INTRODUCTION
eavy Mechanical Complex (Private) Limited is a leading engineering goods manufacturing enterprise in Pakistan located at Taxila about 30 Kilometers north of capital Islamabad. It is a professionally managed progressive organization with over 160,000 sq. meters covered facilities and 1,100 employees.
H
HMC have the resources to handle large projects with demanding delivery schedules. Being the largest and most extensive fabrication and machining facility equipped with state of the art technology. HMC provide manufacturing services both on our own or customers design.
HMC have gained rich experience in designing and manufacturing of large projects through collaboration with internationally reputed engineering organizations. All its processing facilities are in-house including Designing, Fabrication, Machining, Iron and Steel Castings, Forgings, Heat Treatment, Assembly, Sand Blasting, Painting and Galvanizing etc.
HMC is ISO 9001 certified and is authorized to use 4 ASME stamps U, U2, S & PP for equipment manufactured according to ASME code. The manufacturing is backed by excellent quality control and testing facilities to meet the product and customer quality requirements. 3rd party inspection facilities are also available, where required.
Heavy Mechanical Complex Ltd. (HMC), Taxila is a major heavy engineering subsidiary of the State Engineering Corporation (SEC) under the Ministry of Industries & Production, Government of Pakistan.
HMC defines itself as “A technical institute in which all types of machines including Sugar plants, Cement Plants, Road rollers, Over Head Cranes ranging from 0.5 to 50 tons Heat Exchanger boilers, Special Defense parts (i.e., NDC works), Special Vibratory Rollers (which can bear statistically 10 to 12 tons vibratory load) and Pakistan steel
works. Some other processes that are also done by HMC are Designing and manufacturing and assembling and installation with the certification of ISO – 9001.
The Heavy Mechanical Complex (HMC), the biggest undertaking of its type in Pakistan, was established in 1979 with Chinese assistance. The Heavy Forge Factory (HFF) at this complex has
proved crucial for Pakistan's defense production needs. HMC has the capability for designing, engineering and manufacturing of industrial plants and machinery. HMC has the largest fabrication and machining facilities in the country equipped with Computer Aided Designing (CAD) and can undertake a variety of fabrication / machining jobs on sub-contracting basis. HMC manufactures equipment for hydro-electric power plants, thermal power plants, sulphuric acid plants, industrial alcohol plants, oil & gas processing plants, and chemical & petro-chemical plants, etc. Boilers, cranes, construction machinery, material handling equipment, steel structure, railway equipment, etc. are some of the other products which are produced on regular basis. The company's capabilities include engineering and manufacturing of Sugar Mills ranging between 1,500 - 12,000 TCD (tons of cane crushing capacity per day), Portland Cement Plants of 700- 5,500 TPD (tons per day) module and White Cement Plant of 50 - 1,000 TPD.
WORKING STAFF
HMC is a professionally managed progressive organization with 1,100 employees. HMC has a total covered area of 160,000 square feet.
FACTORIES AT HEAVY MECHANICAL COMPLEX
Heavy mechanical complex I (HMC I) Heavy forge and foundry works (HMC II)
Heavy mechanical complex III (HMC III)
Of these the last one is directly under the ministry of defense while the former two are governed by ministry of production.
QUALITY POLICY OF HMC
HMC states its quality policy as follows:“Quality performance is committed to excellence by each company employee. It is achieved by team work and through a process of continuous improvement.”
“We are dedicated to being seen as an organization which provides quality products and services which meet or exceed the expectations of our customers.”
FACILITIES AT HMC
There are several shops in HMC industry. ✔ Design department
✔ Production planning and control (PPC)
✔ Sales department /(PMD i.e. Project Management Department)
✔ Accounts Finance and Administration
✔ Machine shop
✔ Heat treatment shop
✔ Fabrication shop
✔ Forging shop
✔ Hydraulic press shop
✔ Steel foundry
✔ Cast iron foundry
✔ Pattern shop
✔ Maintenance shop
✔ Quality control
PRODUCTION CAPACITY
Machining capacity = 500ton *12 monthsFabrication and Machining capacity= 1000ton *12months Total = 500*12 + 1000*12 = 6000 tons per annum
This production capacity can be increased time to time with the extension of man power and other sources subjecting to sub contractors.
HMC specializes in Engineering, Designing, Manufacturing, Installation and Commissioning of plants and machinery including;
Cement Plant and Spares: 600-5000 TPD Sugar Plant and Spares: 500-12000 TCD
Process Plant Equipment: Pressure Vessels, Columns, Heat Exchangers, Drums, Storage Tanks
and Kilns
Chemical & Petro-Chemical Plants: Sulphuric Acid Plant, Basic Chromium Sulphate Plant,
Industrial Alcohol distillery, Gas Dehydration, LPG/LNG, Gas Purification & Sulphur Recovery Plants.
Industrial Boilers: Fire tube Package units, water tube package units, heat recovery boilers,
begasse fire boilers (capacity up to 200 T/hr
Thermal Power Plants: Equipment for utility boilers, membrane wall, turbine/generator parts. Hydral Power Plants: Gates, penstocks, wicket gates, head covers, turbine/generator parts Cranes: Electric overhead travelling crane, portal & mobile cranes.
Road Construction Machinery: Static & vibratory road rollers, asphalt mixing plant. Steel Structures: For thermal power plants, process plants etc.
Railways Equipment: Railway axles, surface troverser, screw coupling & screw jack. Castings: Iron & steel castings as per specifications
Forgings: Shafts, rings and others as per specifications Automotive Forging: For tractors and other automobile
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PRODUCTION PLANNING & CONTROL
The PPC department has been organized with the objective of improving company’s performance. The dept is headed by a Dy. GM incharge PPC and comprises of the following sections:
Core planning / Data processing
Material management
A. Material management section (MMG)
B. General store
Production technology
A. Feasibility / quantitative detail
B. Process planning
C. Tool designing
Dispatch cell / Material handling
A. Material handling store (MHC)
B. Dispatch cell
Income tax custom rebate (ICR)
1. SALES ORDER NUMBERING SYSTEM
The sales order numbering system allocates a unique identification system to each order acquired by the sales and marketing department. This sales order consists of six digits. The first two of these numbers designate the product group number of the products to be manufactured or services to be provided by the organization. The next two digits specify the fiscal year in which the order is received and the last two digits give the number of similar orders already received in the same fiscal year.
For example, a job order given as 11-10-04 is read as follows 11_______ product group no for sugar spares
10_______represents 2010 as the fiscal year
04_______specifies the fourth order for the current year That is fourth order of sugar spares in 2010.
2. CORE PLANNING SECTION
Master schedule planning
Monitoring all schedules / shop scheduling
Preparing various reports for MIS
Maintenance of balance order position.
Monthly sales and production reports
Sales / production budget.
Project review. Meeting and follow up.
Data entry, loading data and processing data
3. PROJECT PLANNING SECTION
To ensure receipts of all drawings and documentation from design as per contact
and accelerate the schedule for production and procurement. To issue “material purchase requirement” to MMG.
To prepare “bill of material” to be purchased.
To co ordinate with the production technology for preparation of necessary
documents for production.
To prepare and issue job orders and follow up.
To suggest alternate materials from stock to design.
To prepare data and reports for ICR and for survey by CBR.
4. MATERIAL MANAGEMENT
A. MMG Section:
Material requirement planning.
Indenting and follow up of indents.
To keep update purchase status for all the project demands.
Establish stock levels for general consumable items and raw materials.
Issuance of materials to the appropriate job.
To keep and maintain update levels for the store items.
B. General Store:
To receive, issue all the materials, and equipment in stotes as per laid down
procedure.
Maintain detailed record of store movements.
Maintain stock location system.
Maintain daily submission of issue and receipt statement to concerned dept.to keep
store areas secure and organized.
5. PRODUCTION TECHNOLOGY
Feasibility/Quantitative Detail:
Feasibility study and quantitative details of clients requirements for cost estimate.
Process Planning:
Prepare details per list, route cards, cutting plans, time sheets and process maps for
all the processes.
Tool Designing:
Designing of all types of press tools, dies, templates, jigs and fixtures.
Prepare drawings for machinery components, cutting planes, marking templates for
shops etc.
6. DISPACH CELL
To receive finished jobs from shops.
To draw standard items from store for dispatch to customer.
To organize packing etc.
To organize transportation.
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MACHINE SHOP
Machine shop at HMC
has following machines Gear shaper machine Straight bevel machine
Gear hobbing machine
Vertical turret lathe machine
Horizontal lathe machine
Horizontal vertical slope type boring and milling machine.
Universal boring, milling, facing, threading, taping machine.
Plano milling machine.
Horizontal boring machine.
Redial drilling machine.
Gear shaper tool machine
Slotting machine
BVT boring vertical turret machine
Face plat lathe machine.
Double housing planne
Vertical milling machine.
Gear Shaper
A gear shaper is a machine tool for cutting the teeth of internal or external gears. The name shaper relates to the fact that the cutter engages the part on the forward stroke and pulls away from the part on the return stroke, just like the clapper box on a planer shaper. To cut external teeth, a different machine called a hobbing machine can be used.
Spur Gears
They connect parallel shafts, have involute teeth that are parallel to the shaft and can have internal or external teeth. They cause no external thrust between gears. They are inexpensive to manufacture. They give lower but satisfactory performance. They are used when shaft rotates in the same plane.
Helical Gears
Helical gears connect parallel shifts but the involute teeth are cut at an angle to the axis of rotation. Two mating helical gears must have equal helix angle but opposite hand. They run smoother and more quietly. They have higher load capacity, are more expensive to manufacture and create axial thrust. They have longer and strong teeth. They can carry heavy load because of the greater surface contact with the teeth. The efficiency is also reduced because of longer surface contact. The gearing is quieter with less vibration.
Internal Gears
Internal gears are hollow. The properties and teeth shape is similar as of external gears except that the internal gear had different addendum and dedendum values modified to prevent
interference in internal meshes. They are designed to accommodate a wide range of equipment. These are ideal and cost effective. The teeth are cut into the inside diameter while the outside diameter is smooth. These gears are available only in brass. Internal gear offers low sliding and high stress loading. They are used in planetary gears to produce large reduction ratios.
When choosing a mating gear the difference between the number of teeth of girth gear and the pinion should not be less than 15. Their non-binding tooth design ensures smooth, quiet operation. They are used to transmit rotary motion between parallel shafts, the shaft rotating in the same direction as the arrangement.
Worm Gears
The Worm gear is the heart of most mills and kiln drive system. They can't be used in spare parts inventory. They are also used in steel industry, sugar industry, paper and pulp industry. The girth gear has been preferred over the gearless drives due to their lower initial cost, simplicity to install, operate and maintain.
Hobbing
Hobbing is a machining process for making gears, on a hobbing machine, which is a special type
of milling machine .The teeth or spines are progressively cut into the workpiece by a series of cuts made by a cutting tools called a hob. Compared to other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities.
It is the most widely used gear cutting process for creating spur and helical gearsand more gears are cut by hobbing than any other process since it is relatively quick and inexpensive.
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HEAT TREATMENT AND TTC (TECHNICAL
TRAINING CELL)
Heat Treatment – The Processes
• Annealing • Normalizing • Hardening Surface Full Case • Tempering • Stress releasing • Carburizing Gas Pack • PhosphatingHeat treatment
“Heat Treatment is the controlled heating and cooling of metals to alter their physical and mechanical properties without changing the product shape.”
Annealing
Annealing, in metallurgy and materials science, is a heat treatment wherein a material is altered, causing changes in its properties such as strength and hardness. It is a process that produces conditions by heating to above the re-crystallization temperature and maintaining a suitable temperature, and then cooling. Annealing is used to induce ductility, soften material, relieve internal stresses, refine the structure by making it homogeneous, and improve cold working properties.
Annealing, in metallurgy and materials science, is a heat treatment wherein a material is altered, causing changes in its properties such as strength and hardness. It is a process that produces conditions by heating to above the re-crystallization temperature and maintaining a suitable temperature, and then cooling. Annealing is used to induce ductility, soften material, relieve internal stresses, refine the structure by making it homogeneous, and improve cold working properties.
In the cases of copper, steel, silver, and brass this process is performed by substantially heating the material (generally until glowing) for a while and allowing it to cool slowly. In this fashion the metal is softened and prepared for further work such as shaping, stamping, or forming.
Hardening
Flame Hardening:
A high intensity oxy-acetylene flame is applied to the selective region. The temperature is raised high. The "right" temperature is determined by the operator based on experience by watching the color of the steel. The overall heat transfer is limited by the torch and thus the interior never reaches the high temperature. The heated region is quenched to achieve the desired hardness. Tempering can be done to eliminate brittleness.
Induction Hardening:
In Induction hardening, the steel part is placed inside a electrical coil which has alternating current through it. This energizes the steel part and heats it up. Depending on the frequency and amperage, the rate of heating as well as the depth of heating can be controlled. Hence, this is well suited for surface heat treatment. The Induction and flame hardening processes protect areas exposed to excessive wear.
Items that we induction harden include Spur Gears and Spur Pinions ,Helical Gears and Helical Pinions ,Sprockets ,Internal Gears ,Bevel Gears ,Shafts and Pins ,Rails and Racks ,Wheels and Rollers Sheave Wheels ,Links ,Axle Boxes and Bushes ,
Tempering:
Tempering is a heat treatment technique for metals, alloys and glass. In steels, tempering is done to "toughen" the metal by transforming brittle martensite into bainite or a combination of ferrite and cementite. Precipitation hardening alloys, like many grades of aluminum and superalloys, are tempered to precipitate intermetallic particles which strengthen the metal. Tempering is accomplished by a controlled reheating of the work piece to a temperature below its lower critical temperature.
The brittle martensite becomes strong and ductile after it is tempered. Carbon atoms were trapped in the austenite when it was rapidly cooled, typically by oil or water quenching, forming the martensite. The martensite becomes strong after being tempered because when reheated, the microstructure can rearrange and the carbon atoms can diffuse out of the distorted BCT structure. After the carbon diffuses, the result is nearly pure ferrite.
Stress Releasing:
stress releasing is used to reduce residual stresses in large castings, welded parts and cold-formed parts. Such parts tend to have stresses due to thermal cycling or work hardening. Parts are heated to temperatures of up to 600 - 650 ºC (1112 - 1202 ºF), and held for an extended time (about 1 hour or more) and then slowly cooled in still air
Carburizing:
Carburizing, also known as carburization, is a heat treatment process in which iron or steel is heated in the presence of another material (but below the metal's melting point) which liberates carbon as it decomposes. The outer surface or case will have higher carbon content than the original material. When the iron or steel is cooled rapidly by quenching, the higher carbon content on the outer surface becomes hard, while the core remains soft and tough.[1]
This manufacturing process can be characterized by the following key points: It is applied to low-carbon workpieces; workpieces are in contact with a high-carbon gas, liquid or solid; it produces a hard workpiece surface; workpiece cores largely retain their toughness and ductility; and it produces case hardness depths of up to 0.25 inches (6.4 mm).
Phosphating:
Phosphate coatings are used on steel parts for corrosion resistance, lubricity, or as a foundation for subsequent coatings or painting. It serves as a conversion coating in which a dilute solution of phosphoric acid and phosphate salts is applied via spraying or immersion, chemically reacts with the surface of the part being coated to form a layer of insoluble, crystalline phosphates. Phosphate conversion coatings can also be used on aluminium, zinc, cadmium, silver and tin. The main types of phosphate coatings are manganese, iron and zinc. Manganese phosphates are used both for corrosion resistance and lubricity and are applied only by immersion. Iron phosphates are typically used as a base for further coatings or painting and are applied by immersion or by spraying. Zinc phosphates are used for rust proofing (P&O), a lubricant base layer, and as a paint/coating base and can also be applied by immersion or spraying.
LIST OF APPARATUS
Electric Furnaces
:-
1.
Car bottom furnace
Max. temp = 950oC
Plotter and temperature indicator is attached with it.
2. Box type air furnace
It is small and large. Max. temp = 950oC
Size =600 x 500 x 1200 Max. temp = 950oC
Size =450 x 450 x 950
3. Pit type tempering furnace
Max. temp = 950oC
4. Salt bath furnace
Small, medium, large Temp = 550-650oC Size =300 x 400 x 500 Temp = 700-900oC Size =300 x 400 x 800 Temp = 1050-1270oC Size =200 x 300 x 800
5. Flame quenching plant
Vertical : φ1200 x 600 Horizontal : φ 450 x 2400
It is in isolated room, it uses 10,000 volts. It have a copper ring that induct heat to the component’s external part, it have a mechanism of movement of job and quenching. Room is provided with oil and water drum for the purpose of quenching.
7.
Cleaner
It is use to wash salt from metal surface after sand bathing.
8.Manual Straightening Press
It is used to straight long and thin metallic sheets.
9.
Electric gas carburizing furnace
Temp = 950oC
Size =φ 300 x 600
10.
Electric tempering furnace
Temp = 650oC
Size =φ950 x 1220
11. Salt bath
Size =2000 x 2000 x 1400
12. Water quenching tank
Size =1500 x 3000 x 3000
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CTC Fabrication Shop
CTC stands for Central Technical Cell. Basically it is a drawing and planning section of fabrication shop, in this section different drawings are analyzed and then sent to different sections of fabrication shop depending upon the job and capacity of the shop.
Job feeding to shop
Planning
Material check
Observation from manufacturing till sale.
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FABRICATION SHOP
Basically Fabrication Shop is divided into four sections: Heavy bay section,
Medium bay section,
Small bay section
LIST OF APPARATUS AND MACHINES
The machines in the fabrication shop and their capacities are given below:
SMALL BAY
2.5 ton press
5 ton bending machine
MEDIUM BAY
Shaft cutting Circular saw
Cutting Dia 1350mm
Shaft welding machine
Height of beam 450mm
HEAVY BAY
3000 ton press
1000 ton rolling machine
50 ton capacity cranes
MARKING LAYOUT AND CUTTING SECTION
Photo cell cutting machine
Electromagnetic or paper templates are used
CNC cutting machine
A German CNC cutting machine is used for cutting accurate and complex parts
Plasma arc cutting machine for non ferrous metals
Oxygen and natural gas are used for cutting
Mechanical cutting machine(shearing machine)
Parallel cutting machine
Trennjaeger machine
Nine roller
Straightening machine
Welding
Mainly welding is done in all bays of fabrication shop. The type of welding used in fabrication shop is as follows:
1.
Arc Welding:
Arc welding uses a welding power supply to create an electric arc between an electrode and the base material to melt the metals at the welding point. They can use either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes. The welding region is sometimes protected by some type of inert or semi-inert gas, known as a shielding gas, and/or an evaporating filler material. The process of arc welding is widely used because of its low capital and running costs.
2.
Shielded Metal Arc Welding (SMW):
Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode coated in flux to lay the weld. An electric current, in the form of either alternating current or direct current from a welding power supply, is used to form an electric arc between the electrode and the metals to be joined. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapors that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
Because of the versatility of the process and the simplicity of its equipment and operation, shielded metal arc welding is one of the world's most popular welding processes. It dominates other welding processes in the maintenance and repair industry, and though flux-cored arc welding is growing in popularity, SMAW continues to be used extensively in the construction of steel structures and in industrial fabrication. The process is used primarily to weld iron and steels (including stainless steel) but aluminum, nickel and copper alloys can also be welded with this method.
3.
Tungsten Inert Gas Welding:
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is an arc welding process that uses a no consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by a shielding gas (usually an inert gas such as argon), and a filler metal is normally used, though some welds, known as autogenous welds, do not require it. A constant-current welding power supply produces energy which is conducted across the arc through a column of highly ionized gas and metal vapors known as plasma.
GTAW is most commonly used to weld thin sections of stainless steel and light metals such as aluminum, magnesium, and copper alloys. The process grants the operator greater control over the weld than competing procedures such as shielded metal arc welding and gas metal arc welding, allowing for stronger, higher quality welds. However, GTAW is comparatively more complex and difficult to master, and furthermore, it is significantly slower than most other welding techniques. A related process, plasma arc welding, uses a slightly different welding torch to create a more focused welding arc and as a result is often automated.
Gas metal arc welding (GMAW), sometimes referred to by its subtypes metal inert gas (MIG) welding or metal active gas (MAG) welding, is a semi-automatic or automatic arc welding process in which a continuous and consumable wire electrode and a shielding gas are fed through a welding gun. A constant voltage, direct current power source is most commonly used with GMAW, but constant current systems, as well as alternating current, can be used. There are four primary methods of metal transfer in GMAW, called globular, short-circuiting, spray, and pulsed-spray, each of which has distinct properties and corresponding advantages and limitations.
WELDING DEFECTS
Defect found in the welding are• Cracks Blow holes • Crack Spatter • Lack of penetration Undercut
• Pipes Tungsten inclusion • Porosity Restart of welding • Lack of fusion
Slag inclusions
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NON DESTRUCTIVE
TESTING
LAB
Non destructive test is used to identify the defects in welding joints in the NDT lab of HMC NON DESTRUCTIVE EXAMINATION FACILITIES
• x-ray radiography • Gamma ray radiography • Ultrasonic
• Magnetic particle • Liquid penetrant
• Eddy current • Spectroscopy
RADIOGRAPHY TECHNIQUES
Following Radiography techniques are possible, but only three type of radiography are used mostly X-ray, ultrasonic, and gamma ray radiography because other radiography are expensive. A list of available radiographic methods is given below:
• X-ray Radiography • Gamma Ray Radiography • Neutron Radiography • Proton Radiography • Xero Radiography • Fluoroscopy • Micro Radiography • Flash Radiography • Auto Radiography
• Electron transmit Radiography
NDT METHDS APPLICATION AND LIMITATIONS
Radiography testing Method.
1. Radiography is the most universally used NDT method for detection of gas porosity
in the weldments.
2. The radiography image of a “Round Porosity” will appear as oval shaped spots with
smooth edges, while “elongated porosity” will appear as oval shaped spots with major axis. Sometimes several time longer then minor axis.
Ultrasonic Testing Method
1. Ultrasonic testing equipments are highly sensitive, capable of detecting micro
separations.
2. Surface finishing and grain size will affect the validity of the test.
Eddy current Testing Method
1. Normally confined to thin wall welded pipes and tube.
2. Penetration restricts testing to a depth of more than one quarter inch.
Liquid Penetrant Testing Method
a. Normally confined to in processes control of ferrous and non ferrous welds.
b. Liquid penetrant testing is like magnetic particle is restricted to surface
evaluation.
c. Extreme condition must be exercised to prevent any cleaning material and
liquid penetrant materials from becoming entrapped and contaminating the rewelding operation.
Magnetic particle Testing Method
Normally used to detect gas porosity .Only surface porosity would be evident. Near surface porosity would not be clearly defined, since indications are neither strong nor pronounced.
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FORGING SHOP
“Forging is the term for shaping metal by using localized compressive forces.”
Cold forging is done at room temperature or near room temperature. Hot forging is done at a high temperature, which makes metal easier to shape and less likely to fracture. Warm forging is done at intermediate temperature between room temperature and hot forging temperatures. Forged parts can range in weight from less than a kilogram to 170 metric tons. Forged parts usually require further processing to achieve a finished part.
PROCESSES OF FORGING
Open-die drop-hammer forging
Impression-die drop-hammer forging
Upset forging
Automatic hot forging
Net-shape and near-net-shape forging
Induction forging
Of these the first three methods are commonly used in HMC
FUNCTIONS OF FORGE SHOP
Production of large and medium size forgings.
Mostly forged parts include railway axles, draw hooks, screw couplings, cement and
sugar plant parts, boiler components, road rollers parts, cranes and drop tank equipments. Its annual production is 4500 tons.
FORGING EQUIPMENT
HAMMERS:
150kg pneumatic hammer 400kg pneumatic hammer 750kg pneumatic hammerHYDRAULIC PRESSES:
800 ton drawdown type press along with pump, accumulator station and forging
manipulator.
DIE FORGING PRESSES:
60 ton power press 160 ton friction press
400 ton power press
1250 ton friction press.
CRANES:
1 ton stationary stewing crane
12.5 ton overhead crane
20.5 ton forging crane
OTHER APPLIANCESL
Shot blasting machine Pedestal grinder
Quenching tanks_____ 2 oil and water (5m* 3m* 5m each)
FURNACES
Heating furnaces ________ 10
4.84m* 2.08m* 1.5m
Max temp 1300 degree Celsius Heat treatment furnace ________ 5
15m* 4m* 6m
Max temp 1050 degree Celsius
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PATTERN SHOP
The purpose of pattern shop is to make wooden or metallic components for casting process.
TYPES OF PATTERN
One piece or solid pattern
Two piece or split pattern
Three piece pattern
Loose piece pattern.
Self core pattern.
Sweep pattern.
Skeleton pattern.
Match plate pattern.
Connecting pattern.
TYPES OF CORE PRINTS
Top print. Bottom print. Side print. Tail print. Hang print. Balancing print.TYPES OF CORE BOX
Box type core box. Shake out type core box.
Gang type core box
MACHINES IN PATTERN SHOP
Band saw. Joint planner.
Thickness planner.
Disc and spindle sander.
Wooden lathe machine.
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MATERIAL TESTING LABORATORY
The objective of material testing laboratory is to check the chemical composition of different alloys of iron, copper as well as other non metallic elements. The facility contains the following laboratories:
Quick response section.
Mechanical testing section
Heat treatment section
Microscope section
Wet test laboratory
QUICK RESPONSE SECTION
The quick response section is situated near the steel foundry and it helps the foundry men to melt different alloys in exact element ratios to get specific allows. It has the facility to inspect the molten metal from the furnace at intervals and provide the feedback within a few minutes. The facility has the following apparatus:
Emission spectrometer.
Spectrophotometer.
Carbon furnace.
Titration apparatus.
EMISSION SPECTROMETER
This instrument vaporizes the metal by producing an electric spark and then analyses the spectrum of the resulting vapors to identify the percentage of 26 different metals in the given alloy. It has the capability to detect both iron based and copper based metals. The elements that are detected by it include the following:
Carbon, silicon, manganese, phosphorus, sulphur, chromium, molybdenum, aluminum, copper, cobalt, titanium, vanadium, tungsten, lead, boron, tin, zinc, arsenic, bismuth, calcium, cesium, zirconium, and iron.
MECHANICAL TESTING SECTION
This testing section includes the following machines: Universal testing machine
Impact test machine
Brinnel hardness testing machine
Rockwell hardness tester and Vickers
Wear testing machine
WET TEST LABORATORY
In the wet test laboratory, we use the element analysis to measure the moisture contents in any material or a specimen or element.
