Professional Documents
Culture Documents
Submitted by
BHUPENDRA SINGH
B.TECH
In
MECHANICAL ENGINEERING
VIT
UNIVERSITY
(Estd. u/s 3 of UGC Act 1956)
NOVEMBER 2011
1
Introduction
The company has annual sales of $ 5 billion and employs 13,675 people and is listed on
Forbes 2000. A metals powerhouse with a turnover of US$ 14 billion, Hindalco is the
world's largest aluminium rolling company and one of the biggest producers of primary
aluminium in Asia.
Industry Metals
Founded 1962
Employees 13,675
Website Hindalco.com
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HEAD OFFICE & WORKS:
E-mail: hindalco@cal2.vsnl.net.in
EXPORT OFFICE:
E-mail: hindalco.rkt@rmj.sprintrpg.ems.vsnl.net.in
Vision:
To be a premium metals major, global in size and reach, excelling in everything we do,
and creating value for its stakeholders
Mission:
3
Main plant of the company
Hindalco, at Renukoot, house a fully integrated plant, comprising of 3 main Plants i.e.
the Alumina, Smelter & Fabrication Plant. Each plant employs varying Technology.
With integrated facilities, output from various plants are used by others, along with
varying raw materials.
Alumina Plant
Aluminium Smelter
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Fabrication Plant
The Remelt Shop houses 3 Properzi Mills for the production of Wirerods and Feedstock
to Conform Machine.
Cast House is comprised of a state of the art Pig Ingot casting, Rolling Ingot (slab)
casting and Extrusion Billet casting facilities. Product of Pig Ingot Casting is directly
sold to customer and product of slab casting and billet casting are the feedstock to
Rolling Mills and Extrusion presses respectively.
The Company has a Hot Rolling Mill and 2 Cold Rolling Mills. The Rolling Mill
facilities also include a Continuous Strip Caster, which contributes substantially to
Energy efficiency since it eliminates numerous intermediate operations.
The Company’s 3 Extrusion presses and one Conform Machine are well supported by a
well-equipped Die Shop.
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Products
Aluminium:
Hindalco is Asia's largest integrated primary producer of aluminium and among the most
cost-efficient producers globally. Our aluminium units across India encompass the entire
gamut of operations, from bauxite mining, alumina refining, aluminium smelting to
downstream rolling, extrusions and recycling
Product Uses
Aluminium Ingots Remelted and used in the form of Castings, Consumer Durables,
Powders & Chemicals, Redraw Rods etc.
6
About Workshop
Need:
• To repair the regular job e.g. valve body, mise casing, impeller, pot room tool, and dc
casting tool to meat day to day maintence need.
• To fabricate new spare for the entire plant & carry out insitu machining.
• To meet the emergency and break down of whole plant. Workshops provide all type
of repairing at the completive prise in minimum time.
Mission: “to deliver value for customer through protective, timely, flexibly & and
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Machine shop & fabrication (plant repair section):
Work orders are received for repairing of any job from plant and outside parties. It is
processed as per their requirement e.g. turnine, milling, slotting etc.
P.R’s are received to make spare for the plant. The job in this section is made new.
Different tool of reduction plant & dc casting are repaired. Bending, shearing, sling
and press operation are also performed in this section.
In air tool section mise pneumatic tool like rock drill, air motors, jack hammers, &
coke clamps etc are required. Through mechanical maintenance section the
maintenance of all workshop machines are done by PM, OH & daily maintenance.
Tool room:
For economic machining and other processes tool room play major role. As the name
indicates tool room supplies tooling for workshop as per Ned.
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LAYOUT OF WORKSHOP
LAYOUT OF WORKSHOP
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Detail about centre lathe NH 26
In the workshop many type lathe machine like beco lathe, hagorian lathe, blue chip lathe,
H.M.T. lathe. All the machine come under same category i.e. centre lathe. But among the lathe
machine I found that there is 10 H.M.T. lathe machine (NH 26).
Parts of NH 26.
Like the pats of other lathe machine NH26 heaving the same parts which i described
before. But the parts of NH 26 are given below.....
Leg: leg is mounted on the surface it gives the saport to entire lathe machine
Bed:
• Base of the machine
• Head stock and tail stock are located at either end of the bed
• Carriage rests over the lathe bed and slides on it
• Bed material should have high compressive strength should be wear resistant
and absorb vibration
• Cast iron alloyed with nickel & Chromium
Head stock:
• Secured / fixed permanently on the left hand side of the lathe bed
• Provides the mechanical means of rotating the work at multiple speeds
• Comprises a hallow spindle & mechanism for driving & altering the spindle
speed
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Main pats of head stock:
The headstock (H1) houses the main spindle (H4), speed change mechanism (H2, H3),
and change gears (H10). It is made by cast iron.
Tail stock:
• It has a provision to slide and facilitate operations at different locations
• Supports longer blanks and often accommodates tools like drills, reamers etc for
hole making
The tailstock is a toolholder directly mounted on the spindle axis, opposite the
headstock. The spindle (T5) does not rotate but does travel longitudinally under the
action of a leadscrew and handwheel (T1). The tailstock can be positioned along the
bed and clamped (T6) in position as required. There is also provision to offset the
tailstock (T4) from the spindles axis; this is useful for turning small tapers, reduction
gear box (T2) between the handwheel and spindle.
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Carriage:
• Contains certain parts such as Apron, Saddle, cross slide, compound rest and
tool post
• Tool post accommodates the tool
Cross-slide:
The cross-slide (3) rides on the carriage and has a feedscrew that travels perpendicular
to the main spindle axis. This permits facing operations to be performed, and the depth
of cut to be adjusted. This feedscrew can be engaged, through a gear train, to the feed
shaft (mentioned previously) to provide automated 'power feed' movement to the cross-
slide. On most lathes, only one direction can be engaged at a time as an interlock
mechanism will shut out the second gear train.
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Compound rest:
The compound rest (or top slide) (2) is usually where the tool post is mounted. It
provides a smaller amount of movement (less than the cross-slide) along its axis via
another feedscrew. The compound rest axis can be adjusted independently of the
carriage or cross-slide.
Tool post:
The tool bit is mounted in the toolpost (1) which may be of the American lantern style,
traditional four-sided square style, or a quick-change style such as the multifix
arrangement pictured.
The feedscrew (H8) is a long driveshaft that allows a series of gears to drive the
carriage mechanisms. These gears are located in the apron of the carriage. Both the
feedscrew and leadscrew (H7) are driven by either the change gears (on the quadrant)
or an intermediate gearbox known as a quick change gearbox (H6) or Norton gearbox.
These intermediate gears allow the correct ratio and direction to be set for cutting
threads or worm gears.
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Specification of NH 26
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Lubrication system of the NH 26
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LUBRICATION POINT IN NH 26:
The aims in metal cutting are to retain accuracy, to get a good surface finish on the
workpiece and at the same time to have a longer tool life.
However during the metal cutting process heat is generated due to:
• The deformation of the material ahead of the tool
• Friction at the tool point
Heat generated due to friction can readily be reduced by using a lubricant. Heat caused
by deformation cannot be reduced and yet it can be carried away by a fluid. Thus the
use of a cutting fluid will serve to reduce the tool wear, give better surface finish and a
tighter dimensional control.
The proper selection, mixing and application of cutting fluids is however often
misunderstood and frequently neglected in machining practice. In order that the cutting
fluid performs its functions properly it is necessary to ensure that the cutting fluid be
applied directly to the cutting zone so that it can form a film at the sliding surfaces of
the tool.
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Tool Materials and Tools used in Lathe Machine
Contains 1 - 1.4% carbon with some addition of chromium and tungsten to improve
wear resistance. The steel begins to lose its hardness at about 250° C, and is not
favoured for modern machining operations where high speeds and heavy cuts are
usually employed.
Steel, which has a hot hardness value of about 600° C, possesses good strength and
shock resistant properties. It is commonly used for single point lathe cutting tools and
multi point cutting tools such as drills, reamers and milling cutters.
Cemented Carbides
An extremely hard material made from tungsten powder. Carbide tools are usually used
in the form of brazed or clamped tips. High cutting speeds may be used and materials
difficult to cut with HSS may be readily machined using carbide tipped tool.
Tool life:
As a general rule the relationship between the tool life and cutting speed is
V*T*n = C
Where;
V = cutting speed in m/min
T = tool life in min
C = a constant
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Tool geometry:
For cutting tools, geometry depends mainly on the properties of the tool material and
the work material. For single point tools, the most important angles are the rake angles
and the end and side relief angles.
Axial Rake Angle (Milling) - Back Rake Angle (Single Point Tool).
This angle controls the chip flow, and thrust force (into spindle or away from) of the cut
and the strength of the cutting edges. If the back rake angle is too large, the strength of
the tool is reduced as well as its capacity to conduct heat. In machining hard work
materials, the back rake angle must be small, even negative for carbide and diamond
tools. The higher the hardness, the smaller the back rake angle. For high-speed steels,
back rake angle is normally chosen in the positive range.
Corner (Chamfer) Angle - Side Cutting Edge Angle (Single Point Tool).
This angle reduces the thickness of the chip. Shock is absorbed behind the cutting
point, adding strength that influences tool life.
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True Rake Angle (Milling - True Rake Angle (Single Point Tool).
The combination of radial rake, axial rake, and corner angle determines the chip
formation shear angle, the power requirements, tool force and temperature. True rake
angle is the most significant angle in the metal removal process. The higher the positive
true rake angle, the lower the force, the power requirements and the heat generated. The
cutting tool material, machine rigidity and other variables determine the positive or
negative values that can be used.
Dish Angle (Milling) - End Cutting Edge Angle (Single Point Tool).
This provides clearance between the cutter and the finished surface of the work which
blends into the radius or chamfer of the tool. All angles close to zero adds strength but
causes rubbing and generates heat. Too large an angle weakens the tool. Flats parallel
to the finished surface are often ground on the end cutting edge or dish angle to produce
good surface finishes.
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Operations performed on Lathe Machine
i. Turning
ii. Thread cutting
iii. Chamfering
iv. Facing
v. Knurling
vi. Grooving
vii. Drilling
viii. Reaming
ix. Boring & Counter boring
Turning:
Finish turning: Obtain good surface finish, requires high cutting speed, small feed
(0.1 to 0.3 mm/rev) and small depth of cut (0.5 to 1 mm)
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Shoulder turning:
When a w/p having different diameters is turned, the surface forming the step from one
diameter to the other is called as shoulder
Four types, viz., Square shoulder, angular or beveled shoulder, radius shoulder and
undercut shoulder
Taper turning:
Thread cutting:
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Position of the gear in thread cutting:
Facing:
Facing is the process of removing metal from the end of a work piece to produce a flat
surface. Most often, the work piece is cylindrical.
Facing part of the turning process. It involves moving the cutting tool at right angles to
the axis of rotation of the rotating work piece. This can be performed by the operation
of the cross-slide, if one is fitted, as distinct from the longitudinal feed (turning). It is
frequently the first operation performed in the production of the work piece, and often
the last- hence the phrase "ending up".
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Knurling:
Grooving:
A turning operation in which a single-point tool moves radially, into the side of the
workpiece, cutting a groove equal in width to the cutting tool. If the desired groove
width is larger than the tool width, multiple adjacent grooves will be cut. A profiling
cut can be performed to smooth the surface of multiple grooves. Special form tools can
also be used to create grooves of varying geometries.
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Drilling:
Operation of the portable electric and pneumatic drills differs from recommended
operating procedures for the upright drilling machine. The portable drill is hand
supported for most operations, and the cutting speed of the drill is fixed or dependent
upon the operator to control.
When metal is to be drilled with the portable drill, the work piece must be prepared by
locating the center position of the potential hole and marking the location with a center
punch.
Reaming:
An operation in which a reamer enters the workpiece axially and enlarges an existing
hole to the diameter of the tool. Reaming removes a minimal amount of material and is
often performed after drilling to obtain both a more accurate diameter and a smoother
internal finish. A finish reaming operation will use a slower cutting feed and cutting
speed to provide an even better finish.
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Boring & counter boring:
Boring:
An operation in which a boring tool enters the work piece axially and cuts along an
internal surface to form different features. The boring tool is a single-point cutting tool,
which can be set to cut the desired diameter by using an adjustable boring head. Boring
is commonly performed after drilling a hole in order to enlarge the diameter or obtain
more precise dimensions.
Counter boring:
An operation in which a counterbore tool enters the workpiece axially and enlarges the
top portion of an existing hole to the diameter of the tool. Counterboring is often
performed after drilling to provide space for the head of a fastener, such as a bolt, to sit
below the surface of a part. The counterboring tool has a pilot on the end to guide it
straight into the existing hole.
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Formula for calculation of cutting speed and reed rate:
Cutting speed:
Formula in British system:
ߨ×ܰ×ܦ
ܥ. ܵ. = ݐܨ./݉݅݊
12
Cutting time:
Feed rate:
Is decided according to the job material and speed of spindle as per the chart by setting
the lever.
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Job Performed:
Exercise:
Making of shaft as per the given dimension heaving the length 537mm. And bigger dia.
53.5 mm. And give the all the processes detail and step of final finishing.
Material Used: EN 24
Steps on Job:
Step 1: Fix the job on the lathe machine with the help of four jaw chuck
(Independent chuck) and center.
Step 2: After this we make centre on both side of job one by one with an angle 60°.
Step 3: After this turning the dia. 38mm. From the side of tail stock up to distance
66mm. by taking........
• Cutting speed = 38.79 m/min
• Spindle speed = 325 RPM
• Feed rate = 0.12 mm./rev.
Step 4: After this turning the dia. 40mm.up to length 18mm starting from 66mm from
tail stock. By taking..........
• Cutting speed = 40.84 m/min
• Spindle speed = 325 RPM
• Feed rate = 0.12 mm./rev.
Step 5: Making the dia 45mm up to length 51mm. starting from the 84mm from tail
Stock. By teaking.........
• Cutting speed = 45.94 m/min
• Spindle speed = 325 RPM
• Feed rate = 0.12 mm./rev.
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Step 6: Making the thread on the dia. 45mm heaving the pitch 1.5mm by seating
The thread cutting lever, according to thread cutting chart.
Step 7: After this making the dia. 53.5mm up to length 139mm starting from
135mm from the tail stock. By taking....
• Cutting speed = 54.62 m/min
• Spindle speed = 325 RPM
• Feed rate = 0.12 mm./rev.
Step 8: Then reverse the position of the job fro head stock to tail stock.
Step 9: Making the dia 45mm up to distance 43 mm with starting point 274mm from
Tail stock. By taking.......
• Cutting speed = 45.94 m/min
• Spindle speed = 325 RPM
• Feed rate = 0.12 mm./rev.
Step 10: Making the dia 38 mm up to distance 132 mm srating from 317mm from
Tail stock. By teaking........
• Cutting speed = 38.79 m/min.
• Spindle speed = 325 RPM
• Feed rate = 0.12 mm./rev.
Step 11: Making the dia. 28mm up to distance 69mm from starting point 449mm from
Tail stock. By taking......
• Cutting speed = 28.58 m/min.
• Spindle speed = 325 RPM
• Feed rate = 0.12 mm./rev.
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Step 12: Making the dia 16mm with distance 19mm starting point 518mm from
Tail stock. By taking.......
• Cutting speed = 16.33 m/min.
• Spindle speed = 325 RPM
• Feed rate = 0.12 mm./rev.
Step 13: Making the thread on the dia 16mm heaving the pitch 2mm by seating the
Lever, according to thread cutting chart.
Step 14: Making the chamfer on all the outer dia. Of shaft as per given dimension.
i.e. On 38dia 2x45° and on 40, 45, 28, and 16 mm dia 1x45° and on 53.5mm
dia. 1.5x45°.
Step 15: Making the groove at given position in the dimension 2x2mm i.e. 2’U’cut.
Step 16: After this giving the surface finishing of the entire surface with the help of
Emery Seat of different gread.like 1200, 1000, 800 etc. By teaking.....
• Cutting speed = as per our convenience
• Spindle speed = 550 RPM
• Feed rate = 0.5 mm./rev.
Step 17: After this marker mark the position on the job for key way cutting.
Step 18: after this key way cutting is performed on the milling machine by using the
Suitable milling cutter.
RESULT:
And at last we made the shaft of length 537mm.
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CONCLUSION
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