BRIGHTENING LIVES,

POWERING PROGRESS

Submitted to: Submitted by:

Himanshu Sharma
0615340052
4th YEAR(Mechanical)
 ACKNOWLEDGEMENT

It is a matter of great pleasure and privilege for me to present the report on

the practical training of 30 Days on the basis of practical knowledge gained
by me during the practical training at BHARAT HEAVY ELECTRICAL
LIMITED,Haridwar from 14th JUNE to 14th July 2010

I would like to express my gratitude for the people who were part of this
report, directly or indirectly. People who gave unending support right from
the stage the Idea was conceived.

I am also greatly thankfull to all the respondents for their patience and
kindness to respond wisely to the Question.

HIMANSHU SHARMA
TABLE OF CONTENT
1) Introduction
2) BHEL at a GLANCE
3) BHEL HARIDWAR – Introduction
4) STEAM TURBINE
5) Description of Steam Turbine
6) Overview of Bhel Haridwar
7) TURBINE Shop (Block-3)
- LATHE
- HORIZONTAL BORING
MACHINE
- MILLING MACHINE
- SHAPER
- BLANKING
- PIERCING
8) Conclusion
Introduction
BHEL is the largest engineering and manufacturing enterprise in India in the energy-
related/infrastructure sector, today. BHEL was established more than 40 years ago,
ushering in the indigenous Heavy Electrical Equipment industry in India - a dream
that has been more than realized with a well-recognized track record of performance.
The company has been earning profits continuously since 1971-72 and paying
dividends since 1976-77.

BHEL manufactures over 180 products under 30 major product groups and caters
to core sectors of the Indian Economy viz., Power Generation & Transmission,
Industry, Transportation, Telecommunication, Renewable Energy, etc. The wide
network of BHEL's 14 manufacturing divisions, four Power Sector regional
centres,over 100 project sites, eight service centres and 18 regional offices, enables
the Company to promptly serve its customers and provide them with suitable
products, systems and services -- efficiently and at competitive prices. The high
level of quality & reliability of its products is due to the emphasis on design,
engineering andmanufacturing to international standards by acquiring and adapting
some of the best technologies from leading companies in the world, together with
technologies developed in its own R&D centres

BHEL is involved in the development design, engineering, marketing, production,

installation, and maintenance and after-sales service of Rolling Stock and traction
propulsion systems. In the area of rolling stock, BHEL manufactures electric
locomotives up to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP,
both for mainline and shunting duly applications. BHEL is also producing rolling
stock for special applications viz., overhead equipment cars, Special well wagons,
Rail-cum-road vehicleetc.,

BHEL has
Installed equipment for over 90,000 MW of power generation -- for Utilities,
Captive and Industrial users.

Supplied over 2,25,000 MVA transformer capacity and other equipment

operating in Transmission & Distribution network up to 400 kV (AC & DC).

Supplied over 25,000 Motors with Drive Control System to Power projects,
Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement plants, etc.

Supplied Traction electrics and AC/DC locos to power over 12,000 kms
Railway network.

Supplied over one million Valves to Power Plants and other Industries.

BHEL's operations are organised around three business sectors, namely Power,

Industry - including Transmission, Transportation, Telecommunication &

Renewable

Energy - and Overseas Business. This enables BHEL to have a strong customer
orientation, to be sensitive to his needs and respond quickly to the changes in the
market.

BHEL caters to core sectors of the Indian economy viz; power generation &
transmission, industry, transportation, telecommunication, renewable energy,
defence etc. the wide network of BHEL’s 14 manufacturing divisions, four power
sector regional centers, over 100 project sites, eight service centers and 14
regional offices enables the company to be closer to its customers and provide
them with suitable products, systems and services efficiently and at competitive
prices. Having attained ISO 9000 certification, BHEL is now well on its journey
towards total quality management (TQM). On the environmental management
front, the major units of bhel have4 already acquired the ISO 14001 certification,

Vision
A world class, innovative, competitive and profitable engineering enterprise
providing total business solutions.

Mission
To be the leading Indian engineering enterprise providing quality products
systems and services in the field of energy, transportation, infrastructure and
other potential areas.

OHS and environmental policy

Corporate OHS and environmental policy is the principle guiding factor for
BHEL hardwar’s health, safety and environmental management systems.

Health, safety and environmental management systems

BHEL corporate management has recognized health, safety and environmental
issues as a major thrust areas and has issued guidelines to its various units. This
health, safety and environmental management systems manual has been
formulated in line with corporate guidelines on OHS and environmental
management systems and OHSAS 18001:1999 & O 14001:1996 STANDARDS.
The HSE manual is further support by 2nd and 3rd level documents like
departmental manuals, SMIs and work instructions.
The FOURTEEN manufacturing Divisions are located at

• Bhopal(Madhya Pradesh)

• Bharat Heavy Electrical Limited, Ranipur, Haridwar (Uttarakhand) [4]

• Hyderabad (Andhra Pradesh)

• Jhansi (Uttar Pradesh)

• Tiruchirapalli(Tamil Nadu)

• Ranipet (Tamil Nadu)

• Bangalore (Karnataka)

• Jagdishpur (Uttar Pradesh)

• Rudrapur (Uttrakhand)

• Goindwal (Punjab)

• Bharat Heavy Plates and Vessels Limited (Vizag)

Chandigarh

varanasi

Besides these manufacturing units there are four power sectors which undertake
EPC contract from various customers. The Research and Development arm of
BHEL is situated in Hyderabad and two repair shops are at HERP(Heavy Equipment
Repair Plant),Varanasi and EMRP(Electric machines repair plant) Mumbai.
 BHEL, HARDWAR COMPLEX
Location
BHEL, hardwar complex is situated in the foothills of Shivalik range Hardwar
district of Uttranchal state. The main administrative building is at a distance of
about 6K.M from hardwar railway station.

Area
BHEL,Hardwar complex consists of two manufacturing units, namely Heavy
Electrical Equipment Plant(HEEP) and Central Foundry Forge Plant(CFFP).
THE APPROXIMATE TOTAL approximate area of these plants is as follows:

HEEP:.845 sq.Km

CFFP:1.0 sq. Km

About 40% of the area in HEEP and 10% in CFFP is covered area and rest is
occupied by pathways, roads and greenbelts.

Product Profile
HEEP(Heavy Electrical Equipment Plant)
S.NO PRODUCT INSTALLED CAPACITY(LICENSED)

1. thermal sets 5250MW

2. Hydro Sets 625 MW

3. Electrics machines(AC/DC) 450MW

4. Gas Turbines @

5. Super Rapid Guns 3 no.

@ capacity installed for manufacturing of gas turbines componenets like rotor equivalent to
600MW gas turbines. Balance components for turbines from existing thermal sets facilities.

CFFP(Central Foundry Forge Plant)

S.NO. PRODUCT INSTALLED CAPACITY(LICENCED)

1. Castings 6000MT

2. Forgings

1. Heavy Forgings 2410MT

2.Medium Forgings 3000MT

3. Billets and Blooms 4000MT

4. CI Castings 7180 MT

5. Non Ferrous Castings 250MT

Number of employees(Approx.)
HEEP: 5200
CFFP: 780
 No. of approximate contract workers : 1000 No.
Year of Commisioning : 1967

Technical Collaboration
(Milestones of the Unit)
1962 Technical Collaboration with Prommashexport, USSR

1976 Technical Collaboration with KWU (Siemens),

Germany for Thermal Sets upto 1000 MW

1989 Technical Collaboration with KWU (Siemens),

Germany for Gas Turbine

1991 Collaboration signed for Defence Project

2001 Technical Collaboration with Siemens for extended for 10 years

2004 Technical Collaboration with Siemens, for V94.3A Gas Turbine being

finalised

Historical first
(milestones of the unit)

1963 Construction begin with the collaboration of

M/s Prommashexport, USSR

1967 First product (Electric motor) rolled out

1969 First 100 MW Steam Turbine manufactured

1971 First 100 MW Turbo Generator manufactured

1974 Unit’s Breakeven achieved

1977 First 200 MW TG set was commissioned

1983 Commissioning of first set of 500 MW TG

1994 First 150 MW ISO rating Gas Turbine exported to Germany

1997 National Productivity Award

2001 First Top Management TQM Workshop

EXCELLENCE INITIATIVES
(Milestones of the Unit)

1976 Launched Suggestion Scheme

1982 Launched Productivity Movement

1983 Launched Quality Circle Concept

1997 TQM implementation in the entire HEEP

1999 Launched 5-S Implementation

2001 Launching of QTM & RCA at HEEP by CMD

2002 Evolved Business Policy and CSFs

2003 Reviewed Business Policy and CSFs 03-04

2003 Unified Reward Scheme for Suggestions & Improvement Projects

2004 Three Inter Unit TQM Workshops

2004 Reviewed Business Policy and CSFs 04-05

BHEL Haridwar Contribution to National Power Generation

42% HARDWAR

36% BHEL OTHER THAN HARDWAR

22% OTHERS

List of Certification during 2000-2004

 1ISO-14001 Certification was awarded in May 2000.

 NLC Trophy for best Public Sector undertaking in the field of QC for years
2000.

 Prime Minister’s Shram Award for year 2000 to one employee Sri Satya
Pal Singh.
  Vishwakarma Rashtriya Puruskar to 27 employees during last three
years.

 INSAAN award from last ten consecutive years for Excellence in

Suggestion Scheme.

 Best Productivity Performance Award in the category of Heavy

Engineering Industry by National Productivity Council for the year1998.

Products
Steam turbine
Gas turbine
Hydro Turbines
Steam Generators
Oil field equipments
Boiler drum
Water wall panel
Wind mill

BHEL HARIDWAR mainly produces the steam TURBINE

Steam turbine
A steam turbine is a mechanical device that extracts thermal energy from
pressurized steam, and converts it into rotary motion. Its modern manifestation was
invented by Sir Charles Parsons in 1884.

Because the turbine generates rotary motion, it is particularly suited to be used to

drive an electrical generator – about 80% of all electricity generation in the world
is by use of steam turbines

History
The first device that may be classified as a reaction steam turbine was little more
than a toy, the classic Aeolipile, described in the 1st century by Greek
mathematician Hero of Alexandria in Roman Egypt. More than a thousand years
later, in 1543, Spanish naval officer Blasco de Garay used a primitive steam
machine to move a ship in the port of Barcelona.
The modern steam turbine was invented in 1884 by the Englishman Sir Charles
Parsons, whose first model was connected to a dynamo that generated 7.5 kW
(10 hp) of electricity.[8] The invention of Parson's steam turbine made cheap and
plentiful electricity possible and revolutionised marine transport and naval warfare.
[9]
His patent was licensed and the turbine scaled-up shortly after by an American,
George Westinghouse. The Parson's turbine also turned out to be easy to scale up.
Parsons had the satisfaction of seeing his invention adopted for all major world
power stations, and the size of generators had increased from his first 7.5 kW set
up to units of 50,000 kW capacity.

Types
Steam turbines are made in a variety of sizes ranging from small <1 hp (<0.75 kW)
units (rare) used as mechanical drives for pumps, compressors and other shaft
driven equipment, to 2,000,000 hp (1,500,000 kW) turbines used to generate
electricity. There are several classifications for modern steam turbines.

Steam Supply and Exhaust Conditions

These types include condensing, noncondensing, reheat, extraction and induction.

Noncondensing or backpressure turbines are most widely used for process steam
applications. The exhaust pressure is controlled by a regulating valve to suit the
needs of the process steam pressure. These are commonly found at refineries,
district heating units, pulp and paper plants, and desalination facilities where large
amounts of low pressure process steam are available.

Condensing turbines are most commonly found in electrical power plants. These
turbines exhaust steam in a partially condensed state, typically of a quality near
90%, at a pressure well below atmospheric to a condenser.

Reheat turbines are also used almost exclusively in electrical power plants. In a
reheat turbine, steam flow exits from a high pressure section of the turbine and is
returned to the boiler where additional superheat is added. The steam then goes
back into an intermediate pressure section of the turbine and continues its
expansion.
Extracting type turbines are common in all applications. In an extracting type
turbine, steam is released from various stages of the turbine, and used for industrial
process needs or sent to boiler feedwater heaters to improve overall cycle
efficiency. Extraction flows may be controlled with a valve, or left uncontrolled.

Induction turbines introduce low pressure steam at an intermediate stage to

produce additional power.

Casing or Shaft Arrangements

These arrangements include single casing, tandem compound and cross compound
turbines. Single casing units are the most basic style where a single casing and
shaft are coupled to a generator. Tandem compound are used where two or more
casings are directly coupled together to drive a single generator. A cross compound
turbine arrangement features two or more shafts not in line driving two or more
generators that often operate at different speeds. A cross compound turbine is
typically used for many large applications.

Principle of Operation and Design

An ideal steam turbine is considered to be an isentropic process, or constant
entropy process, in which the entropy of the steam entering the turbine is equal to
the entropy of the steam leaving the turbine. No steam turbine is truly “isentropic”,
however, with typical isentropic efficiencies ranging from 20%-90% based on the
application of the turbine. The interior of a turbine comprises several sets of
blades, or “buckets” as they are more commonly referred to. One set of stationary
blades is connected to the casing and one set of rotating blades is connected to the
shaft. The sets intermesh with certain minimum clearances, with the size and
configuration of sets varying to efficiently exploit the expansion of steam at each
stage.
Turbine efficiency

To maximize turbine efficiency the steam is expanded, generating work, in a

number of stages. These stages are characterized by how the energy is extracted
from them and are known as either impulse or reaction turbines. Most steam
turbines use a mixture of the reaction and impulse designs: each stage behaves as
either one or the other, but the overall turbine uses both. Typically, higher pressure
sections are impulse type and lower pressure stages are reaction type.

Impulse turbines
An impulse turbine has fixed nozzles that orient the steam flow into high speed
jets. These jets contain significant kinetic energy, which the rotor blades, shaped
like buckets, convert into shaft rotation as the steam jet changes direction..

As the steam flows through the nozzle its pressure falls from inlet pressure to the
exit pressure Due to this higher ratio of expansion of steam in the nozzle the steam
leaves the nozzle with a very high velocity. The steam leaving the moving blades is
a large portion of the maximum velocity of the steam when leaving the nozzle. The
loss of energy due to this higher exit velocity is commonly called the "carry over
velocity" or "leaving loss".
Reaction turbines
In the reaction turbine, the rotor blades themselves are arranged to form
convergent nozzles. This type of turbine makes use of the reaction force produced
as the steam accelerates through the nozzles formed by the rotor. Steam is directed
onto the rotor by the fixed vanes of the stator. It leaves the stator as a jet that fills
the entire circumference of the rotor. The steam then changes direction and
increases its speed relative to the speed of the blades. A pressure drop occurs
across both the stator and the rotor, with steam accelerating through the stator and
decelerating through the rotor, with no net change in steam velocity across the
stage but with a decrease in both pressure and temperature, reflecting the work
performed in the driving of the rotor.

Operation and Maintenance

When warming up a steam turbine for use, the main steam stop valves (after the
boiler) have a bypass line to allow superheated steam to slowly bypass the valve , a
turning gear is engaged when there is no steam to the turbine to slowly rotate the
turbine to ensure even heating to prevent uneven expansion. After first rotating the
turbine by the turning gear, allowing time for the rotor to assume a straight plane
(no bowing), then the turning gear is disengaged and steam is admitted to the
turbine, first to the astern blades then to the ahead blades slowly rotating the
turbine at 10 to 15 RPM to slowly warm the turbine.

Speed regulation
The control of a turbine with a governor is essential, as turbines need to be run up
slowly, to prevent damage while some applications (such as the generation of
alternating current electricity) require precise speed control Uncontrolled
acceleration of the turbine rotor can lead to an overspeed trip, which causes the
nozzle valves that control the flow of steam to the turbine to close. If this fails then
the turbine may continue accelerating until it breaks apart, often spectacularly.
Turbines are expensive to make, requiring precision manufacture and special
quality materials. During normal operation in synchronization with the electricity
net powerplants are governed with a five percent droop speed control . This means
the full load speed is 100% and the no load speed is 105%. This is required for the
stable operation of the network without hunting and dropouts of powerplants.
Normally the changes in speed are minor . Adjustments in power output are made
by slowly raising the droop curve by increasing the spring pressure on a centrifugal
governor. Generally this is a basic system requirement for all powerplants because
the older and newer plants have to be compatible in response to the instantaneous
changes in frequency without depending on outside communication.

Bearings and Lubrication

Two types of bearings are used to support and locate the rotors of steam
turbines:

Journal bearings are used to support the weight of the turbine rotors. A journal
bearing consists of two half-cylinders that enclose the shaft and are internally
lined with Babbitt, a metal alloy usually consisting of tin, copper and antimony;
and Thrust bearings axially locate the turbine rotors. A thrust bearing is made up
of a series of Babbitt lined pads that run against a locating disk attached to the
turbine rotor.
High-pressure oil is injected into the bearings to provide lubrication. The oil is
carefully filtered to remove solid particles. Specially designed centrifuges remove
any water from the oil.

Shaft Seals
The shaft seal on a turbine rotor consist of a series of ridges and groves around the
rotor and its housing which present a long, tortuous path for any steam leaking
through the seal. The seal therefore does not prevent the steam from leaking,
merely reduces the leakage to a minimum. The leaking steam is collected and
returned to a low-pressure part of the steam circuit.

Turning gear
Large steam turbines are equipped with "turning gear" to slowly rotate the turbines
after they have been shut down and while they are cooling. This evens out the
temperature distribution around the turbines and prevents bowing of the rotors.

Vibration
The balancing of the large rotating steam turbines is a critical component in ensuring
the reliable operation of the plant. Most large steam turbines have sensors installed to
measure the movement of the shafts in their bearings. This condition monitoring can
identify many potential problems and allows the repair of the turbine to be planned
before the problems become serious.

Multi-level steam turbines

In modern steam turbines not only one impeller is propelled, but several being in
a series. Between them idlers are situated, which don't turn. The gas changes its
direction passing an idler, in order to perform optimally work again in the next
impeller. Turbines with several impellers are called multi-level. The principle was
developed 1883 by Parsons. As you know, with the cooling gas expands.
Therefore it is to be paid attention when building steam turbines to a further
problem: With the number of passed impellers also the volume increases, which
leads to a larger diameter of the impellers. Because of that, multi-level turbines
are always conical.

Coupling of several turbines

In power stations today, different types of turbines are used in a series, e.g. one
high pressure -, two medium- and four low pressure turbines. This coupling leads
to an excellent efficiency (over 40%), which is even better than the efficiency of
large diesel engines. This characteristic and the relatively favorable production
make the steam turbine competitionless in power stations. Coupled with a
generator and fired by an atomic reactor, they produce enormously much electric
current. The strongest steam turbines achieve today performances of more than
1000 megawatts.

Ranipur, Uttarakhand
Bharat Heavy Electricals Ltd.(BHEL) Haridwar has two manufacturing plants:-
Heavy Electrical Equipment Plant (HEEP) and Central Foundry Forge Plant (CFFP).

The Heavy Electricals Equipment Plant (HEEP) located in Haridwar, is one of the
major manufacturing plants of BHEL. The core business of HEEP includes design
and manufacture of large steam and gas turbines, turbo generators, hydro
turbines and generators, hydro turbines and generators, large AC/DC motors and
so on.

Central Foundry Forge Plant (CFFP) is engaged in manufacture of Steel Castings:

Upto 50 Tons Per Piece Wt & Steel Forgings: Upto 55 Tons Per Piece Wt.
Overview
The town was built in the early 60s, around the Ranipur plant of Bharat Heavy
Electricals Limited (BHEL) part of Nehruvian dream of "temples of modern
India". It was developed with Russian and Czech technological collaboration, at
peak of Indo-Soviet partnership. In an important move in 1964, Indian signed an
agreement with the Soviet Union for the supply of Rs. 23 crores worth of
equipment by Heavy Electrical Equipment Plants.[1] In the subsequent years,
looking at the need for more advanced technology, it tied up with Siemens AG of
Germany for the production of high capacity steam turbines and generators.[2] In
1999, the Ranipur plant, reached a turnover of Rs 1100 crore,[3] which reached Rs
2,658 crore for the year 2007-08. The HEEP plant along had over 7,500
employees.[4]

Today BHEL, is one of India's nine largest Public Sector Undertakings or PSUs,
known as the Navratnas or 'the nine jewels'.[5] The old village of Ranipur still
exists at the edge of the township, just at the entrance of Rajaji National Park. As
the town developed, schools eventually over 17 and basic infrastructure, including
roads, hospitals and community recreational centres was put into place. Soon
ancillaries came around the township in surrounding area, led to economic
development of the Jwalapur, and the main Haridwar town itself, which till then
survived mostly on tourism.

BHEL Haridwar has a campus of 7000 acres, now 2034 acres of which is inhabited
by 200 companies like Hero Honda, Maruti, ITC and many more in the nearby
SIDCUL (State Infrastructure and Industrial Development Corporation of
Uttarankhand) industrial area. The Integrated Industrial Estate of SIDCUL was an
attractive proposition promoted by the Uttarakhand government whereby various
financial incentives such as Central Excise duty( 100% for 10 years), Income
Tax(100% for 5 years) et al. is being granted.[6] BHEL Haridwar plant itself
consists of two plants namely HEEP (Heavy Electricals Equipment Plant) & CFFP
(Central Foundry & Forge Plant). CFFP has one of the heaviest forge machines in
India.

With Haridwar becoming a district headquarter in 1998, saw new offices were set
up near the township in areas surrounding Roshanabad, especially after the
formation of Uttarakhand state in 2000.
Demographics
As of 2001 India census,[7] Bharat Heavy Electricals Limited Ranipur had a
population of 43,252. Males constitute 53% of the population and females 47%.
Bharat Heavy Electrical Limited Ranipur has an average literacy rate of 81%,
higher than the national average of 59.5%; with male literacy of 86% and female
literacy of 75%. 9% of the population is under 6 years of age.

Transport
BHEL Ranipur, is well connected by road to National Highway 58, between Delhi
and Manapass. Nearest railway stations are at Jwalapur and Haridwar. The nearest
airport is Jolly Grant Airport, Dehradun, though Indira Gandhi International
Airport in New Delhi is preferred.

Industries
BHEL is a major contributor of equipment and systems to industries: cement,
sugar, fertilizer, refineries, petrochemicals, steel, paper etc. the range of systems
and equipment supplied includes: captive power plants, dg power plants, high
speed industrial drive turbines, industrial boilers and auxillaries, waste heat
recovery boilers, gas turbines, heat exchangers and pressure vessels, centrifugal
compressors, electrical machines, pumps, valves, seamless steel tubes and
process controls, control systems for process industries, and control and
instrumentation systems for power plants, defence and other applications. The
company has commenced manufacture of large scale desalination plants to help
augment the supply of drinking water to people.
Telecommunication
Bhel also caters to telecommunication sector by way of small, medium, and large
switching systems.

Renewable energy
Technologies that can be offered by BHEL for exploiting non-conventional and
renewable resources of energy include:wind electric generators,solar power
based water pumps,lighting and heating systems.

The company manufactures wind electric generators of unit size upto 250 KW for
wind farms, to meet the growing demand for harnessing wind energy.

Lathe
Description
The purpose of a lathe is to rotate a part against a tool whose position it
controls. It is useful for fabricating parts and/or features that have a
circular cross section. The spindle is the part of the lathe that rotates.
Various workholding attachments such as three jaw chucks, collets, and
centers can be held in the spindle. The spindle is driven by an electric
motor through a system of belt drives and/or gear trains. Spindle speed is
contolled by varying the geometry of the drive train.

The tailstock can be used to support the end of the workpiece with a
center, or to hold tools for drilling, reaming, threading, or cutting tapers.
It can be adjusted in position along the ways to accomodate different
length workpices. The ram can be fed along the axis of rotation with the
tailstock handwheel.

The carriage controls and supports the cutting tool. It consists of:

 A saddle that mates with and slides along the ways.

 An apron that controls the feed mechanisms.
 A cross slide that controls transverse motion of the tool (toward or
away from the operator).
 A tool compound that adjusts to permit angular tool movement.
 A toolpost T-slot that holds the toolpost.

Choosing a Cutting Tool

 Cutting Tool Terminology

The figure above shows a typical cutting tool and the terminology used to describe
it. The actual geometry varies with the type of work to be done. The standard
cutting tool shapes are shown below.

 Facing tools are ground to provide clearance with a center.

 Roughing tools have a small side relief angle to leave more material to
support the cutting edge during deep cuts.
 Finishing tools have a more rounded nose to provide a finer finish. Round
nose tools are for lighter turning. They have no back or side rake to permit
cutting in either didection.
 Left hand cutting tools are designed to cut best when traveling from left to
right.
 Aluminum is cut best by specially shaped cutting tools (not shown) that are
used with the cutting edge slightly above center to reduce chatter.
 Standard Cutting Tools

Installing a Cutting Tool

Lathe cutting tools are held by tool holders. To install a tool, first clean the holder,
then tighten the bolts

The tool post is secured to the compound with a T-bolt. The tool holder is secured
to the tool post using a quick release lever.

Positioning the Tool

In order to move the cutting tool, the lathe saddle and cross slide can be moved by hand.

There are also power feeds for these axes. Procedures vary from machine to machine.

A third axis of motion is provided by the compound. The angle of the compound can be
adjusted to allow tapers to be cut at any desired angle. First, loosen the bolts securing the
compound to the saddle. Then rotate the compound to the desired angle referencing the
dial indicator at the base of the compound. Retighten the bolts. Now the tool can be hand
fed along the desired angle. No power feed is available for the compound. If a fine finish
is required, use both hands to achieve a smoother feed rate.

The cross slide and compound have a micrometer dial to allow accurate positioning, but
the saddle doesn't. To position the saddle accurately, you may use a dial indicator
mounted to the saddle. The dial indicator presses against a stop (often a micrometer as
shown in the clip below).
Feed, Speed, and Depth of Cut
Cutting speed is defined as the speed at which the work moves with respect to
the tool (usually measured in feet per minute). Feed rate is defined as the
distance the tool travels during one revolution of the part. Cutting speed and feed
determines the surface finish, power requirements, and material removal rate.
The primary factor in choosing feed and speed is the material to be cut. However,
one should also consider material of the tool, rigidity of the workpiece, size and
condition of the lathe, and depth of cut. For most Aluminum alloys, on a roughing
cut (.010 to .020 inches depth of cut) run at 600 fpm. On a finishing cut (.002 to .
010 depth of cut) run at 1000 fpm. To calculate the proper spindle speed, divide
the desired cutting speed by the circumference of the work. Experiment with feed
rates to achieve the desired finish. In considering depth of cut, it's important to
remember that for each thousandth depth of cut, the work diameter is reduced
by two thousandths.

Turning
The lathe can be used to reduce the diameter of a part to a desired dimension.
First, clamp the part securely in a lathe chuck (636kB). The part should not extend
more that three times its diameter. Then install a roughing or finishing tool
(whichever is appropriate). If you're feeding the saddle toward the headstock (as
in the clip below) use a right-hand turning tool. Move the tool off the part by
backing the carriage up with the carriage handwheel, then use the cross feed to
set the desired depth of cut. In the clip below, a finish cut is made using the
power feed for a smoother finish. Remember that for each thousandth depth of
cut, the work diameter is reduced by two thousandths.
Facing
A lathe can be used to create a smooth, flat, face very accurately perpendicular to
the axis of a cylindrical part. First, clamp the part securely in a lathe chuck
(636kB). Then, install a facing tool. Bring the tool approximately into position, but
slightly off of the part. Always turn the spindle by hand (248kB) before turning it
on. This ensures that no parts interfere with the rotation of the spindle. Move the
tool outside the part and adjust the saddle to take the desired depth of cut. Then,
feed the tool across the face with the cross slide. The following clip shows a
roughing cut being made; about 50 thousandths are being removed in one pass. If
a finer finish is required, take just a few thousandths on the final cut and use the
power feed. Be careful clearing the ribbon-like chips; They are very sharp. Do not
clear the chips while the spindle is turning. After facing, there is a very sharp edge
on the part. Break the edge (205kB) with a file.

Parting
A parting tool is deeper and narrower than a turning tool. It is designed for
making narrow grooves and for cutting off parts. When a parting tool is installed,
ensure that it hangs over the tool holder enough that the the holder will clear the
workpiece (but no more than that). Ensure that the parting tool is perpendicular
to the axis of rotation and that the tip is the same height as the center of the part.
A good way to do this is to hold the tool against the face of the part. Set the
height of the tool, lay it flat against the face of the part, then lock the tool in
place. When the cut is deep, the side of the part can rub against sides of the
groove, so it's especially important to apply cutting fluid. In this clip, a part is cut
off from a piece of stock.
Drilling
A lathe can also be used to drill holes accurately concentric with the
centerline of a cylindrical part. First, install a drill chuck into the tail stock.
Make certain that the tang on the back of the drill chuck seats properly in
the tail stock. Withdraw the jaws of the chuck and tap the chuck in place
with a soft hammer.

Move the saddle forward to make room for the tailstock. Move the tailstock into
position, and lock the it in place (otherwise it will slide backward as you try to
drill). Before starting the machine, turn the spindle by hand. You've just moved the
saddle forward, so it could interfere with the rotation of the lathe chuck. Always
use a centerdrill to start the hole. You should use cutting fluid with the centerdrill.
It has shallow flutes (for added stiffness) and doesn't cut as easily as a drill bit.
Always drill past the beginning of the taper to create a funnel to guide the bit in. In
this clip, a hole is drilled with a drill bit.Take at most one or two drill diameters of
material before backing off, clearing the chips, and applying cutting fluid. If the
drill bit squeeks, aplly solvent more often. The drill chuck can be removed from
the tail stock by drawing back the drill chuck as far as it will easily go, then about a
quarter turn more. A pin will press the chuck out of the collet.

Boring
Boring is an operation in which a hole is enlarged with a single point cutting tool.
A boring bar is used to support the cutting tool as it extends into the hole.
Because of the extension of the boring bar, the tool is supported less rigidly and is
more likely to chatter. This can be corrected by using slower spindle speeds or by
grinding a smaller radius on the nose of the tool.
Single Point Thread Turning
External threads can be cut with a die and internal threads can be cut with a tap.
But for some diameters, no die or tap is available. In these cases, threads can be cut
on a lathe. A special cutting tool should be used, typically witha 60 degree nose
angle. To form threads with a specified number of threads per inch, the spindle is
mechanically coupled to the carriage lead screw. Procedures vary for different
machines.
A CNC Lathe is Efficient and Easy to Use
CNC lathe machines are known not only for their ability to get the job done, but
also for how they are relatively easy to use. These machines work with a Windows
environment, so that means that almost any computer in any household can be
used. Your designs, whether made in programs like CorelDraw or manually
created for a short production run, will all come to life cleanly, thanks to the CNC
machine’s user-friendly and compatible software infrastructure. It won’t matter
whether your design depends on measurements by inches or in metric measures;
the machine will take care of the rest for you.

Between manual and automated operation

A surprising (and some would say a disconcerting) number of shops in this country have
no numerically controlled (NC) machine tools at all. Machine tool builders are now
recognizing these shops as an important but overlooked market and are introducing
products specifically designed to attract these first-time buyers.

Apparently, the idea is to overcome resistance to this technology and make entry into the
world of CNC (computer numerical control) turning an easy one. The new lathe is even
being called the EZ-Path.

So what has been causing some shops to stay away from CNC turning? Although the
benefits of CNC turning for quality and throughput improvements are generally
understood and accepted, the decision to move up to CNC turning can be a difficult one
for a shop owner. First, there are the costs associated with new equipment. For a shop
operating on a small margin, the prospect of any major capital expenditure is not
appealing, particularly in a slow-moving economy.

Another consideration is CNC technology. There are lingering misconceptions in the

machine tool market that CNC equipment is difficult to operate, and may even require
highly trained, and costly, computer programmers to develop turning programs.

Yet customers are forcing the decision by demanding tighter tolerances, faster deliveries,
and lower costs. Can a shop stay in business today if the owner doesn't move to CNC?

The new lathe lets users turn parts manually or automatically, or in combination, for what
the company calls an operator-paced move into automated turning. It is priced in the mid-
$30,000 range, or roughly half what many CNC turning centers would cost.

Switching between manual and automated operation is not difficult so operators

unfamiliar with automated turning can learn the system as they go and proceed at a pace
commensurate with their skill level. As turning skills grow, more of the operation can be
automated. Key features are the dual electronic handwheels. These handwheels connect
to encoders and servomotors which move the tool. Using the handwheels, which are
located on the lathe apron, the user can turn, face, bore, as well as cut a taper, chamfer, or
radius by hand.

Using the same concept, automated sequences can be overridden at any time by the
operator when manual turning is judged more appropriate to the application. For
example, when machining a casting, the inside of the workpiece might be turned using
full automatic operation. Because casting dimensions vary slightly, even in the same lot,
automated turning may not be appropriate for the outside of the casting because of the
set-up time required. Each casting is, in effect, a different workpiece. Cutting a chamfer
or radius on the outside of a workpiece like this is more efficiently done manually.

As the operator moves up the learning curve at his own pace, the lathe's programmability
facilitates advancement. For fully automatic operation, the operator answers screen
prompts on a nine-inch monitor. A fill-in-the-blank format simplifies the entering of part
dimensions and machining data. The control system has a number of built-in routines for
automatic turning, facing, grooving, drilling, and boring without the need to enter each
cutting pass.

A teach mode allows the operator to first cut a workpiece manually, then automatically
thereafter. By hitting one of two dedicated keys for a feed move or rapid move after each
cut, the machine's position is stored in the lathe's two-axis microprocessor-based digital
readout (DRO) controller. This controller calculates, stores, and displays part shapes, and
provides a graphic preview of stored operations for program verification.

To keep costs down, the lathe is constructed using an H-bed design. The H-bed
construction consists of four castings (base, headstock, bed, and tailstock support) that
are bolted together. These castings are less costly to produce separately and assemble
than a single large casting typically used for a slant-bed lathe. In addition, the H-bed
design accommodates a workpiece up to twice as long as that expected on a traditional
slant-bed. Clearly, the company recognized that the acquisition cost of the EZ-Path had to
be attractive for short-run production, which is characteristic of the shops this machine is
aimed at.
 Horizontal boring machine

A horizontal boring machine or horizontal boring mill is a machine tool which

bores holes in a horizontal direction. There are three main types — table, planer
and floor. The table type is the most common and, as it is the most versatile, it is
also known as the universal type.

A horizontal boring machine has its work spindle parallel to the ground and work
table. Typically there are 3 linear axes in which the tool head and part move.
Convention dictates that the main axis that drives the part towards the work spindle
is the Z axis, with a cross-traversing X axis and a vertically-traversing Y axis. The
work spindle is referred to as the C axis and, if a rotary table is incorporated, its
centre line is the B axis.

Horizontal boring machines are often heavy-duty industrial machines used for
roughing out large components but there are high-precision models too. Modern
machines use advanced CNC control systems and techniques. Charles DeVlieg
entered the Machine Tool Hall of Fame for his work upon a highly precise model
which he called a JIGMIL.

taper turning   An operation performed on a lathe that feeds a tool at an

angle to the length of the workpiece in order to create a conical shape.

tapping     The process of cutting internal threads in a workpiece with a multi-
point tool.

grooving     The process of cutting an internal channel or passageway into a

drilled hole.
 Milling machine
A milling machine is a machine tool used to machine solid materials. Milling machines exist in
two basic forms: horizontal and vertical, which refers to the orientation of the cutting tool
spindle. Both types range in size from small, bench mounted devices to room-sized machines.
Unlike a drill press, which holds the workpiece stationary as the drill moves vertically to
penetrate the material, milling machines also move the workpiece against the rotating cutter,
which cuts on its flanks as well as its tip. Workpiece and cutter movement are precisely
controlled to less than 0.001 in (0.025 mm), usually by means of precision ground slides and
leadscrews or analogous technology. Milling machines may be manually operated, mechanically
automated, or digitally automated via computer numerical control (CNC).

Milling machines can perform a vast number of operations, some very complex, such as slot and
keyway cutting, planing, drilling, diesinking, rebating, routing, etc. Cutting fluid is often pumped
to the cutting site to cool and lubricate the cut and to wash away the resulting swarf.
Comparing vertical with horizontal
In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in
the spindle and rotate on its axis. The spindle can generally be extended (or the
table can be raised/lowered, giving the same effect), allowing plunge cuts and
drilling. There are two subcategories of vertical mills: the bedmill and the turret
mill. Turret mills, like the ubiquitous Bridgeport, are generally smaller than
bedmills, and are considered by some to be more versatile. In a turret mill the
spindle remains stationary during cutting operations and the table is moved both
perpendicular to and parallel to the spindle axis to accomplish cutting. In the
bedmill, however, the table moves only perpendicular to the spindle's axis, while
the spindle itself moves parallel to its own axis. Also of note is a lighter machine,
called a mill-drill. It is quite popular with hobbyists, due to its small size and lower
price. These are frequently of lower quality than other types of machines, however.

A horizontal mill has the same sort of x–y table, but the cutters are mounted on a
horizontal arbor (see Arbor milling) across the table. A majority of horizontal mills
also feature a +15/-15 degree rotary table that allows milling at shallow angles.
While endmills and the other types of tools available to a vertical mill may be used
in a horizontal mill, their real advantage lies in arbor-mounted cutters, called side
and face mills, which have a cross section rather like a circular saw, but are
generally wider and smaller in diameter. Because the cutters have good support
from the arbor, quite heavy cuts can be taken, enabling rapid material removal
rates. These are used to mill grooves and slots. Plain mills are used to shape flat
surfaces. Several cutters may be ganged together on the arbor to mill a complex
shape of slots and planes. Special cutters can also cut grooves, bevels, radii, or
indeed any section desired. These specialty cutters tend to be expensive. Simplex
mills have one spindle, and duplex mills have two. It is also easier to cut gears on a
horizontal mill.
Computer numerical control
Most CNC milling machines (also called machining centers) are computer
controlled vertical mills with the ability to move the spindle vertically along the Z-
axis. This extra degree of freedom permits their use in diesinking, engraving
applications, and 2.5D surfaces such as relief sculptures. When combined with the
use of conical tools or a ball nose cutter, it also significantly improves milling
precision without impacting speed, providing a cost-efficient alternative to most
flat-surface hand-engraving work.

CNC machines can exist in virtually any of the forms of manual machinery, like
horizontal mills. The most advanced CNC milling-machines, the multiaxis
machine, add two more axes in addition to the three normal axes (XYZ).
Horizontal milling machines also have a C or Q axis, allowing the horizontally
mounted workpiece to be rotated, essentially allowing asymmetric and eccentric
turning. The fifth axis (B axis) controls the tilt of the tool itself. When all of these
axes are used in conjunction with each other, extremely complicated geometries,
even organic geometries such as a human head can be made with relative ease with
these machines. But the skill to program such geometries is beyond that of most
operators. Therefore, 5-axis milling machines are practically always programmed
with CAM.

SAFETY RULES FOR MILLING MACHINES

Milling machines require special safety precautions while being used.

 Do not make contact with the revolving cutter.

 Place a wooden pad or suitable cover over the table surface to protect it from possible
damage.
 Use the buddy system when moving heavy attachments.
 Do not attempt to tighten arbor nuts using machine power.
 When installing or removing milling cutters, always hold them with a rag to prevent
cutting your hands.
 While setting up work, install the cutter last to avoid being cut.
 Never adjust the workpiece or work mounting devices when the machine is operating.
 Chips should be removed from the workpiece with an appropriate rake and a brush

 Shut the machine off before making any adjustments or measurements.

 When using cutting oil, prevent splashing by using appropriate splash guards. Cutting oil
on the floor can cause a slippery condition that could result in operator injury
Shaper
A shaper is a type of machine tool that uses linear relative motion between the
workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is
analogous to that of a lathe, except that it is linear instead of helical. A shaper is
analogous to a planer, but smaller, and with the cutter riding a ram that moves
above a stationary workpiece, rather than the entire workpiece moving beneath
the cutter. The ram is moved back and forth typically by a crank inside the
column; hydraulically actuated shapers also exist.

Operation
A shaper operates by moving a hardened cutting tool backwards and forwards
across the workpiece. On the return stroke of the ram the tool is lifted clear of the
workpiece, reducing the cutting action to one direction only.

The workpiece mounts on a rigid, box-shaped table in front of the machine. The
height of the table can be adjusted to suit this workpiece, and the table can traverse
sideways underneath the reciprocating tool, which is mounted on the ram. Table
motion may be controlled manually, but is usually advanced by an automatic feed
mechanism acting on the feedscrew. The ram slides back and forth above the work.
At the front end of the ram is a vertical tool slide that may be adjusted to either
side of the vertical plane along the stroke axis. This tool-slide holds the clapper
box and toolpost, from which the tool can be positioned to cut a straight, flat
surface on the top of the workpiece. The tool-slide permits feeding the tool
downwards to deepen a cut. This adjustability, coupled with the use of specialized
cutters and toolholders, enable the operator to cut internal and external gear tooth
profiles, splines, dovetails, and keyways.

The ram is adjustable for stroke and, due to the geometry of the linkage, it moves
faster on the return (non-cutting) stroke than on the forward, cutting stroke.
Blanking
Blanking is a shearing process where a punch and die are used to create a
blank from sheet metal or a plate. The blank is workpiece ejected from the starting
stock. The process and machinery are usually the same as that used in piercing,
except that the piece being punched out in the piercing process is scrap.

Fine blanking
Fine blanking is a specialized form of blanking where there is no fracture zone
when shearing. This is achieved by compressing the whole part and then an upper
and lower punch extract the blank. This allows the process to hold very tight
tolerances, and perhaps eliminate secondary operations.

Materials that can be fine blanked include aluminium, brass, copper, and carbon,
alloy and stainless steels.

Fine blanking presses are similar to other metal stamping presses, but they have a
few critical additional parts. A typical compound fine blanking press includes a
hardened die punch (male), the hardened blanking die (female), and a guide plate
of similar shape/size to the blanking die. The guide plate is the first applied to the
material, impinging the material with a sharp protrusion or stinger around the
perimeter of the die opening. Next a counter pressure is applied opposite the
punch, and finally the die punch forces the material through the die opening. Since
the guide plate holds the material so tightly, and since the counter pressure is
applied, the material is cut in a manner more like extrusion than typical punching.
Mechanical properties of the cut benefit similarly with a hardened layer at the cut
edge from the cold working of the part. Because the material is so tightly held and
controlled in this setup, part flatness remains very true, distortion is nearly
eliminated, and edge burr is minimal. Clearances between the die and punch are
generally around 1% of the cut material thickness, which typically varies between
0.5–13 mm (0.020–0.51 in). Currently parts as thick as 19 mm (0.75 in) can be cut
using fine blanking. Tolerances between ±0.0003–0.002 in (0.0076–0.051 mm) are
possible based on material thickness & tensile strength, and part layout.

With standard compound fine blanking processes, multiple parts can often be
completed in a single operation. Parts can be pierced, partially pierced, offset (up
to 75°), embossed, or coined, often in a single operation. Some combinations may
require progressive fine blanking operations, in which multiple operations are
performed at the same pressing station.
Advantages & disadvantages

The advantages of fine blanking are:

 excellent dimensional control, accuracy, and repeatability through a

production run.
 excellent part flatness is retained.
 straight, superior finished edges to other metal stamping processes.
 smaller holes possible relative to thickness of material.
 little need to machine details.
 multiple features can be added simultaneously in 1 operation.
 more economical for large production runs than traditional operations
when additional machining cost and time are factored in (1000–20000
parts minimum, depending on secondary machining operations)

The disadvantages are:

 slightly higher tooling cost when compared to traditional punching

operations.
 slightly slower than traditional punching operations.
Piercing
Piercing is a shearing process where a punch and die are used to create a hole in
sheet metal or a plate. The process and machinery are usually the same as that used
in blanking, except that the piece being punched out is scrap in the piercing
process. There are many specialized types of piercing: lancing, perforating,
notching, nibbling, shaving, cutoff, and dinking.

The amount of clearance between a punch and die for piercing is governed by the
thickness and strength of the work-piece material being pierced. The punch-die
clearance determines the load or pressure experienced at the cutting edge of the
tool, commonly known as point pressure. Excessive point pressure can lead to
accelerated wear and ultimately failure.

Burr height is typically used as an index to measure tool wear, because it is easy to
measure during production.

For simple piercing operations a pancake die is used.

Specialized types
Lancing

Lancing is the manufacturing process where a piece of material is sheared and bent
in order to make tabs, vents, and louvers. A key part of this process is that there is
not reduction of material, only a modification in its geometry.

There are three key characteristics to the process of lancing: 1. The material is only
modified, nothing is removed.

2. One or more cuts are made, with the remainder being bent to the necessary
angle or curve.

3. Ability to make a special feature in a part using only one cut in the material.
The cut made in lancing is not a closed cut, like in perforation even though a
similar machine is used, but a side is left connected to be bent sharply or in more
of a rounded manner. Mechanical presses are used to perform lancing, commonly

Lancing can be used to make partial contours and free up material for other
operations further down the production line. Along with these reasons lancing is
also used to make tabs (where the material is bent at a 90 degree angle to the
material), vents (where the bend is around 45 degrees), and louvers (where the
piece is rounded or cupped).

Normally lancing is done on a mechanical press, lancing requires the use of

punches and dies to be used. The different punches and dies determine the shape
and angle (or curvature) of the newly made section of the material. The dies and
punches are needed to be made of tool steel to withstand the repetitious nature of
the procedure.

Notching

The notching process removes material from the edge of the workpiece

Nibbling

The nibbling process cuts a contour by producing a series of overlapping slits or

notches. This allows for complex shapes to be formed in sheet metal up to 6 mm
(0.25 in) thick using simple tools. The nibbler is essentially a small punch and die
that reciprocates quickly; around 300–900 times per minute. Punches are available
in various shape and sizes; oblong and rectangular punches are common because
they minimize waste and allow for greater distances between strokes, as compared
to a round punch. Nibbling can occur on the exterior or interior of the material,
however interior cuts require a hole to insert the tool.

The process is often used on parts that do not have quantities that can justify a
dedicated blanking die. The edge smoothness is determined by the shape of the
cutting die and the amount the cuts overlap; naturally the more the cuts overlap the
cleaner the edge. For added accuracy and smoothness most shapes created by
nibbling undergo filing or grinding processes after completion
CONCLUSION
The vocational training at BHEL,Haridwar helped me in improving
practical knowledge and awareness regarding STEAM TURBINE to a
large extent.

Here I came to know about the technology and material used in

manufacturing of steam turbine. Besides this I also visualized the parts
involved or equitment used in general.

Here I learnt about how the turbines are being manufactured and how
they tackle the various problem under different circumstances. At least I
could say that the training at BHEL, haridwar is great Experience for me
in making my knowledge about turbines