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INTRODUCTION
1. COMPANY PROFILE
A) GENERAL : COMPANY INTRODUCTION
INDIA METALS, was established in 1967 for manufacturing track items, started in own
premises at 21, Industrial Area, Phase -1, Chandigarh.
Business works
The business practice of M/s INDIA METALS, is to improve the quality of its products up to
the entire satisfaction of customer. We always try to achieve our works on time and also
achieving. Production level with minimum rejection.
Quality policy
We, INDIA METALS, committed to satisfy our customers by supplying quality products through
continual improvement.
Quality objective
Implementation method
System is implement to the staff & trained labor for quality product through continuous and
effective training programmers from time to time.
`2
ORGANISATION CHART
NAME OF KEYPERSONNEL
Sr. Name of the Manufactured Quantity/ Capacit Unique SI No. Year of Documents Year of
N Equipment/ By/ Model No. No.s y Of Machine(IM) Procurement Established Manufacture
o Machine ownership
Mechanical Basant 2 Nos 100 Ton 14,15 1973 Owned 1973
1. Power Press
(Bar Cutting)
3-8Ft. 03
Grinder
1. POWER PRESS
A Power press is a special kind of machine that can bend any sheet metal into a specific shape.
There are various products made of metal which we use in our day to day life like automobiles,
electronic gadgets etc. Sheet metal is required to be cut, bended and pressed to form a particular
shape. In ancient times, these jobs were done manually but now to make the process quick, it is
used which can cut, bend and press metals to form shapes with accuracy. A forming press,
commonly shortened to press, is a machine tool that changes the shape of a workpiece by the
application of pressure. Presses can be classified according to-
2. SURFACE GRINDER
Surface grinding is used to produce a smooth finish on flat surfaces. It is a widely used
abrasive machining process in which a spinning wheel covered in rough particles (grinding
wheel) cuts chips of metallic or non-metallic substance from a workpiece, making a face of
it flat or smooth. Surface grinding is the most common of the grinding operations. It is a
finishing process that uses a rotating abrasive wheel to smooth the flat surface of metallic or
non-metallic materials to give them a more refined look or to attain a desired surface for a
functional purpose.
`10
3. LATHE MACHINE
A lathe is a machine tool which rotates the workpiece on its axis to perform various
operations such as cutting, sanding, knurling, drilling, or deformation, facing, turning, with
tools that are applied to the workpiece to create an object which has symmetry about an
axis of rotation. Lathes are used in woodturning, metalworking, metal spinning, Thermal
spraying/ parts reclamation, and glass-working. Lathes can be used to shape pottery, the
best-known design being the potter's wheel. Most suitably equipped metalworking lathes
can also be used to produce most solids of revolution, plane surfaces and screw threads or
4. DRILLING MACHINE
Radial drilling machine, also known as cross arm drill. Spindle box can move around on the
rocker, and with the rocker arm around Column The rotary 180 Drilling machine (see
photo). The rocker arm can lift along the outer column, in order to adapt to different
workpiece height. The smaller The workpiece Can be installed on the work table, the larger
workpieces can be directly placed on Machine tool A base or on the ground. Radial drilling
machine widely used in single piece and small batch production, processing of large volume
and weight of the workpiece hole. Radial drilling machine processing range, can be used for
drilling screw holes, cut large parts of the thread bottom hole and the hole. Radial drilling
machine's main forms a slide block and a universal type two. Slide type radial drilling
machine is the base type radial drilling machine to slide to slide along the bed, Guide
Mobile, to expand the processing Range , suitable for boiler, bridge, vehicle and ship,
Machining Industry, etc.. Universal radial drilling machine Rocker except for vertical and
rotary Movement Outside, and can move horizontally, the spindle box can tilt adjustment in
the rocker arm, to adapt to different parts of the processing
`12
5. MILLING MACHINE
Milling is the machining process of using rotary cutters to remove material[1] from a
workpiece by advancing (or feeding) in a direction at an angle with the axis of the tool. It
covers a wide variety of different operations and machines, on scales from small individual
parts to large, heavy-duty gang milling operations. It is one of the most commonly used
processes in industry and machine shops today for machining parts to precise sizes and
shapes.
Milling can be done with a wide range of machine tools. The original class of machine tools
for milling was the milling machine (often called a mill). After the advent of computer
numerical control (CNC), milling machines evolved into machining centers (milling
machines with automatic tool changers, tool magazines or carousels, CNC control, coolant
systems, and enclosures), generally classified as vertical machining centers (VMCs) and
horizontal machining centers (HMCs). The integration of milling into turning environments
and of turning into milling environments, begun with live tooling for lathes and the
occasional use of mills for turning operations, led to a new class of machine tools,
multitasking machines (MTMs), which are purpose-built to provide for a default machining
strategy of using any combination of milling and turning within the same work envelope.
`13
6. POWER HACKSAW
Power hacksaws are used to cut large sizes (sections) of metals such as steel. Cutting
diameters of more than 10/15mm is very hard work with a normal hand held hacksaw.
Therefore power hacksaws have been developed to carry out the difficult and time
consuming work.
The heavy arm moves backwards and forwards, cutting on the backwards stroke
The metal to be cut is held in a machine vice which is an integral part of the base. Turning
the handle tightens or loosens the vice. The vice is very powerful and locks the metal in
position. When cutting is taking place, the metal and especially the blade heats up quickly.
Coolant should be fed onto the blade, cooling it down and lubricating it as it cuts through
the metal.
Without the use of coolant the blade will over heat and break/snap. This can be dangerous
as the blade can break with powerful force, shattering. When the metal is placed and fixed
in the vice, the blade is lowered onto its top surface. The diagram below shows the arm
being lowered with the adjusting handle
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S. no. Name of Manufact Quanti Capaci Unique Year of Documen Year Calb. Calb.
equipment/ma ured ty/ ty S.I. No. procurem ts of Date Due
chine by/Model No.s of ent establishe Man
No. machine d u.
ownershi
p
1. Computerized FIE 1 No. 40 Ton 76/111 2011 TM/64/I 2011 10.03. 10.03.
Universal UTN-40 M/2010- 14 15
Testing TO 11
Machine UTN-ES-
40
2. Vernier Mitutoya 1 No. 0 to 0607878 NA NA NA 04.01. 04.01.
caliper Japan 150 6 14 15
mm
3. Computerized FIE 1 No. 3000K 04/2011- 2011 TM/64/I 2011 11.05. 11.05.
Brinell B-3000PC gf 131 M/2010- 14 15
Hardness 11
Tester
Machine
4. Standard Test BLUE 1 No. 140 - 2012 Invoice 2012 - -
Block STAR BHN
140BHN
5. Metallurgical Radical 1 No. Slide RXM 7D 2014 M720 2014 Dec Dec
microscope 1/100 2014 2015
6. Polishing Radical 1 No. 12 RXM 7D 2014 M720 2014 Dec Dec
Machine 2014 2015
7. Approved sets RDSO 2 set - - 2012 QA/CT/ 2012 Gauge Next
of gauges approved for ML approv approv
each al al due
Drg. letter 31.12.
No. dt. 15
T- 09.10.
3738 12
T-
For 3740
internal T-
used 3741
T-
3742
1 set
for
each
Drg.
No.
T-
3738
T-
`15
3740
T-
3741
T-
3742
`16
A universal testing machine (UTM), also known as a universal tester,[1] materials testing
machine or materials test frame, is used to test the tensile strength and compressive
strength of materials. The "universal" part of the name reflects that it can perform many
standard tensile and compression tests on materials, components, and structures (in other
words, that it is versatile).The set-up and usage are detailed in a test method, often published
by a standards organization. This specifies the sample preparation, fixturing, gauge length
(the length which is under study or observation), analysis, etc. The specimen is placed in the
machine between the grips and an extensometer if required can automatically record the
change in gauge length during the test. If an extensometer is not fitted, the machine itself can
record the displacement between its cross heads on which the specimen is held. However,
this method not only records the change in length of the specimen but also all other
extending / elastic components of the testing machine and its drive systems including any
slipping of the specimen in the grips. Once the machine is started it begins to apply an
increasing load on specimen. Throughout the tests the control system and its associated
software record the load and extension or compression of the specimen.
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2. VERNIER CALLIPER
A vernier Scale also known as vernier calliper is a device that lets the user measure more
accurately than could be done by reading a uniformly-divided straight or circular
measurement scale. It is scale that indicates where the measurement lies in between two of the
marks on the main scale.
internal dimensions (using the uppermost jaws in the picture at right), external dimensions
using the pictured lower jaws, and in many cases depth by the use of a probe that is attached
to the movable head and slides along the centre of the body. This probe is slender and can get
into deep grooves that may prove difficult for other measuring tools
The vernier scales may include metric measurements on the lower part of the scale and inch
measurements on the upper, or vice versa, in countries that use inches. Vernier calipers
commonly used in industry provide a precision to 0.01 mm (10 micrometres), or one
thousandth of an inch. They are available in sizes that can measure up to 1,829 mm (72 in).
DIGITAL CALLIPER- A refinement now popular is the replacement of the analog dial
with an electronic digital display on which the reading is displayed as a single value. Some
digital calipers can be switched between centimeters or millimeters, and inches. All provide
for zeroing the display at any point along the slide, allowing the same sort of differential
measurements as with the dial caliper. Digital calipers may contain some sort of "reading
hold" feature, allowing the reading of dimensions even in awkward locations where the
display cannot be seen.
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4. METALLURGICAL MICROSCOPE
Metallurgical microscope is the optical microscope, differing from other microscopes in the
method of the specimen illumination. Since metals are opaque substances they must be
illuminated by frontal lighting, therefore the source of light is located within the microscope
tube. This is achieved by plain glass reflector, installed in the tube.
The optical scheme of metallurgical microscope is shown in the picture.
The image quality and its resolving power are mainly determined by the quality of the objective.
The objective magnification depends on its focal length (the shorter focal length, the higher
magnification). The eyepiece is the lens nearest the eye. The image is magnified by eyepiece in
x6, x8 or x10.
M = L*E/ F
Where
S.no CODE
1. IS: 2062:2011 Hot rolled low, medium and high tensile structural steel.
4. IS: 228 (Part - 8)- 1989 Determination of silicon by gravimetric method (for Si 0.05% -
5.0%).
7. IS: 228 (Part - 20)- 2003 Determination of carbon and sulphur by infrared absorption
method (for carbon0 .005 to 2.0% and sulphur 0.001 to 0.05%).
8. `IS: 1500-2005 Method for Brinell hardness test for metallic materials.
9. IS: 2500 (Part - 1) 1992-2000 Sampling inspection procedure attribute, sampling plans indexed
by acceptable quality level for lot by lot inspection.
10. IS: 1153-2000 Specification for temporary corrosion preventives hard, film,
solvent deposited.
12. IS: 4748:2009 Steel-Determination delivery requirements for Steel & Steel
product
13. STR: IRS Specification for metal liners for use with ERC (prov.)2013
Up to date calibration of testing equipment i.e. UTM & vernier is maintained at a frequency
of 1 year, calibration stickers indicating the date of calibration and the due date of calibration
is pasted on the respective equipments. These calibration certification are submitted to the
inspecting engineer with every inspection.
We have 3 sets of gauges for Drg. i.e. for metal linear to Drg. No. RDSO/T-3738, RDSO/T-
3740, RDSO/T-3742. Two set of each Drg. is sent to RDSO for approval and 1 set of each Drg
are for internal use. These gauges are hardened by heat treatment to have minimum wear and
tear while using it. The gauges approved by RDSO is kept for inspection ( 1 set for inspecting
engineer and 1 set as master gauge ) as advised by RDSO.
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11.1.1 For procuring Raw Material/section of metal liners it is ensured that for rolling of
Section/raw material has been procured from the market so as to match With Chemical &
rnechanical properties to confirm to grade designation F 250 Quality C as I laid in Table
1&2 of IS: Billets is procured with the specification that if the steel is killed by silicon
alone , the silicon content should not be less than 0.1% when steel is killed by Aluminum
alone. the Aluminum content not be less than 0.02% when the steel is killed by silicon-
Aluminium, the silicon content should not less than 0.03% and total Aluminum content
should not less than 0.01% . we procure certified copy of Original Invoice and test
certificate from the re-rollers. Traceability of billets to rolled section is maintained by the
manufacturer. The billets is re-rolled into desired metal liners bars and the rolling is done at
following firms.
The re-roller firm is having facilities of normalizing liner bars through heat treatment in a
separate normalizing furnace by properly soaking in appropriate authentic state for a
suitable period followed by cooling in still air.
11.1.2 Raw material received at work premises is identified/checked by matching the derails
provided in the original invoice.
11.1.3 After proper identification of raw material the raw material unloaded at the work
premises.
11.1.4 The unloaded raw material is Stacked in raw material stock yard heat wise/section
wise.
11.1.5 To ensure that the different heats of raw material do not get mixed up following
information is displayed on each bays of raw material:-
a) Heat no
b) Drawing no./Section
c) Quantity
d) Source of raw material
e) P.O Placing Railway
f) Supplier of billets/bloom
`24
To demonstrate the achievement of desired quality of raw materials as rolled section are checked
for various properties as per IRS specification metal liners use with Elastic Rail Clips (ProvisionaI)
2013 each heat/section separately for the following:-
1) Visual and from surface defects: In this test raw material is checked visually as hot
rolling in involved in the manufacturing of raw material, hence visual check is required to
check that no over heating not have occurred. Mill scale is also removed from shape &
Section bars with help Of emery paper as for Iron & Steel, All bars are thorough checked
any die marks occur during rolling. Samples are cut randomly from bars & dipped In acid to
test for seam or any other surface defect and details recorded in the Annexure-I. If any seam
is occurred 1 particular heat then the whole heal is rejected & rejection is returned back to
the manufacturing source. After the material is found satisfactory then we go for
dimensional check.
Dimensions :- In this process the raw material is checked dimensionally with the help of
RDSO approved gauges (G-2 & G-6) and drawings. In metal liners all the dimensions are
to be maintained as per RDSO Drg.
for above properties of the rolled section at least 2% bars for each heat are checked. The
dimensions are checked with RDSO approved gauges (G2 & G6) and the observations are
recorded in a Performa given in annexure-1 and same checked with respect to their
acceptability as per specifications and respective drawing.
(1) Chemical composition: From the raw material small pieces are cut & prepared as specified
with the help of shape & surface grinding machine. Three samples from each heat is drawn
for chemical test for ensuring better quality & practically no chance for any type of error.
These polished samples are chemically tested at Govt. approved lab or RDSO approved lab
Indiana Ferro Alloys, Mohali . Chemical composition of 6 elements is checked i.e. Carbon,
Manganese, Sulphur, Phosphorous, Silicon & Aluminum. Raw material test certificate is also
procured from the raw material supplier & to ensure that no human error has been occurred
the chemical test certificate received from the raw material supplier is compared with
chemical test report of the samples got tested internally by us. No raw material is used for
manufacturing of metal liner if it doesnt in the prescribed limit.
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(2) Physical properties Like( Bend test, Yield, Tensile strength & % elongation etc. in this
test dumbles are prepared from bars from each heat for each section for bend test. These
pieces undergoes tensile test , yield and elongation test at 40 Ton capacity UTM machine.
Prescribed limit for yield test is 250 N/mm2 and tensile test I 410 N/mm2. And %elongation
is 23% Bend test pieces are also tested at UTM machine, if material is passed from the test
then the material is issued for production.
(3) Non Metallic Inclusion Contents & apparent Grain Size Determination: The
determination of contents of nonmetallic inclusion and Grain size is done by microscopic
method with the help of Trinocular Metallurgical Microscope having Grain Size Eyepiece
WF 10x with adjustable focusing calibration side 1/100 mm form the raw material small
pieces are cut & prepared as specified with the help of shaper & polishing machine. Two
samples from each heat are drawn and checked for inclusion contents in accordance with IS:
4163-2004 in longitudinal section with inclusion rating shall not be worse that 2.0. A.B.C.D.
for both thick and thin series when compared to the chart for determining the inclusion
content of secondary refined steels (Fig.) of IS 4163-2004. The microstructure of the samples
is checked with the fine grain ferrite and pearlite with grain size of ASTM-6 of finer.
Two Nos. of bars for each heat and for each section are checked for the above properties
results of observations are recorded in a pro-forma given in Annexure-2,3&4 and same are
seen for their acceptability as per specification and also compared with the test certificates.
If the variation is beyond the specified tolerance the heat section is rejected and stored
separetly till is disposed off. Only passes material in all parameters is used for manufacture
of the product.
`26
(1) CUTTING OPERATION: Cutting of raw material is done with Power Press of sufficient
capacity. The Die work is done with the help of stoppers engraved for dimension control.
The prescribed length for all types of metal liners is 107.5 to 109 mm. To check taper while
cutting angle gauge is used. The dies are checked regular intervals and faces are sharpened
at surface grinding machine if bluntness occurs. To demonstrate the achievements required
quality at least 20 samples of metal liners are checked every hour during the cutting
operation.
(2) SLOTTING OPERATION: After cutting the material undergoes slotting operation at
Power Press of sufficient capacity. Here also dies are operated with stoppers engraved as
per prescribed limit. These stoppers are made of Tank Plates having very low wear and tear.
The slotting operation is very important operation with tolerance is only 0.5mm. This
tolerance is as per area available between inserts and tracks while lying of metal liners at
railway track. This dimension is very crucial and important and is prescribed length is
77.5mm to 79mm which is designed as per tolerance of area between SGCI to rail foot. All
the die operation is done with the help of guide die which control press stocks so that the
force occurs on the material should be cut as per desired dimension. This slotting operation
is the basic operation for manufacturing metal liners. To demonstrate the achievements
required quality at least 20 samples of metal liners are checked every hour during the
cutting operation and the data are recorded as per per-forma given in the Annexure-5.
(3) NOTCHING OPERATION : In this operation notching /V-Cutting is done with help of
die guided plate and stoppers. Notching is done in such a manner that the upper dimension
`27
(5) PUNCH MARKING OF LOT NO: All liners shall be punch marked with lot no. along
with other requirement of respective drawing of liner.
(6) PARTING OPERATION : As the raw material is rolled in such a way that two pices of
liners are rolled together. Parting is done in such a way that ther vertical stroke of the
Power Press parts the product into two liners of equal dimenion . Here also the total die
operation is guided by the guide , if the cutting edges become blunt then the edges are
sharpened at surface grinding machine.
(7) GRINDING : To remove the burs & sharp edges of liners each metal liner grinded on
bench grinder s as per the requirement of respective drawing.
(8) SCREEN PRINTING : Screen Printing as per Drg. Is also marked to distinction between
GS T- 3741) & NGS(T-3742) liners. In case their purchaser desires to dispenser with screen
printing on the liners then either it is specifically mentioned in the purchase order/contract.
(9) GAUGING & INTERNAL TESTING OF FINISHED PRODCUTS : After 100% Visual
Test gauging is done with help of RDSO approved Gauges from Gauge No. G-1 to G-
8, G-1 Gauge is for to check the thickness of the rib. G-2 Gauge is for to check the
thickness of liner, G-3 Gauge is for to check the length of horns, G-4 is to check the
`28
length between two horn. G-5 is to check the internal width ,G-6 is to check the overall
width of the liner , G-7 and G-8 are to check the overall fitting and sitting of liner Sampling
Plan IS-2500 Part-1-2000 with sampling size as per Table 1 GIL-II and
acceptance/rejection level of Table 2 A(Single sampling plan for normal inspection) AQL
2.5% is stricity followed .
(11) INCLUSION CONTENT & GRAIN SIZE TEST: For each test 5% of the sample size or
Minimum 5 nos are checked for inclusion test the inclusion rating when determinate as per
IS: 4163-2004 should not be worse than 2.0 A,B,C,D both for thick & thin series when
compared to the chart in fig. 2 of IS: 4163-2004. The grain size is determined as per IS:
474-l998 and should be fine with grain size of ASTM-6 or finer. The record is maintained
as per Annexure XII
(12) CHEMICAL COMPOSITION: Chemical composition from the finished material is done
on small pieces cut & prepared as specified with the help of shaper & surface grinding
machine as described in clause 11.2.2 (i) shall be tested after manufacturing Three sample
per lot from each section is drawn for chemical test. Record is maintained as per Annexure-
IX 13.0 Physical Properties like (Bend test, Yield, Tensile Strength & % Elongation etc. as
described in clause 11.2.2 (ii) shall he tested after manufacturing. Three Sample per lot
from each section is drawn for physical test. Record is maintained as per Annexure X
`29
After the material is found satisfactory the material is send for packing, before packing
screen-printing or oiling is done with rust preventive oil as specified or as required by the
purchasing agency. After oiling, packing of liner is done in old gunny bags (Containing 100
pieces of liner in each bag). Stacking is done in heat wise/batch wise with 100 bags per
batch. After this whole process the material is offered for final inspection the authorized
inspecting authority, inspection is done in our own premises and the sampling plan used by
the inspecting agency is as per inspection level II and AQL 2.5% shall be as per IS-2500 Part
1-2000. Every day record of raw material received, heat No. 1nvoice NO Production don
balance quantity of raw material, quantity dispatched along with rejection shall be
maintained.
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Raw Surface defect 100% Visual Free from all Any bar found
Material Examination surface defects as defective return
mentioned in to supplier
specification
%Elongation=23%
min
Process Surface 100% Visual Free from all surface Any sample
Control/ defects Examination defects as mentioned found defective
Final testing in specification cut in two pieces
& scraped
%Elongation=23%
min
Freedom 5% of the Macro Free from all surface Rejected & cut in
from surface samples size Examination defects as per clause two pieces &
defect or min. 5 6.3.1 of specification scraped
pieces per lot
of each
section
Bibliography
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2) Wikipedia.com
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