of the ferrite plates into
equiaxed grains.
17
COMPOSITION OF 50CRM04:
S : 0.03 max,
during annealing, the hardness and strength decreases, whereas the ductility increases.
some useful graphs are
20
4. Heating is done in fixed hearth type furnace for forging operation. Heating is
done up to 1250.c. for 5 hrs. At the rate of 200.c / hr heating is done then half
an hour soaking is done.
5. With the help of manipulator and open die hammer, manual forging is done.
Only 90 mm size is forged. Shank portion width is made to 36 mm. And total
length is made to 360 mm. shank portion length is kept as per drawing equal to
193.5 mm. for checking the size during the process template is used. After this
process the BHN of BHH is approx 350BHN.
6. Annealing is done after forging in order to reduce hardness from 350 to 220
.so that drilling may take place successfully. Room temp loading is done for
annealing, it is heated up to 500.c at the rate of 150.c /hr then half an hr
soaking again heating at the same rate up to 850 .c then one hr soaking. Then
furnace cooling is done for 38 hrs. Due to this annealing hardness come down
to 210-220 BHN.
7. Inspection is done with respect to shape and size of BHH.
8. BHH is sent to Central Machine shop after inspection. They are sent in batch
as Batch size is 400 jobs per batch.
(1) Heating the hammers up to 600 +0+25 at a constant rate of 150.c /hr.
(2) Soaking at 600.c for 30 minute.
(3) Raising the temp from 600.c to 875.c at 100.c/hr.
(4) Soaking at 875+0+25 for 2 hrs.
(5) Quenching in recirculating water up to 100 mm.
c)TEMPERING-
500
100
time
TEMPERING CYCLE FOR BHH
2. SHEARING OF BILLETS
3
3. HEATING FOR FORGING UPTO 1250.C
4
4. FORGING
6
6. INSPECTION FOR DIMENTIONAL CHECKING
7. TRANSPORTATION TO CMS
7
24
8
8. DRILLING OF 50 MM HOLE
9. HARDENING 9
10. TEMPERING 1
0
11. SAMPLING
1
1
12. INSPECTION FOR HARDNESS CHECKING
12
13. TRANSPORTION TO CUSTOMER
13
LOW LIFE
FRACTURE
POOR CRUSHING
LOW PRODUCTION
CUSTOMER SATISFACTION
Lowlife and High WEAROUT of the hammers is identified as the
root cause for all above problems initiating alternatives for making a better Bhh.
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hammer and dolomite. We can cool it by circulating cool air the spark (heat)
generated will be given less time to propagate through the material and change the
grain size and deformation. Another idea is pre-crushing of the dolomite ore installing
one more raw material handling plant. if we want to enhance the life of hammer
without any changes in the current process we can focus on two areas.
1. heat treatment
is, we concentrate on whether the treatment is good or not. We are quenching after the
heat treatment and sending them to sinter plant if we temper (reheating) the brittleness
can be reduced.
is made of 40cr4. The hammer which is rotating at 1000rpm is wearing quickly than
the shield which is stationary the idea is to make the hammer with the same material
as that of shield.
changing the composition is a risky one because the people working there are facing
The bottom surface of the hammer is in contact with the floor of the furnace. If we
keep the bottom portion of the hammer open to air by means of a shaft as shown in
fig.
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The heat treatment should be done at a proper temp. The best temp suitable foe heat
Since martensite is formed from the austenite by diffusion less, two step shear
During quenching martensite is formed. The formation will be more if the time given
for quenching is less by means of relatively cool water than we are using now. The
We should also take care about the brittleness if we cool fast it will be more brittle. So
So our point out interest is to maximize the amount of martensite in the quenched
hammer.
Three bull head hammers have been studied for analysis to identify
the reasons to improve the life of bull head hammers in crushers of Sinter
Plant.
This hammer was broken at neck portion while crushing, was sent for
study in QATD (Quality assurance and technology department) for its micro
structure. The following are the pictures of broken Bull head hammer.
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stamping
(b) Heat treatment as per proposed cycle is difficult to achieve due to poor
(c) Heat transfer rate is difficult to achieve in furnaces since there is no facility of
to control the heat treatment , pyrometer may be used for checking temp of different
different burners of heat treatment furnace may be kept on or off so that uniform
temp of each bull head hammer may be achieved as per proposed heat treatment
cycle.
(d) Tempering furnace also has no facility to control the heat transfer rate. Air-
automatically, will reduce the problems related to heat treatment of bull head
hammers.
Quench cracks also come during quenching of bull head hammer... Magnetic
it is less it is more prone to failure. Right now there is no provision for checking
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of toughness of bull head hammer. Izod impact test / charpy test may be done on
sample basis.
100 mm in head area, but due to boiled water bubble formation length may goes
maintained carefully.
(g) Proper care during heat treatment can be done; pyrometer may be used for
this measured temp different burners of heat treatment furnace may be kept on or
off so that uniform temp of each bull head hammer may be achieved as per
100 mm in head area, but due to boiled water bubble formation length may goes
maintained carefully.
(i) Due to not proper recirculation of water, in quench area steam layer forms,
which resists further cooling and contact of water. So it is desired that proper
(j)Range of hardness as per drawing is 380 to 500 BHN. This large range may
lead to variation of properties of each and every bull head hammer. This range
should be minimized in order to get uniform properties of each and every bull
head hammer.
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1. Forging is done for the handle portion only. If the head can be forged it will
give better mechanical properties for the hammer. Chances of better hammer
2. The existing recommended range of hammer hardness is 150 BHN i.e. from
also result in improvement of life time due to the formation of uniform grain
5. Productivity may also be increased by crushing the raw material in two stages.
BIBLIOGRAPHY: