AN INDUSTRIALTRAINING REPORT-1

Submitted by

AKRIT KUMAR CHATURVEDI (RA1511002020014)

During the period

01-12-16 to 15-12-16

AT

JINDAL STEEL & POWER Ltd.

RAIPUR, CHATTISGARH

In partial fulfilment for the award of the degree

Of

B.TECH (FULL TIME)

In

MECHANICAL ENGINEERING

SRM UNIVERSITY

Ramapuram

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 SRM UNIVERSITY
RAMAPURAM CAMPUS

RAMAPURAM CHENNAI-600 089

Regestration No: RA1511002020014

BONAFIDE CERTIFICATE

This is certify that this is a bonafied record of pratical work done by

AKRIT KUMAR CHATURVEDI of V semester of Mechanical

department in the subject Industrial Training-1 during 2017-2018.

Head Of The Department Staff Incharge

Submitted for the university Examination held on…………..

Internal Examiner-1 Internal Examiner-II

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 ACKNOWLEDGEMENT

We place on regard our deep sense of gratitude to our beloved chancellor

Dr. T. R. PACHAMUTHU for providing us with requisite infrastructure through
the course.

We would like to thank our Chairman, SRM UNIVERSITY, Ramapuram

campus, Dr. R. SHIVAKUMAR, for his constant encouragement.

We express our sincere gratitude to our beloved dean,

Dr. V. SUBBAIAH BHARATHI, for his kind inspiration and supporting us with
necessary infrastructure for completion of this project.

Our heartfelt thanks to our Vice Principal (Academic) and Head of Department,
Dr. K. C. UDAIYAKUMAR, for his encouragement support and guidance.

We express our heartfelt and sincere gratitude to our guides

Mr. SUYASH SHARMA, for his guidance and inspiration throughout the training
period.

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 COMPANY INTRODUCTION

JINDAL STEEL & POWER Ltd.

JSPL is an industrial powerhouse with a dominant presence in steel, power, mining and
infrastructure sectors. Part of the US $ 18 billion OP Jindal Group this young, agile and responsive
company is constantly expanding its capabilities to fuel its fairy tale journey that has seen it grow
to a US $ 3.3 billion business conglomerate.

Led by Mr Naveen Jindal, the youngest son of the legendary Shri O.P. Jindal, the company
produces economical and efficient steel and power through backward and forward integration.

From the widest flat products to a whole range of long products, JSPL today sports a product
portfolio that caters to markets across the steel value chain. The company produces the world's
longest (121-meter) rails and it is the first in the country to manufacture large-size parallel flange
beams.

JSPL operates the largest coal-based sponge iron plant in the world and has an installed capacity
of 3 MTPA (million tonnes per annum) of steel at Raigarh in Chhattisgarh. Also, it has set up a 0.6
MTPA wire rod mill and a 1 MTPA capacity bar mill at Patratu, Jharkhand, a medium and light
structural mill at Raigarh, Chhattisgarh and a 2.5 MTPA steel melting shop and a plate mill to
produce up to 5.00-meter-wide plates at Angul, Odisha.

An enterprising spirit and the ability to discern future trends have been the driving force behind
the company's remarkable growth story. The organisation is wedded to ideals like innovation and
technological leadership and is backed by a highly driven and dedicated workforce of 15000
people.

JSPL has been rated as the second highest value creator in the world by the Boston Consulting
Group, the 11th fastest growing company in India by Business World and has figured in the
Forbes Asia list of Fab 50 companies. It has also been named among the Best Blue Chip
companies and rated as the Highest Wealth Creator by the Dalal Street Journal. Dun & Bradstreet
has ranked it 4th in its list of companies that generated the highest total income in the iron and
steel sector.

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Alongside contributing to India's growth story the company is driving an ambitious global
expansion plan with its sights set on emerging as a leading transnational business group. The
company continues to capitalise on opportunities in high growth markets, expanding its core areas
and diversifying into new businesses. In Oman (Middle East), the company has set up a US $ 500
million, 1.5 MTPA gas-based Hot Briquetted Iron (HBI) plant. It has now added a 2 MTPA
integrated steel plant.

In Africa, the company has large mining interests in South Africa, Mozambique, Namibia,
Botswana and Mauritania and is expanding into steel, energy and cement. In Australia, the
company is investing in greenfield and brownfield resource sector companies and projects to
supplement its planned steel and power projects in India and abroad.

In Indonesia, the company has invested on the development of two greenfield exploration assets. It
is also exploring investment opportunities in the power and infrastructure sector in Indonesia.

The company endeavours to strengthen India's industrial base by aiding infrastructural

development, through sustainable development approaches and inclusive growth. It deploys its
resources to improve infrastructure, education, health, water, sanitation, environment and so on in
the areas it operates in. It has won several awards for its innovative business and social practices.

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 DAY -1

(All ten Sheds)

Day started with introduction about plant, rules & regulations, and works done in Jindal Steel
Plant Limited.

Plant details-

Alongside contributing to India's growth story the company is driving an ambitious global
expansion plan with its sights set on emerging as a leading transnational business group. The
company continues to capitalise on opportunities in high growth markets, expanding its core areas
and diversifying into new businesses. In Oman (Middle East), the company has set up a US $ 500
million, 1.5 MTPA gas-based Hot Briquetted Iron (HBI) plant. It has now added a 2 MTPA
integrated steel plant.

In Africa, the company has large mining interests in South Africa, Mozambique, Namibia,
Botswana and Mauritania and is expanding into steel, energy and cement. In Australia, the
company is investing in Greenfield and Brownfield resource sector companies and projects to
supplement its planned steel and power projects in India and abroad.

In Indonesia, the company has invested on the development of two Greenfield exploration
assets. It is also exploring investment opportunities in the power and infrastructure sector in
Indonesia.

The company endeavours to strengthen India's industrial base by aiding infrastructural

development, through sustainable development approaches and inclusive growth. It deploys its
resources to improve infrastructure, education, health, water, sanitation, environment and so on in
the areas it operates in. It has won several awards for its innovative business and social practices.

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 DAY -2

(Shed -2)

Fig. 2.1 JSPL Raipur, Heavy Machinery Section

Day started in Machining Section Shed-2, trainer gave the small introduction about Shed 2.
According to trainer’s instructions, we saw each and every machine asking the minute details
about CNC machines & MC machines. All of the machines are below:

1. Lathe Machine

2. CNC Machines

3. Milling Machine

4. Boring Machine

5. Shaping Machine

1. Lathe Machine

A lathe is a machine tool which turns cylindrical material, touches a cutting tool to it, and
cuts the material. The lathe is one of the machine tools most well used by machining. Material is
firmly fixed to the chuck of a lathe. The lathe is switched on and the chuck is rotated. And since

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the table which fixed the byte can be moved in the vertical direction, and the right-and-left
direction by operating some handles shown. It touches a byte's tip into the material by the
operation, and makes a mechanical part.

Operations of Lathe Machine:

(i) Facing: This operation is almost essential for all works. In this operation, as shown in fig., the
work piece is held in the chuck and the facing tool is fed from the centre of the work piece
towards the outer surface or from the outer surface to the centre, with the help of a cross-slide.

(ii) Plane Turning: It is an operation of removing excess amount of material from the surface the
surface of the cylinder work piece. In this operation, shown in fig., the work is held either in the
chuck or between centres & the longitudinal feed is given to the tool either by hand or power.

(iii) Step Turning: It is an operation of producing various steps of different diameters of in the
work piece as shown in fig. This operation is carried out in the similar way as plain turning.

(iv) Drilling: It is an operation of making a hole in a work piece with the help of a drill. In this
case as shown in fig., the work piece, by rotating the tail stock hand wheel. The drill is fed
normally, into the rotating work piece, by rotating the tail stock hand wheel.

Fig. 2.2 a) Facing b) Plain Turning c) Step Turning

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 Fig. 2.3 a) Drilling b) Reaming

2. CNC MACHINES

i) PAMA –I

ii) CNC DOUBLE / SHIN NIPPON KOKI (SNK)

iii) CNC PLANO MILLING MACHINE

iv) SANCO/ PM-6

v) CNC VERTICAL MILLING MACHINE

vi) CNC HORIZONTAL MACHINES

vii) JUARISTI

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i) PAMA -1

The pama floor type horizontal milling machine speed mill is the ideal solution for all
application requiring high speed machining coupled with high precision multi axis contouring,
with the advantage of a horizontal spindle chip evacuation. Our exclusive solution utilizing direct
drive for the spindle allows taking advantage of today’s latest tooling technology as well as it’s
ready for future tooling developments.

 Floor Type Horizontal Boring & Milling Machine

 Large size CNC boring and milling machines

The hydrostatic boring and milling machine Speedram is designed for high precision,
power and structural rigidity, providing the perfect machining solution for the most demanding
applications on all heavy, medium to large size components, requiring high material removal rate
coupled to high precision and superior finishing even in hard-to-cut materials. Speedram CNC
boring and milling machines can be equipped with several type of tool magazines and automatic
attachment changers and customized accessories (such as universal heads, 2 axes contouring
heads, right angle heads, universal heads with orthogonal axes and facing heads) to cater for the
needs of the most demanding applications in fields of applications such as:

Energy

Oil & Gas

Shipbuilding

Earth Moving

General Machining

Best In Class In Traditional Milling And Boring

Boring Spindle Diameter 130 – 320 Mm

Vertical Stroke From 2000 – 10000 Mm

The hydrostatic floor type boring and milling machines Speedram are available in six basic
models with boring spindle diameter from 130 to 320 mm, spindle power from 37 to 145 kW and
vertical strokes from 2000 to 10000 mm. The boring and milling machine Speedram can be
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equipped with a wide range of hydrostatic rototraversing tables with loading capacity from 25 to
600t.

For high speed machining

Direct drive spindle.

Max. load capacity-

40 Tons

Spindle diameter –
160 mm

X- 10000 mm
Y- 3500 mm
Z- 1200 mm
V- 200 mm
W- 300 mm

Floor table dimensions –

2000 x 3000 mm2

PAMA

Table - 2.1 PAMA

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 ii) SHIN NIPPON KOKI (SNK)

Fig. 2.4 SHIN NIPPON KOKI

The machine was shown in Japan International Machine Tool Fair (JIMTOF
2012) (and) seen by many visitors during the exhibition.
RB five-face high-speed multi-centre series that fulfils high productivity has
undergone a complete makeover to become your best partner.

Features:

Full-stroke under NC control in W - axis (crossrail) makes possible for machining

workpiece with steps and challenging shapes.

High-precision machining that takes advantage of the features of the round column.

Round quill for easy operation as axis named as C - axis.

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Spindle type can be selected from “Standard type”, “High-speed type”, “High-power type and
“High-torque type” (as spindle line-up) for various machining conditions.

New five-face machining software that “facilitates five-face/multi-face machining “is provided.
The software has some functions such as: automated coordinate conversion, fully automated
sorting for Z-W axis, a wealth of interactive machining pattern software.

iii) JUARISTI

A type of horizontal boring and milling machine

 Heidenhain iTNC 530 CNC Control

 NC-Rotary Table – 0.001 Degree

 W-Axis Control

 Direct Measuring System – X,Y,Z Axis

 SEP 2 Spindle Sleeve

 Sealing Air

 Air Blow

 Siemens Digital Drives

 Adjustment ATC

 Spindle Oil Cooler

 Electronic Handheld Control

 M+H PS 20.41 Infra-Red Measuring Probe

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 SPECIFICATIONS

Spindle diameter –
150 mm

Load capacity ---

18 Ton

Table --
2000 X 2000 mm2

X – Axis--- 4000
Y– Axis--- 2500
Z– Axis--- 2400
W– Axis--- 1000

JUARISTI

Table 2.2 JUARISTI

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3. Horizontal Milling Machine

Horizontal Milling Machine is a very robust and sturdy machine. A variety of cutters are
available to removed/shape material is normally held in a strong machine vice. This horizontal
miller is used when a vertical miller is less suitable. For instance, of material has to be removed by
the cutters or there is less of a need for accuracy – a horizontal milling machine is chosen.

Fig. 2.5 Horizontal Milling Machine

The cutter can be changed very easily. The arbor bracket is removed by loosening nuts and
bolts that hold the arbor firmly in position. The arbor can be slid off over the arm. The spacers are
removed as well as the original cutter. The new cutter is placed in position spacers slid back onto
the arbor and the arbor bracket tightened back in position.

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4. Horizontal Boring Machine

The work is supported on a table which is stationary and tool revolves in horizontal
axis.Can perform boring, reaming, threading, facing, milling, grooving and many other
operations.Work piece which are heavier and asymmetrical can be easily held and
machined.Different types has been designed to suit the different purpose.

Fig. 2.6 Horizontal Boring Machine

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 Fig. 2.7 Horizontal Boring Machine in sketch

Applications of HBM

1. Horizontal boring machine can be used to drill, bore ream holes.

2. These are widely used in batch production where work piece is less.
3. These machine can also be used for machining type parts like gear boxes and engine
blocks.

5. Vertical Boring Machine

The work rotates on a horizontal table about a vertical axis and the tool is stationary except for
feed. Machine may look like a vertical lathe. Larger diameter and heavy work pieces, can be set
up more quickly than in lathe. Multiple tooling may be adapted with its turret type tool post,
increasing the rate of production.

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 Fig. 2.8 Vertical Boring Machine

Operations in Vertical Boring Machine:

Fig. 2.9 Operations by Vertical Boring Machine

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 6. Shaping Machine

A shaping machine is used to machine surfaces. It can cut curves, angles and many other
shapes.It is a popular machine in a workshop, because its movements is very simple although
it can produce a variety of work. Shaping machines once in a range of sizes but the most
common size is shown below.

Fig. 2.10 Vertical Boring Machine

The main parts are indicated below:-

The tool feed handle can be turned to slowly feed the cutting tool into the material as the
'ram' moves forwards and backwards. The strong machine vice holds the material securely. A
small vice would not be suitable as the work could quite easily be pulled out of position and be
damaged. The vice rests on a steel table which can be adjusted so that it can be moved up and

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down and then locked in position. Pulling back on the clutch handle starts the 'ram' moving
forwards and backwards.

Principle of Operation of the Shaping Machine:

1. Shaper machine is used for generating flat surfaces.

2. Single Point Tool reciprocates on the job.
3. Job is fed across the tool.
4. Tool is moved downward after completion of cross feed.

The length of stroke and position of stroke can be changed.

After all the these small intros about CNC & MC machines, we got some new info’s about
them, but main thing was Coding in CNCs. This was the main attraction for us. After that we
planned to learn CNC coding anyhow, we decided to learn by our own, because there were
restrictions not to touch or work, any part of machine.

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 DAY- 3

(Shed - 6)

After the better start with huge gigantic machines, trainer said us to meet the supervisor of
welding section i.e. in Shed -6. We met our new trainer . He started with basic details of welding.
He also told about, type of welding maximum times they use. He told us point to point info’s.
Some of them are below, and some of them are in our brain. Because those are the experience
gained by them which violates the procedure of welding. These knowledge only we got from the
temporary employees working there. Lets we proceed with small-small detailing about welding.

1. Welding Machine

The process of joining together two pieces of metal so that bonding accompanied by
appreciable interatomic penetration takes place at their original boundary surfaces. The boundaries
more or less disappear at the weld, and integrating crystals develop across them. Welding is
carried out by the use of heat or pressure or both and with or without added metal. There are many
types of welding including Metal Arc, Atomic Hydrogen, Submerged Arc, Resistance Butt, Flash,
Spot, Stitch, Stud and Projection.

a) DCEP (reverse polarity) – SMAW, SAW, GMAW (MIG, MAG), FCAW.

b) DCEN (straight polarity) – GTAW [TIG].
c) AC (alternating current) – ALUMINIUM WELDING.

During training we studied about the use of different welding machine for different purpose

i) MIG (METAL INERT GAS WELDING)

ii) TIG (TUNGSTEN INERT GAS WELDING)
iii) SMAW (SHEILD METAL ARC WELDING)

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i) Metal Inert Gas Welding (MIG)

MIG is also known as SHEILD INERT GAS METAL ARC WELDING (SIGMA) uses a
shielded stuck between a bare metal electrode and the work piece. Metal electrode provide in the
form of roll. It is fed continuously through the feed mechanism at the rate at which it is being
consumed so as to maintain the welding arc between its end and the base metal. The arc is
shielded by an inert gas atmosphere provided by the gas flowing through the nozzle of the holder
through which electrode wire also passes. The welding equipment consists of a pistol shaped wire
gun, a gas hose with a concentric metallic tube for conveying filler wire , control cables, wire feed
system, wire reel, welding power source and the inert gas cylinder.

Equipment

● DC output power source

● Wire feed unit

● Torch

● Work return welding lead

● Shielding gas supply, (normally from cylinder)

Power Source

MIG welding is carried out on DC electrode (welding wire) positive polarity (DCEP).
However DCEN is used (for higher burn off rate) with certain self- shielding and gas shield cored
wires. DC output power sources are of a transformer-rectifier design, with a flat characteristic
(constant voltage power source). The most common type of power source used for this process is
the switched primary transformer rectifier with constant voltage characteristics from both 3-phase
415V and 1-phase 240V input supplies.

Shielding Gas

This is a complicated area with many various mixtures available, but the primary purpose
of the shielding gas in the MIG process is to protect the molten weld metal and heat affected zone
from oxidation and other contamination by the atmosphere. The shielding gas should also have a
pronounced effect on the following aspects of the welding operation and the resultant weld.

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• Arc Characteristics a basic position or starting point would be

• Mode of Metal Transfer

• Penetration and Weld Head Profile Aluminum - Argon

• Speed of Welding Magnesium - Helium

• Undercutting Tendency Copper Alloys - Argon - Helium Mix

• Cleaning Action Steel - CO2 not commonly used * Weld Metal Mechanical Properties today,
Ar-CO2 mix is preferred.

ii) Tungsten Inert Gas Welding (TIG)

The electrode used in this process is made of either tungsten or thoriated tungsten. The
process is therefore, sometimes called Tungsten Inert Gas (TIG) or Gas Tungsten Arc welding
(GTAW). Thoriated tungsten electrode run cooler than plain tungsten electrodes and maintains
square arcing ends but arc more expensive. The inert gas is supplied to the weld area through a
water cooled electrode holder It provides a protective shield around the arc. The inert gas
generally used is argon though helium or mixture or a mixture of the two may also be used. When
required a filler may be added just like in gas welding. The current source may be either DC or
AC depending upon application. DC straight polarity arc is used in metals other than aluminium
and magnesium including copper alloys, cast iron, steel and stainless steel. It gives good heat
concentration and produces weld that are deep and narrow. Welding rates are high and there is less
distortion of base metal. DC reverse polarity is generally used because it produces shallow and
wide weld. AC arc is used for welding aluminium, magnesium, cast iron and a number of other
metals.

Fig. 3.1 Vertical Boring Machine

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Advantages

The TIG welding process has a very large area of application due to its many advantages, e.g.:

• It provides a concentrated heating of the work piece.

• It provides an effective protection of the weld pool by an inert shielding gas.

• It can be independent of filler material.

• The filler materials do not need to be finely prepared if only the alloying is all right.

• There is no need for after treatment of the weld as no slag or spatter is produced.

Materials for TIG welding

The most important area of application is:

• Welding of thin materials in stainless steels

• Aluminium

• Nickel

• Nickel alloys

The increasing demands to the weld quality has made TIG welding very popular for welding of
smaller tube dimensions as well as root runs in both non-alloyed and alloyed materials in heavier
plates.

TIG Welding Equipment

Configuration
In order to handle the TIG welding process and make it work to its full capability you need
equipment consisting of different parts with their own separate function.

The TIG welding equipment chiefly consists of:

• A TIG torch that is the tool the welder uses to control the arc.

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• A power source which is capable of providing the necessary welding current.

• A TIG unit with incorporated control systems that make it possible to adjust the welding current,
arc initiation etc.

• A shielding gas cylinder with pressure reducing valve and flow meter.

1 Cable for welding current

2 Cable for welding current

3 Control cable for TIG unit

4 Shielding gas

5 Cable for welding cable for TIG torch

6 Control cable for TIG torch

7 Welding cable with +polarity

TIG Torch

The main purpose of the TIG torch is to carry the welding current and shielding gas to the
weld. The TIG torch is constructed on the basis of the welding handle and a torch head that is
coated with an electrically insulated material

The torch handle is usually fitted with a switch to turn the welding current and the shielding gas
on and off.

1. Torch head

2. Handle

3. Control switch

4. Electrode cap

5. Sealing ring

6. Electrode collet

7. Heat shield

8. Collet body
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9. Gas Nozzle

iii) Shield Metal Arc Welding (SMAW) & Baking of Electrodes

The flux coating on Shielded Metal Arc Welding (SMAW) electrodes is hydroscopic or
moisture absorbing. The amount of moisture absorbed is dependent on the atmospheric conditions
of temperature and humidity experienced by the electrode after the packaging has been opened.
The amount of moisture, which is absorbed, increases with time of exposure.

During the manufacturing process SMAW electrodes are baked at a high temperature and
following manufacture the flux coating has a low moisture content. Prior to use, electrodes should
be left in their unopened original moisture proof hermetically sealed containers and stored in a dry
area. Once the container is opened, the deep seating lid should be replaced as the lid provides an
effective barrier to moisture ingress. Once the container is opened, the electrodes should be stored
in a cabinet equipped with either a desiccant or heated to 1015ºF (6-8ºC) above the highest
expected ambient temperature or both.

Electrodes which have absorbed excessive moisture should be re-baked in a vented oven at
600ºF ±25°F (315ºC±15°C) for one hour or 500ºF±25°F (260ºC±15°C) for two hours. Electrodes
must be removed from their original containers during this re-baking operation. Electrodes should
not be stacked more than 6 layers deep on shelves within the oven. Most electrodes can be re-
baked at least 2-3 times without substantially affecting both the integrity of the flux coating and
their welding performance. Following the re-baking operation the electrodes should be allowed to
cool to room temperature prior to use.

A common problem that may occur is the uneven absorption of moisture by the electrodes.
For example, electrodes exposed overnight may exhibit "fingernailing" (uneven burn-off on one
side of the electrode) problems during welding when used the next day. In this instance the reason
that "fingernailing" occurs is due to moisture being absorbed by only one side of the electrode
causing that side to burn off more slowly and unevenly. Correct storage conditions will prevent
this type of "fingernailing" problem.

Submerged Arc Welding (SAW) Fluxes:-

Agglomerated submerged arc welding (SAW) fluxes are manufactured using minerals and
metallic powders held together by silicate binders. Fused fluxes are manufactured using minerals,
which are melted to form a glass, which is subsequently crushed to form the flux particles.
Submerged arc welding fluxes absorb moisture with the amount of moisture absorbed being
27
dependent upon the atmospheric conditions and time of exposure. Most of the Special Metals
fluxes are supplied in air tight 90 mil plastic buckets with an 'O' ring seal in the lid. The 'O' ring
seal is an effective moisture barrier that works when the bucket is both opened and re-sealed
correctly to allow the 'O' ring to seat properly. To open the bucket of flux, the embossed tab on the
lid must be pulled, or cut free, and then peeled loose from the lid. This removes a thin ring of
plastic from the circumference of the lid. Once this ring of plastic is removed, the lid is quickly
and easily opened and resealed. Properly seating the 'O' ring is necessary in order to prevent any
flux that remains in the bucket from absorbing moisture. INCOFLUX 9 is supplied in heavy duty
plastic sacks. Fluxes should be stored in a dry area and labels should never be removed from the
packaging.

Submerged arc welding fluxes can be re-baked if it is suspected that the flux has absorbed
excessive moisture. Re-baking should be performed at 700-900ºF (375-480ºC) for two hours in a
vented oven for all INCOFLUX fluxes except INCOFLUX 9. For INCOFLUX 9 re-baking
should be conducted at 300-480ºF (150- 250ºC) in a vented oven. Flux should be placed on metal
trays with a maximum flux depth on the tray of 2" (50mm). The plastic buckets and plastic sacks
should not be baked.

Process

The SMAW process is an arc welding process which produces coalescence of metal by
heating them with an arc between a covered metal electrode and the work. Sheilding is obtained
from decomposition of the electrode covering. Pressure is not used. Filler metal is obtained from
the electrode

Typical SMAW setup

1. Welding power source (suitable for work to be performed)

2. Length of suitable welding cable

3. Length of suitable ground cable

4. Suitable electrode holder

5. Suitable ground clamp

6. Covered electrode (matched to base metal)

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7. Welding helmet and protective equipment

A constant current type power source is most commonly used: these are available in AC,
AC/DC combination or DC output with mechanical, electrical, solid state controls, either static or
dynamic. Constant current power sources come in a large variety of output characteristics,
capacities and controls. They can be static or dynamic. All AC and AC/DC combination static
power sources require single phase input (primary power). The industrial classes are usually
reconnect able on different voltages i.e. 230, 460 or 575; while the limited input machines are
single voltage connection i.e. 208, 230 or 575. Most of the DC output machines require three
phase primary power. These are also normally reconnect able on different voltages.

Heating Just Before Welding

Temperature approximately measured by marker having the melting capacity at 150oC to

melt. & if the marker melted within in fraction of seconds under a second then the temperature
reaches to the required temperature i.e. 300oC.

2. WELDING DEFECTS

 Undercutting
Undercutting is one of the more severe welding defects. It is essentially an unfilled groove
along the edge of the weld (see Figure 2). The causes are usually associated with incorrect
electrode angles, incorrect weaving technique, excessive current and travel speed. Undercutting
can be avoided with careful attention to detail during preparation of the weld and by improving the
welding process. It can be repaired in most cases by welding up the resultant groove with a
smaller electrode.

 Concave and Convex Welds

Misshaped welds are caused by a combination of incorrect electrode current and speed.
Excessive concavity (lack of reinforcement), results in insufficient throat thickness in relation to
the nominated weld size. Excessive convexity results in poor weld contour. In multilayer welds
this can give rise to slag inclusions, while in the finished weld it provides a poor stress pattern and
a local notch effect at the toe of the weld. They can be avoided by using an appropriate electrode
size, current and weaving pattern. Repair by either filling with further weld material or by grinding

29
back to the base metal on each side of the weld and re-welding.

 Cracking
Cracks and planar discontinuities are some of the most dangerous especially if they are
subject to fatigue loading conditions. There are several different type of cracks and none are
desired. They must be removed by grinding back (if superficial) or repaired by welding. Cracks
can occur in the weld itself, the base metal, or the heat affected.

 Holes (Porosity)
Porosity can be caused by one or more of: contamination of weld surfaces or filler metals,
improper electrode selection, inadequate shielding, unstable arc, too short or too long an arc
length, too high a travel speed, and generally poor welding technique. The effect of porosity on
weld performance will depend on the number, location, and size of the holes. Porosity cannot be
repaired by welding overtop of the problem. Grind out to remove the porosity, then re-weld.

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 DAY 4

(Sheds -2&6)

With the better start of the training day, came with some of the machining command
doubts and welding description. Directly our trainer told us to go and see the working with
commands given to CNCs. Said to ask from employees about the better working, function, learn
some commands. And we went tried to gather all information, but it is already said, one cannot
capture every thing in same time, without problems.

Now come to the point, some basic coding of action of these CNCs we learnt, those are as follows:

Fig. 4.1 Remote Controller of CNC Machine With code show Panel

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 DAY 5

(Shed -7)

After the completion of the basic training, trainer asked us to go Shed 7, i.e., casting
section. Below this shed the basic casting of shapes are occurring, not for full production, only for
materials which they are used at the time of manufacturing. This shed is smaller than other shed.

Casting is a manufacturing process in which a liquid material is usually poured into

a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The
solidified part is also known as a casting, which is ejected or broken out of the mold to complete
the process Casting process is generally used for steel materials

Casting Process Consists Of The Following Steps:

1.Pattern process

2.Moulding Process

3.Melting Process

4.Pouring Process

5.Knockout Process

6.Heat Treatment

7.Dimension

8.Mechanical+Chemical Testing

9.Inspection

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Steel Is Divided Into Categories According To The Carbon Content:-

1.Low Carbon Steel

2.Medium Carbon Steel

3.High Carbon Steel

4.Stainless Steel

1. PATTERN PROCESS

Pattern is the shape in which we want our mould to be formed .There are different
materials used to pattern such as wood ,Plastic ,Steel. The pattern is used to create mould . From
which we can form the desired shape

2. MOULDING PROCESS

In this pattern is used to form mould(cavity of our desired shape) in the sand.Pattern is
used to create each half of the desired shape .In which we pour our molten metal

Fig. 5.1 Casting Block

3. MELTING PROCESS

In this the metal is melted in the furnace which is to be to be poured in the mould. Metal is
heated at a very high temperature so a to melt it into liquid

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4. POURING PROCESS

In this process the molted metal is poured in the mould cavity from the sprue to the core.
The molten metal is the cooled so as to get our desired shape

Fig. 5.2 Pouring of Melt Metal

5. KNOCKOUT PROCESS

When the metal is cooled down so as to get our desired shape all the parts of the casting
system are removed i.e. sprue, riser, runner, channel .The sand on the pattern produced is then
removed by the process of vibration

6. HEAT TREATMENT

The pattern produced by casting by the above process is not hard . Can be broen easily. To
harden the material we eat the pattern at a suitable temperature so that the material hardness
increases and do not break easily

7. DIMENSIONS

It is one of the inspection process .In this the dimension of the pattern produced is
measured the measuring tapes. From this we can check the dimension of the pattern produced. If
there are any errors in the dimension we can reduce the size according to our need by suitable
process

8. MECHANICAL +CHEMICAL TESTING

In this the pattern produced from the above process is undergone series of mechanical and
chemical test. In mechanical testing we determine the strength of the pattern produced .The
capacity to bear the load. In chemical testing we determine the corrosive strength of the material

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9. INSPECTION

In this various methods are use such as ultrasonic and radiography methods. These
methods are also known as NDT. In this respective waves are passed through the pattern and
reading is noted on the photographic plates. The places where there are errors are noted on the
plate which can later be rectified

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 DAY 6

(Shed -8)

After the whole process of casting which was done, for machining, drilling or grinding,. As
machining is already done, now left thing was grinding. This was done under shame casting shed,
but named as Shed- 8. So many grinders were there, some of them were made by employees only
for their daily and easy use. Now come the section:

1. GRINDING

Process for giving the surface finishing in the job. These grinders are setup with abrasives
in the grinding wheels of grinders.

Grinding is a material removal and surface generation process used to shape and finish
components made of metals and other materials. The precision and surface finish obtained through
grinding can be up to ten times better than with either turning or milling. Grinding employs an
abrasive product, usually a rotating wheel brought into controlled contact with a work surface.
The grinding wheel is composed of abrasive grains held together in a binder. These abrasive
grains act as cutting tools, removing tiny chips of material from the work.

Failure or fracture of bonding between the abrasives.

Abrasive components which are harder than the work

Shock- and heat-resistant abrasive wheels

Abrasives that are friable. That is, they are capable of controlled fracturing

Most abrasives used in industry are synthetic.

some of the abrasives used are:

AL2O3, CSI AND CERAMICS.

During training we studied about the use of different grinders for different purpose

 Ag4
 Rotor grinder

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 Fig. 6.1 Ag4 Grinder

2. DRILLING

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-
section in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed
against the work piece and rotated at rates from hundreds to thousands of revolutions per minute.
This forces the cutting edge against the work piece, cutting off chips (swarf) from the hole as it is
drilled.

PROCESS

 Establishing a centering mark or feature before drilling, such as by:

 Casting, molding, or forging a mark into the work piece
 Center punching
 Spot drilling (i.e., center drilling)
 Spot facing, which is facing a certain area on a rough casting or forging to establish,
essentially, an island of precisely known surface in a sea of imprecisely known surface
 Constraining the position of the drill bit using a drill jig with drill bushings
 Surface finish in drilling may range from 32 to 500 microinches. Finish cuts will generate
surfaces near 32 microinches, and roughing will be near 500 microinches.

Cutting fluid is commonly used to cool the drill bit, increase tool life, increase speeds and
feeds, increase the surface finish, and aid in ejecting chips. Application of these fluids is usually
done by flooding the workpiece or by applying a spray mist.

In deciding which drill(s) to use it is important to consider the task at hand and evaluate which
drill would best accomplish the task. There are a variety of drill styles that each serve a different
purpose. The subland drill is capable of drilling more than one diameter. The spade drill is used to
drill larger hole sizes. The indexable drill is useful in managing chips.

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 DAY 7

(Shed -3&4)

Fig. 7.1 Fabrication Shed or Plate Mill

Process were continued, working according to the instructions. A bunch of welding

employees, grinder employees, and driller. Working simultaneously. Two different operations
which we saw were rolling& bending of metal sheets also met with Quality Checking Manager.
Let’s start with rolling.

1. ROLLING

In metalworking, rolling is a metal forming process in which metal stock is passed

through one or more pairs of rolls to reduce the thickness and to make the thickness uniform. The
concept is similar to the rolling of dough. Rolling is classified according to the temperature of the
metal rolled.

This is done by passing the raw material which is in the form of plates through two rollers.Which
under pressure reduces the thickness of the plate

Rolling can be done in a 1 way process or 2 way process.If one wants to reduce the
thickness upto a greater extenet .The plate should be passed through the roller more than once .

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 Fig. 7.2 Rolling Process

Rolling process is also used to bend the plates in the form of cylindrical surface. When the
plates are passed through the rollers the surface becomes circular which is then welded along the
ends to form a cylindrical structure.

2. BENDING

Fig. 7.3 Rolling of sheets into curved Sheets

ROLLING PLATES(RAW MATERIAL) INTO CYLINDRICAL SHAPE

Plates are rolled in a plate bending or rolling machine into cylindrical shape. By passing
the plates b/w the rollers and rolling with pressure.

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 DAY 8

(Shed -1)

Fabrication, Machining, Installation

In training period plant was making 300 TONS CRANE, acc to the vendor’s plan,
requirement. So whatever we saw up to six days those all works are for making this huge heavy
rolling 300 ton crane. In this section also grinders, welders, basic machine tools and machinery
were available. Welding up huge parts of machines, by 120 ton crane, which was rolling over our
head. Like this crane there were total 7 cranes of same weight i.e. 150 Tons.

Huge shafts of 10 metres, wheels of dia 5meters, heads of 20 meters, weight up to 300
tons, as already said. All were assembling in one place.

Fig. 8.1 Assembly Section

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 DAY 9

(Sheds -9&10)

Pressure Vessels

Fig. 9.1 PressureVessel

A pressure vessel is a container designed to hold gases or liquids at a pressure substantially

different from the ambient pressure.Pressure vessels are used in steam boilers.Pressure vessels are
used to store chemical in chemical plants ,petroleum products such as petrol,diesel.It is also used
in engine cylinders

Shape of pressure vessel

Shape of pressure vessel changes accordingto the requirments. Pressure vessels can
theoretically be almost any shape, but shapes made of sections of spheres, cylinders, and cones are
usually employed. A common design is a cylinder with end caps called heads. Head shapes are
frequently either hemispherical or dished (torispherical). More complicated shapes have
historically been much harder to analyze for safe operation and are usually far more difficult to
construct.

Process of manufacturing of pressure vessel

It involves process in the following order:-

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1.Procure raw material

2.Rolling plates into cylindrical surface

3.Forming of dish end by pressing.

4.Welding process

1. Procure Raw Material

Procure required which is normally carbon steel.Raw materials is generally in the form of
plates, pipes, forgings, fasteners. Sometimes anti corrosive materials are used as well for the
construction of pressure vessel.

2. Rolling Plates (Raw Material) Into Cylindrical Shape

Plates are rolled in a plate bending or rolling machine into cylindrical shape. By passing
the plates b/w the rollers and rolling with pressure.

Fig. 9.2 Pressure Vessel

3. Forming Of Dish End By Pressing

The plates are first cut into circular shape. Dish ends are formed by pressing this circular
plate in a pressing machine. The dish are attached to the sides of the cylindrical surface as shown
in the figure below

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 Fig. 9.3 Pressure Vessel

4. Welding

The rolled ends of the shell are welded by either manual or automatic welding processes.
The cylindrical shape are then welded along the edges together to form the shell part of the
pressure vessel. The dishes are then welded at the sides of the shell to form the stucture

Now the nozzle are welded to the shell and the dish to complete the pressure vessel also
saddles are welded at the bottom of the vessel to support the same. The nozzel welded on the
dishes are usually man holes. Generally two more nozzles are welded on the cylindrical surface ,
One is outlet nozzle and other is Inlet nozzle. More nozzles can be added as per the drawing.

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 DAY 10&11

(Shed – 9&10)

Inspection Process & Leak Proof Checking

Inspection process starts from the raw material stage during fabrication and after
completion. Manly there two types of inspection for a pressure vessel which are dimensional
inspection and welding strength. Dimensional inspection by using measuring tapes .Welding
strenght inspection is done by using NDT process such as radiography, ultrasonic etc

Radiography and Ultrasonic inspection generally involves the process passing thee
respectives waves and getting the reading to ensure required quality of the weld. The differnce in
reading on a certain part of the plate shows the defect , impurity or damage in pressure
vessel.Which can then be resolved.

Fig. 10.1 Inspection Process done in JSPL Raipur

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 DAY 12

(In Huge Closed Chamber)

Post Weld Heat Treatment

During process such as rolling bending and welding various stresses are induced in the
pressure vessel. Which can be removed by post heating the entire structure.In this process the
pressure vessel is heated in a furnace which removes the internal stresses induced. This process is
also known as Annealing. There are other various process to remove th induced stresses

Fig. 12.1 Pressure Vessel in heat treatments

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 DAY 13

(Done in Small Chamber)

Surface Treatment

In surface treatment the surface of pressure vessel is undergone a series of process to

strengthen the surface and make it anti corrosive. This process involves removing rust ,blasting
and coating it with an anti corrosive paint.

Fig. 13.1 Surface Treatment

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 DAY 14

(Shed -2)

CAD Chamber

Fig. 14.1 Cad Cam Analysis And Designing By Designer

With all of the works completed, trainer said to go inside the CAD Chamber, if interested
in CAD CAM softwares, we saw everything, every single calculations with perfection was doing
by designer. According to him only precautions on dimensions were set. Type of grinding is given
by vendor, but value type is set by designer. Every process in CNCs first analyzed by designer
only, then 2-D diagram sheet will proceed for next.

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 DAY 15

The final over view of JINDAL STEEL PLAND Ltd. was done, went to the packaging and
transport section, and had some talk there. And final reports were submitted to the HR. After
interview HR rewarded with certificate

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 CONCLUSION

The overall visit to the factory was really wonderful and productive
knowledge was gained. Many new things, systems were seen in an engineering
point of view.

Cleanliness, discipline and safety were up to the mark and expectation.

Coordination and communication with the employees was spectacular. It made me
feel as a par of the plant itself.

Technically speaking everything was manufactured precisely with all factors

of safety considerations and checking was done in every single stage in the
machines and machine lines.

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