A MINI PROJECT REPORT ON STUDY OF CROSS TRAVEL SHAFT IN GAS CUTTING MACHINE UNDER CONTINUOUS CASTING PROCESS Submitted

in partial fulfillment of the requirements for the award of degree of

BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING

Submitted by the project associates

D.ABHINAY KUMAR V.V.SUBBA REDDY R.RAGUNATHA REDDY P.FIROZ KHAN K.KARTHIK R.RAMA KRISHNA

(08L41A0322) (08L41A0335) (08L41A0332) (08L41A0343) (08L41A0301) (08L41A0324)

Under the guidance of Mr.S.K.V.ACHARYULU

Deputy Chief Manager(Mechanical) Continous Casting Department Vizag Steel plant

Mr.T.N KRISHNA MURTHY B.E

Workshop superintendent Mekapati Raja Mohan Reddy Institute of Technology & sciences

Department of Mechanical Engineering

MEKAPATI RAJA MOHAN REDDY INSTITUTE OF TECHNOLOGY & SCIENCE (Affiliated to JNTU Anantapur, Udayagiri, S.P.S.R.Nellore Dt.524226)

MEKAPATI RAJA MOHAN REDDY INSTITUTE OF TECHNOLOGY & SCIENCES

Department of Mechanical Engineering

(Affiliated to JNTU Ananthapur, Udayagiri, S.P.S.R.Nellore Dt.524226)

CERTIFICATE
This is to certify that the mini project report titled STUDY OF CROSS TRAVEL SHAFT IN GAS CUTTING MACHINE UNDER CONTINOUS CASTING PROCESS is being submitted by NAME OF THE STUDENT D.ABHINAY KUMAR V.V SUBBA REDDY P.FIROZ KHAN R.RAGUNATHA REDDY R.RAMAKRISHNA K.KARTHIK REGD.NO 08L41A0322 08L41A0335 08L41A0343 08L41A0332 08L41A0324 08L41A0301

In B.tech III year II semester MECHANICAL ENGINEERING is record bona fide work carried out by them. The results embodied in this report have not been submitted to any other University for the award of any degree.

Mr. T.N KRISHNA MURTHY B.E Workshop superintendent, Mechanical Department, MeRITS, Udayagiri ,

Dr .M.MANOJ KUMAR REDDY Head of the Department, Mechanical Department, MeRITS, Udayagiri,

ACKNOWLEDGEMENT

With great pleasure we want to take this opportunity to express our heartfelt gratitude to all the people who helped in making this mini project work a grand success. First of all we are highly indebted to our Principal Dr V.K.R JEYA SINGH, for giving us permission to carry out this project We would like to thank our Head of the Department Dr. M.MANOJ KUMAR REDDY, for being moral support through the period of study We express our deep sense of gratitude to Mr. T.N KRISHNA MURTHY in Mechanical department for his valuable guidance and suggestions without which we could not have completed the project

We are glad to express our sincere thanks to Mr.S.K.V ACHARYULU, Deputy Chief Manager of Continuous Casting Department

Finally I would like to thank all the Teaching & Non teaching staff of Mechanical department for sharing their knowledge with us.

CONTENTS
LIST OF FIGURES ABSTRACT INTRODUCTION TO VISHAKAPATNAM STEEL PLANT 1. STEEL PLANT OVERVIEW 1.1 BACK GROUND 1.2 PRODUCT MIX 1.3 MAJOR PLANT FACILITIES 1.4 MODREN TECHNOLOGY 1.5 RAW MATERIAL LINKAGES 1.6 WATER SUPPLY 2. CONTINOUS CASTING DEPARTMENT 2.1 GENERAL 2.2 B-D BAY (TUNDISH PREPERATION BAY) 2.3 D-F BAY (LADDLE DISTRIBUTION BAY) 2.4 F-H BAY (CASTING BAY) 2.5 H-K BAY (HANDLING AND FINISHING LINE) 2.6 BSY (BLOOM STORAGE YARD) 2.7 DESIGN (BASIS) 2.8 PRODUCTION REQUIREMENTS 2.9 MAIN EQUIPMENT IN CONTINOUS CASTING DEPRTMENT 3. CONTINOUS CASTING PROCESS 3.1 EQUIPMET AND PROCESS REQUIRED 3.2 STARTING OF THE PROCESS 3.3 ADVANTAGES CONTINOUS CASTING MACHINE 4. GAS CUTTING MACHINE 4.1 PRINCIPLE 4.2 TYPES OF GAS CUTTING MACHINE 4.3 OXY FUEL CUTTING 4.4 ELEMETS USED IN GCM 4.5 TOP QUALITY GAS CUTTING 4.6 LIMITATION 4.7 INTIAL SETTINGS FOR GCM 5. ANALYSIS 5.1 PROBLEMS OCCURING IN GAS CUTTING MACHINES 5.2 PROBLEM DEFINITION 5.3 STEPS INVOLVED IN REPLACING CROSS TRAVEL SHAFT 6. MODIFICATION CARRIED OUT 6.1 ADVANTAGE AFTER MODIFICATION CARRIED OUT 7. COST ESTIMATIONS AND SAVINGS CONCLUSION BIBLIOGRAPHY

LIST OF FIGURES Page. No 1. Continuous casting machine (model view)...15 2. TK1.TK2, TK3, TK4 STANDS...15 3. Continuous casting process..19 4. Line diagram of gas cutting machine..21 5. Cutting of blooms by GCM (side view).22 6. Cutting of blooms by GCM (front view)..22 7. Single stage regulator..25 8. Double stage regulator.....25 9. Torch used in GCM (line diagram)..28 10.Torch used in GCM (real view).29 11. Nozzle used in ALBA machine......29 12. Nozzle used in GEGA machine...29 13. Types of flames...30 14.Views of integral shaft..34 15.Modifications carried out in shaft.37 16.Modified shaft.38

ABSTRACT

In steel milling section the blooms coming from the continuous casting machine are cut into reselected bloom lengths by gas cutting machine. During gas cutting the clamping arms stops functioning due to damage of cross travel shaft by high chocking of water and temperature deviations

The damaged cross travel shaft has to be replaced immediately in order to maintain the production process continuously. But in the present production process to replace the cross travel shaft takes 12 hrs of time. Delaying the production for 2 days.

In this project work an attempt is made to reduce the replacing time of the cross travel shaft by modification of cross travel shaft by using chuck nut and modifying the flange so that shaft can be easily detached from the flange. In our observations the time is reduced from 12hrs to 4hrs

INTRODUCTION TO VISHAKAPATNAM STEEL PLANT (VSP)

Vishakhapatnam steel plant, the first coastal based steel plant of India is located 16 km south west of city of destiny i.e., Vishakhapatnam. Best owed with modern technologies, VSP has an installed capacity of 3 million tonnes per annum of liquid steel and 2.656 million tonnes of saleable steel. At VSP there is emphasis on total automation ,seamless integration and efficient up gradation, which result in wide range of long and structural products to meet stringent demands of discerning customers with in India and structural products to meet exalting international quality standards such as JIS,DIN,and BIS,BS etc. VSP has become the first integrated steel plant in the country to be certified to all the three international standards for quality (ISO-9001), for environment management (ISO-14001) and for occupational health and safety (OHSAS-18001). VSP exports quality pig iron and steel products to Sri lanka, Maynmar,Nepal,Middle-east,USA and South East Asia(pig iron).Having a total man power of about 16755 VSP has envisaged a labor productivity of not less than 262 tonnes per year of liquid steel which is best in country and comparable with international levels.

VSP TECHNOLOGY: STATE-OF-THE-ART:

7m tall coke oven batteries with coke dry quenching

Biggest blast furnaces in the country

Bell-less top charging system in the blast furnace

100% slag granulation at the blast furnace cast house

Suppressed combustion LD-gas recovery system

100% continuous casting of liquid steel

"TEMPCORE" & "STELMOR" cooling process in LMMM & WRM respectively

Extensive waste heat recovery systems

Comprehensive pollution control measures

CHAPTER-1 STEEL PLANT OVER VIEW

1.1 BACK GROUND

The decisions of the government of India to set up and integrated steel plant at Vishakhapatnam was announced by the prime minister Indira Gandhi in parliament on 17th April 1970.The site near Balacheruvu creak was chosen by the selection committee and the formal inauguration was done on 20th January 1971 by the prime minister. The Soviets delaminated the DPR prepared by Daustr and offered technical and economic corporation for the same. The Government of India and USSR signed an agreement on June 12, 1979, for corporation setting up the 3.4 millions tonnes integrated steel plant at Vishakhapatnam. In term of this agreement, the earlier, DPR of duster co. was revised jointly by Soviet and Indian design organizations, and a comprehensive revised DPR (CRDPR) for VSP was submitted in November 1980. The project was estimated to cost Rs.3897.28 Crores, based on prices as on 4th quarter of 1981. But during the implementation of VSP.It has been observed that the project cost has been increased substantially over the sanctioned cost, mainly due to price escalations and under provisions in DPR estimates ,In view of this and the critical fund situation, alternatives for implementation of VSP with rationalization of approved concept were studied in 1986.

The rationalization has basically been form the point of view of obtaining the maximum output from the equipment already installed, planned for procurement, achieving higher levels of operational efficiency and labor productivity over what was envisaged earlier. Under the rationalized concept, 3.0 million tonnes of liquid steel is to be produced in a year and the project is estimated to a cost of Rs.5822.17 crores basis on fourth quarter of 1987.

1.2 PRODUCT MIX:

VSP produces angles, channels, bars, wire rods, billets for re rolling. The plant also produces pig iron and 1.44 million tonnes of slag per annum, besides normal bi-products from the coke oven coal chemical plant.

1.3 MAJOR PLANT FACILITIES

VSP has the following major production facilities: 3 Coke oven batteries of 67 ovens each having 41.6 M volume. Sintered machines of 312 M2 areas. 2 blast furnace of 3200 M2 area. Steel melt shop with 3 LD Converters (2 operating and one stand by) of 150 tonnes capacity each and 6Nos. of 4 standard continuous bloom casters. Light and Medium Merchant Mill of 710,000 tonnes per year capacity. Extensive facilities have been provided for repair and maintained as well as manufacture of spare parts. A Power Plant, Acetylene plant, compressed air plant etc. also form part facilities.

1.4 MODREN TECHNOLOGY;

Vishakhapatnam Steel plant is the most sophisticated and modern integrated steel plant in the country. Modern technology has been adopted in many areas of production, some of them for the first time in the country. Among these are: Selective crushing of coal. 7meters tall coke ovens. Dry quenching of coke. On ground blending of Sinter base mix. Conveyor charging and bell less top for blast furnace. 100% continuous casting of liquid steel. Gas expansion turbine for power generation utilizing blast furnace top gas pressure Hot metal desulfurization. Extensive treatment facilities of effluents for ensuring proper environmental protection. Computerization for process control. Sophisticated, high speed and high production rolling mills.

1.5 RAW MATERIAL LINKAGES:

The steel plant is getting its iron ore-lumps and fines from Baliadilla deposits in Madhya Pradesh, blast furnace grade lime stone comes from jaggayyapeta in Andhra Pradesh, SMS grade lime stone from jaisaimer & Goton in Rajastan.Blasts furnace and SMS grade Dolomite from Birmitrapur (Orissa) the khammam deposits in Andhra Pradesh 70% of the coking respectively coal requirements are met by imports through Vishakhapatnam harbor while the balance come from Bengal Bihar area. Coal from Anantha deposits of falcher region in Orissa.

1.6 WATER SUPPLY:

Requirement of water during the peak of construction were of the order 4.5mgd.This was met from the Megadrigaddaand Raiwada schemes of A.P State Government. Operational Water requirements 70mgd. Of the steel plant is met from the Yeleru water supply scheme provided by the AP state government. This involved construction of a storage reservoir at Yeleswaram at a 153 kms long limited canal to plant site apart Kanithi Balancing Reservoir.

CHAPTER-2 CONTINOUS CASTING DEPARTMENT

2.1 GENERAL:

Steel melt shop in Vishakhapatnam has been set up with an annual capacity of 3MT of liquid steel. The shop comprises of 3 converters and six 4strand bloom casters. This shop is located in the north end of the SMS block, the south end is being left for any further expansion. Continuous casting department has been set west of the converter in North-South Direction. All the bays in CCD have set perpendicular to the rail line for steel transfer car.

2.2 B-D BAY (TUNDISH PREPERATION BAY):

Liquid steel in steel ladles is brought from the converter shop to CCD by steel transfer cars on rails. Steel (ladles) travel westward. Steel is rinsed with argon at the rinsing station situated in the tundish preparation bay.

2.3 D-F BAY (LADLE DISTRIBUTION):

After rinsing, the transfer car is moved further toward the west ladle distribution bay. From here the ladle distributing crane lifts the steel ladle and places it on the life and turn stand of the continuous casting machine which is under operation.
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2.4 F-H BAY (CASTING BAY):

All the six nos of four stand bloom casters are located in this bay thats why it is known as casting bay. The molten steel is casted into solid blooms and required lengths are cut down by gas cutting machines and further will be sent to the H-K bay

2.5 H-K BAY (HANDILING AND FINISHING BAY):

The blooms coming out from the GSM will be taken with the help of rotating roller tables and sent to bloom storage yard

2.6 BSY (BLOOM STORAGE YARD):

The blooms will be stacked in bloom storage yard and inspected for any defects further they will be fed to rolling mills.BSY is again sub divided into different bays namely L-M,M-Q,Q-R bays

2.7 DESIGN BASIS:

Steel melt shop of Vishakhapatnam can be classified to two stages. In the first stage. Plant was to produce 1.5MT of liquid steel from 2nos of 150 T converters. While in second stage an additional converter installed to make a total of three converters to produce 3MT of liquid steel .In CCD a two block concept was followed. Accordingly 3bloom casters were provided in first stage while in second stage three more bloom casters were provided
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2.8 PRODUCTION REQUIRMENTS:

Out of 3.0MT of liquid steel, 1.915MT of liquid steel is used to produce cast blooms of cross section (250x320) and 0.905MT are used to produce cast blooms of cross section (250x250).

2.9 MAIN EQUIPENTS IN CONTINOUS CASTING:

A) Lift & Turn Stand B) Tundish c) Tundish car D) Mould E) MOM (Mould Oscillating Mechanism) F) Section G) N1 Cassette H) TK1 Stand I) Dummy bar J) DBHM K) N2 Cassette M) Roller Table N) GCM
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Lift and Turn Stand (L & T Stand): Lift and Turn stand is basically used for the continuity of the casting. It is having lifting-lowering as well as rotating mechanisms. As soon as the metal in casting ladle is exhausted, the spare steel ladle is taken on to the casting position and the casting will be continued. The ladle opening and closing is done through a slide gate mechanism. TK1 STAND: It is the first with drawl stand having two top rollers cassette can be lifter/lowered with the help of a hydraulic cylinder. The TK1 stand is mainly used to hold the dummy bar before the start of casting. DUMMY BAR: It is a solid chain having 23 links mainly used to hold the metal in the mould and supporting at the start of casting. DBHM (Dummy Bar Handling Mechanism): Dummy bar handling mechanism is used to take out the Dummy bar from the machine and parking on the conveyor system and reinsertion during machine preparation. N1 CASETTE: After secondary cooling, hot blooms will enter in to N1 cassette where additional cooling zone (Zone-4) is provided. Zone-4 is used at higher casting speeds.N1 Cassette will also give support for the hot blooms. TK2 STAND: It is the second withdrawal stand which will help in the drawl of the dummy bar. It is usually in the lifted condition during casting.
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TK3 STAND: It is third stand which will help in the withdrawal of the dummy bar as well as the hot blooms. It is lowered in condition during casting. TUNDISH: The steel metal from the ladle is taken in to an intermittent vessel called Tundish. It is refractory and can give maximum life of 5-6 heats. TUNDISH CAR: It is mainly used to hold the tundish. There will be two cars for each machine one for the casting and the other for the hot standby. MOULD: The metal from the tundish is taken in to four nos of copper moulds with the help of stopper rod mechanisms. In mould basically primary cooling takes place and outer shell will be found.

MOM (Mould Oscillating Mechanism): Mould oscillating mechanism is used for the oscillation of mould. It is having an eccentric mechanism at 9.1 mt with which it will oscillate with a stroke of 6-8 mm. SECTION: After primary cooling in the mould, metal will enter in to secondary cooling zone where direct water spray will takes place. The stream generated due to the water spray over the hot blooms will be taken out with the help of two nos of steam exhausters located at 9.1 mt level on each side of the machine.
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N2 CASETTE: Hot blooms form TK1 stand will enter in to N2 cassette where radiation cooling (Tertiary cooling) takes place. N2 cassette also gives support for the blooms. TK4 STAND: It is the fourth with drawl stand which will help in the withdrawal of the dummy bar as well as the hot blooms. It is lowered in condition during casting. ROLLER TABELS: The rotating roller tables are mainly used for the transfer of the blooms from the Radial part (TK1, TK2, TK3, and TK4) in to GCM GCM: Gas cutting machine cuts the casted blooms into selected sizes generally employed sizes are 6 Meters.LPG gas combined with oxygen is generally employed for cutting

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CHAPTER -3 CONTINUOUS CASTING PROCESS

Continuous casting, also called strand casting, is the process whereby molten metal is solidified into a "semi finished" billet, bloom, or slab for subsequent rolling in the finishing mills. Prior to the introduction of continuous casting in the 1950s, steel was poured into stationary molds to form ingots. Since then, "continuous casting" has evolved to achieve improved yield, quality, productivity and cost efficiency. It allows lower-cost production of metal sections with better quality, due to the inherently lower costs of continuous, standardized production of a product, as well as providing increased control over the process through automation. This process is used most frequently to cast steel (in terms of tonnage cast). Aluminum and copper are also continuously cast. 3.1 EQUIPEMENT AND PROCESS:

Molten metal known as hot metal in industry is tapped into the ladle from furnaces. After undergoing any ladle treatments, such as alloying and degassing, and arriving at the correct temperature, the ladle is transported to the top of the casting machine. Usually the ladle sits in a slot on a rotating turret at the casting machine. One ladle is 'on cast' (feeding the casting machine) while the other is made ready, and is switched to the casting position when the first ladle is empty. From the ladle, the hot metal is transferred via a refractory shroud (pipe) to a holding bath called a tundish. The tundish allows a reservoir of metal to feed the casting machine while ladles are switched, thus acting as a buffer of hot metal, as well as smoothing out flow, regulating metal feed to the molds and cleaning the metal
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Metal is drained from the tundish through another shroud into the top of an open-base copper mold. The depth of the mold can range from 0.5 to 2 meters (20 to 79 in), depending on the casting speed and section size. The mold is water-cooled to solidify the hot metal directly in contact with it; this is the primary cooling process. It also oscillates vertically (or in a near vertical curved path) to prevent the metal sticking to the mold walls. A lubricant can also be added to the metal in the mold to prevent sticking, and to trap any slag particles including oxide particles or scale that may be present in the metal and bring them to the top of the pool to form a floating layer of slag. Often, the shroud is set so the hot metal exits it below the surface of the slag layer in the mold and is thus called a submerged entry nozzle (SEN). In some cases, shrouds may not be used between tundish and mold; in this case, interchangeable metering nozzles in the base of the tundish direct the metal into the moulds. Some continuous casting layouts feed several molds from the same tundish. In the mold, a thin shell of metal next to the mold walls solidifies before the middle section, now called a strand, exits the base of the mold into a spray chamber. The bulk of metal within the walls of the strand is still molten. The strand is immediately supported by closely spaced, water cooled rollers which support the walls of the strand against the Ferro static pressure (compare hydrostatic pressure) of the still-solidifying liquid within the strand. To increase the rate of solidification, the strand is sprayed with large amounts of water as it passes through the spray-chamber; this is the secondary cooling process. Final solidification of the strand may take place after the strand has exited the spraychamber.
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In a radial casting machine, the strand exits the mold vertically (or on a near vertical curved path) and as it travels through the spray chamber, the rollers gradually curve the strand towards the horizontal.

fig 1. Continuous casting machine (model view)

Fig2. TK1, TK2, TK3, TK4 STANDS

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3.2 STARTING OF THE PROCESS: Starting a continuous casting machine involves placing a dummy bar (essentially a curved metal beam) up through the spray chamber to close off the base of the mould. Metal is poured into the mould and withdrawn with the dummy bar once it solidifies. It is extremely important that the metal supply afterwards be guaranteed to avoid unnecessary shutdowns and restarts, known as 'turnarounds'. Each time the caster stops and restarts a new tundish is required, as any uncast metal in the tundish cannot be drained and instead freezes into a 'skull'. Avoiding turnarounds requires the melt shop, including ladle furnaces (if any) to keep tight control on the temperature of the metal, which can vary dramatically with alloying additions, slag cover and dis-lagging, and the preheating of the ladle before it accepts metal, among other parameters. However, the cast rate may be lowered by reducing the amount of metal in the tundish (although this can increase wear on the tundish), or if the caster has multiple strands, one or more strands may be shut down to accommodate upstream delays. Turnarounds may be scheduled into a production sequence if the tundish temperature becomes too high after a certain number of heats. Continuous casting operations are now fully computer-controlled. Several electromagnetic and thermal sensors in the ladle shroud, tundish and mould sense the metal level or weight, flow rate and temperature of the hot metal and the programmable logic controller (PLC) can set the rate of strand withdrawal via speed control of the withdrawal rolls.

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The flow of metal into the moulds can be controlled via two methods: By slide gates or stopper rods at the top of the mould shrouds If the metal is open-poured, then the metal flow into the moulds is controlled solely by the internal diameter of the metering nozzles. These nozzles are usually interchangeable.

Overall casting speed can be adjusted by altering the amount of metal in the tundish, via the ladle slide gate. The PLC can also set the mould oscillation rate and the rate of mould powder feed, as well as the spray water flow. Computer control also allows vital casting data to be repeated to other manufacturing centers (particularly the steelmaking furnaces), allowing their work rates to be adjusted to avoid 'overflow' or 'under run' of product. The strand is then withdrawn through a set of guiding rolls and further cooled by spraying with a fine water mist. The solidified shell continues to thicken until the strand is fully solidified. Finally, the strand is cut into desired lengths by using gas cutting machines or any other cutting methods and these are either discharged to a storage area or to the hot rolling mill. In Vishakhapatnam steel plant Strand that are produced are blooms A wide range of strand dimensions can be cast depending on final application: slabs for flat products such as plate and strip, blooms for sections such as beams, and billets for long products such as wire. Techniques have also been developed to cast steel directly to thin strip (<3 mm thick) and cast strip is now available commercially.

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3.3 ADVANTAGES CONTINOUS CASTING MACHINE OVER OTHER MOULDS: More consistent composition and dimension. Better surface and internal quality. Higher yield. Energy savings. Less labor intensive.

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BRIEFING OF PROCESS:

FIG 3.CONTINOUS CASTING PROCESS 1) Before casting begins a dummy bar is used to close the bottom of the mould. 2) A ladle of molten steel is lifted above the casting machine and a hole in the bottom of the ladle is opened, allowing the liquid steel to pour into the mould to form the required shape. 3) As the steel's outer surface solidifies in the mould, the dummy bar is slowly withdrawn through the machine, pulling the steel with it. 4) Water sprays along the machine to cool/solidify the steel. 5) At the end of the machine, the steel is cut to the required length by gas torches.

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CHAPTER- 4 GAS CUTTING MACHINE (GCM)

4.1 PRINCIPLE:

The blooms that are coming out from the mould are cut down into required lengths by using gas torches which are technically known as gas cutting machine. This cutting is process is particularly suitable for steels. The basic reaction with steel is: Fe (ferrous) +O (oxygen)FeO+heat 2Fe (ferrous)+2O2(oxygen) Fe3O4+heat 4Fe (ferrous)+3O2(oxygen) 2Fe2O3+heat

The greatest heats produced by the second reaction, and it can produce a temperature up to 1800 oc. Cutting mainly occurs by the oxidation (burning of steel)

4.2 TYPES OF GCM:

There are mainly two types of gas cutting machines generally employed for steel cutting they are: 1. ALBA(Gas Cutting Machine) 2. GEGA(Gas Cutting Machine)
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As because of ALBA (Gas Cutting Machine) rather advantageous than GEGA (Gas Cutting Machine) hence Mostly ALBA gas cutting machines is employed for steel cutting.

4.3 OXY-FUEL CUTTING:

The major operation involved in gas cutting machine is oxy-fuel cutting, in generally acetylene is used for along with oxygen, but for cutting steels mostly Liquefied petroleum gas (LPG) is used along with oxygen as to prevent chemical reaction with steel and also give clear cut as that of acetylene Oxy-fuel cutting is a chemical reaction between pure oxygen and steel to form iron oxide. It can be described as rapid, controlled rusting. Preheat flames are used to raise the surface or edge of the steel to approximately 1800F (bright red color). Pure oxygen is then directed toward the heated area in a fine, high pressure stream. As the steel is oxidized and blown away to form a cavity, the preheat and oxygen stream are moved at constant speed to form a continuous cut. In oxy-fuel cutting, a cutting torch is used to heat metal to kindling temperature. A stream of oxygen is then trained on the metal and metal burns in that oxygen and then flows out of the cut (kerf) as an oxide slag. Torches that do not mix fuel with oxygen (combining, instead, atmospheric air) are not considered oxy-fuel torches and can typically be identified by a single tank (Oxy-fuel welding/cutting generally requires two tanks, fuel and oxygen). Most metals cannot be melted with a single-tank torch. As such, singletank torches are typically used only for soldering and brazing, rather than welding.
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Oxygen is not the fuel. It is what chemically combines with the fuel to produce the heat for cutting.. In the case of hydrogen, the product of combustion is simply water. For the other hydrocarbon fuels, water and carbon dioxide are produced. The heat is released because the molecules of the products of combustion have a lower energy state than the molecules of the fuel and oxygen. In oxy-fuel cutting, oxidation of the metal being cut (typically iron) produces nearly all of the heat required to "burn" through the work piece.

Fig 4. Line diagram of gas cutting machine

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Fig 5.CUTTING OF BLOOMS BY GCM (side view)

Fig 6.CUTTING OF BLOOMS BY GCM (front view) 23

4.4 ELEMENTS USED IN GCM: 1. Regulator 2. Gas hoses 3. Non return value 4. Check value 5. Cutting Torches REGULATOR:
The regulator is used to control pressure from the tanks to the required pressure in the hose. The flow rate is then adjusted by the operator using needle valves on the torch. Accurate flow control with a needle valve relies on a constant inlet pressure to it. Most regulators have two stages: the first stage of the regulator is a fixed-pressure regulator whose function is to release the gas from the cylinder at a constant intermediate pressure, despite the pressure in the cylinder falling as the gas in the cylinder is used. This is similar to the first stage of a scuba diving regulator. The adjustable second stage of the regulator controls the pressure reduction from the intermediate pressure to the low outlet pressure. The regulator has two pressure gauges, one indicating cylinder pressure, and the other indicating hose pressure. The adjustment knob of the regulator is sometimes roughly calibrated for pressure, but an accurate setting requires observation of the gauge. Some simpler or cheaper oxygen-fuel regulators have only a single stage regulator, or only a single gauge. A single-stage regulator will tend to reduce its outlet pressure as the cylinder is emptied, requiring manual readjustment. For lowvolume users, this is an acceptable simplification.
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Fig 7. SINGLE STAGE REGULATOR

Fig 8. DOUBLE STAGE REGULATOR

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GAS HOSES: A gas hose is a hose that is made for the specific purposes of carrying gases from one point to another with as little leakage as possible. A hose is a flexible, cylindrical tube that is used for containing various substances. Making and selecting a gas hose poses specific challenges to those who need to do so, as gas particles are often very small and mobile and can easily leak out of the smallest gap. This is particularly bad when the gas or gases carried by the hose are flammable or explosive; this in particular can be a major issue in labs and major industries. These hoses are specifically designed for welding and cutting. The hose is usually a double-hose design, meaning that there are two hoses joined together. These hoses are color-coded for visual identification and their threaded connectors are handed to avoid accidental mis-connection: oxygen is right-handed as normal, fuel gases use a left-handed thread. These left-handed threads also have an identifying groove cut into their nuts. Connections between flexible hoses and rigid fittings are made by a crimped hose clip over a barbed spigot.

NON RETURN VALUE: LPG is not just flammable, it is also a high explosive; it has no upper flammability limit, and the LPG hose needs no oxygen to power an explosion. If a detonation wave enters the LPG tank, the tank will be blown apart by the decomposition. Ordinary check valves that normally prevent back flow cannot stop a detonation wave as they are not capable of closing before the wave passes around the gate, and for that reason a flashback arrestor is needed.

It is designed to operate before the detonation wave makes it from the hose side to the supply side. Between the regulator and hose, and ideally between hose and torch on both oxygen and fuel lines, a flashback arrestor and/or non-return valve (check valve) should be installed to prevent flame or oxygen-fuel mixture being pushed back into either cylinder and damaging the equipment or making a cylinder explode. European practice is to fit flashback arrestors at the regulator and check valves at the torch. US practice is to fit both at the regulator. The flashback arrestor (not to be confused with a check valve) prevents the shock waves from downstream coming back up the hoses and entering the cylinder (possibly rupturing it), as there are quantities of fuel/oxygen mixtures inside parts of the equipment (specifically within the mixer and blowpipe/nozzle) that may explode if the equipment is incorrectly shut down; and acetylene decomposes at excessive pressures or temperatures. The flashback arrestor will remain switched off until someone resets it, in case the pressure wave created a leak downstream of the arrestor.

CHECK VALUE: A check valve lets gas flow in one direction only. Not to be confused with a flashback arrestor, a check valve is not designed to block a shock wave. The pressure wave could occur while the ball is so far from the inlet that the pressure wave gets past before the ball reaches its off position. A check valve is usually a chamber containing a ball that is pressed against one end by a spring: gas flow one way pushes the ball out of the way, and no flow or flow the other way lets the spring push the ball into the inlet thus blocking the flow.
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CUTTING TORCH: A cutting torch head is used to cut materials. It is similar to a welding torch, but can be identified by the oxygen blow out trigger or lever. The metal which is already in cherry red. Once oxygen is supplied to the heated parts by pressing the "oxygen-blast trigger". This oxygen reacts with the metal, forming iron oxide and producing heat. It is this heat which continues the cutting process. A nozzle is connected to the cutting torch that directs the oxy-fuel flame at point providing a smooth cut.

fig 9. Torch used for continuous casting (line diagram)

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Fig10. Torch used in gas cutting machine (real view)

Fig11. Nozzle used along with torch in ALBA MACHINE

Fig 12.Nozzle use along with the torch in GEGE machine

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The melting point of the iron oxide is around half of that of the metal; as the metal burns, it immediately turns to liquid iron oxide and flows away from the cutting zone. However, some of the iron oxide remains on the work piece, forming a hard "slag" which can be removed by gentle tapping, and/or a grinder

(A)

(B)

(c)

(D)

Fig 13. Types of flames employed by using different nozzles

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4.5 TOP QUALITY GAS CUTTING: Square top corner (with minimum radius) Cut face flat top to bottom (no undercut) Cut face square with respect to top surface Clean smooth surface with near vertical drag lines, and Little to no slag on bottom edge (easily removed by scraping)

4.6 LIMITATIONS: Only metals whose oxides have a lower melting point than the base metal itself can be cut with this process. Otherwise as soon as the metal oxidizes it terminates the oxidation by forming a protective crust. Only low carbon steel and some low alloys meet the above condition and can be cut effectively with the oxy-fuel process.

4.7 INTIAL SETTINGS FOR GEGA MACHINE: Cutting speed: 50800 mm/min depending on material Temperature: up to 900 C

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CHAPTER- 5 ANALYSIS

5.1 PROBLEMS OCCURING IN GAS CUTTING MACHINES: Failure of working of clamping arms due to high choking of water and temperature deviation. Failure of working of torch nozzles due to accumulation of carbon particles As LPG gas is used which is flammable continuous inspection on fuel leakages must be carried out. The ratio of fuel supply to oxygen is difficult to maintain constant. Regular replacement of troches and nozzles occur.

5.2 PROBLEM DEFINITION: The major problem that occurs in gas cutting machines is that failure of clamping arms, because of high choking of water and temperature deviation. As the water which is supplied for cooling produces a heavy pressure on the cross travel shaft in gas cutting machine and temperature deviation causes damages the cross travel shaft

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As the shaft is damaged the clamping arms stops functioning so in order to continue the production the shaft must be replaced immediately. But replacing the shaft takes nearly 12 hours resulting in the delay of production for 2 days. So to keep up with the production a new shaft must be replaced immediately.

5.3 STEPS INVOLVED IN REPLACING CROSS TRAVEL SHAFT: 1. Initially the production in the continuous casting is to be shut down.

2. Then the pressure levels are lowered down in the regulators.

3. The water supply is to be stopped for time being. 4. The gas cutting machines skeleton is to be removed and machine is visualized carefully.

5. The machine is inspected in case of any further damage.

6. The components surrounding the shaft must be removed

7. Then the cross travel is replaced by a new one.

8. Then again the GCM is reassembled and is ready to use

The replacing of cross travel shaft is time consuming process as it takes nearly 12 hrs to replace a new shaft. Therefore our aim of the project is to reduce the replacement time as much as possible
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Side view of the shaft

front view of the shaft

Integral shaft

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CHAPTER -6 MODIFICATION CARRIED OUT

As we know that the cross travel shaft which is damaged must be replaced. In actual practice the shaft is an integral part with the flange hence both must be removed and it is complicate to remove the shaft and flange because of the other surrounding parts. Therefore the cross travel shaft is modified such that shaft consists of a detachable flange with square cross section fixed with chuck nut. STEPS INVOLVED IN REPLACING CROSS TRAVEL SHAFT (AFTER MODIFICATION): 1. Initially the production in the continuous casting is to be shut down.

2. Then the pressure levels are lowered down in the regulators.

3. The water supply is to be stopped for time being 4. The gas cutting machines skeleton is to be removed and machine is visualized carefully.

5. The machine is inspected in case of any further damage.

6. Then the chuck nut and bolt is removed so that shat detaches from flange and it is removed and replaced by new one.
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ADVANTAGE AFTER MODIFICATION: In out detail observation we observed that the modification had reduced the replacement time to 4 hrs from 12hrs.By doing this, we have Increased the rate of production of the ingots. Economical consumption is reduced. Maintenance cost is reduced. Replacement time is reduced to half.

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Modified flange with square hole

Side view of the shaft

front view of the shaft

Top view of the nut

side view of the nut

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MODIFIED SHAFT

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CHAPTER -7

COST ESTIMATIONS AND SAVINGS:

The replacement cost before modification for a shaft is to be around Rs 12000, but after the modification the cost has been reduced to Rs 4000. Thus making a saving of Rs 8000 per stand.

Total no. of stands in each casting machine = 4; Total savings per machine of 4 stands at the rate of RS 8000 per stand is Rs 32000(4X8000).

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CONCLUSION

In this project work an attempt is made to reduce the replacing time of the cross travel shaft by modification of cross travel shaft by using chuck nut and modifying the flange. So that can be easily detached from the flange. In our practical observation the replacement time of the shaft has been reduced from 12 hrs to 4 hrs, thus by doing so the production rate can be improved greatly. Not only has the maintenance cost required for replacing the shaft has been greatly reduced. Hence the modification had finally served its purpose

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BIBLIGROPHY

1. SERPOPE KALPAKJIAN &STEVEN R.SCHMID,MANUFACTURING ENGINEERING AND TECHNOLOGY,FOURTH EDITION

2. http://en.wikipedia.org/wiki/Oxy-fuel_welding_and_cutting 3. http://www.albacut.com/CUTTING-TIPS.html 4. http://www.gega.de/153-1-products.html