Professional Documents
Culture Documents
GUIDED BY-
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ACKNOWLEDGEMENTS
Sonia Priyadarshini
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CERTIFICATE
V.CHITTIBABU
Dy.Chief Manager
(Engg Shops&Foundry)
VisakhapatnamSteel plant
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A Case study on
“Failure of Bull head hammers for the last three months”.
INTRODUCTION
Engineering Shops and Foundry Department caters to the needs of ferrous
and nonferrous spares of different departments. ES&F manufactures as well as
repairs the job as required by Customer departments. ES&F has various sections
like CENTRAL MACHINE SHOP, STRUCTURAL SHOP, FORGE SHOP, FOUNDRY
SHOP, and UTILITY EQUIPEMENT REPAIR SHOP. Central planning section is the
main planning section of Engg shops and foundry and it works as a bridge
between Customer departments and shops of ES&F. Central Machine Shop(CMS)
is having facilities for turning boring, milling, thread cutting and various
machining operations. Heat treatment furnaces, equipments for assembly &
dismantling are also available in CMS. Forge shop as name indicates, forging is
the main function of this shop. It produces shafts couplings, flanges, Drill rods for
BF, bull head hammers for SP, V-hooks for SMS etc. In Structural shop, fabrication
and repair of structural jobs are done. UERS is responsible for repair and
manufacturing of small spares, impellers, valves etc. In Foundry, casting of cast
iron, cast steel and non-ferrous materials of different shape and size as required
by the customer.
Out of the spares supplying by ES&F, Bull head hammer is one of the
important spares, which is used in Hammer crusher of Sinter Plant for crushing of
Dolomite and Limestone. These hammers are made in Forge shop and Central
machine shop. In forge shop, raw material is forged to the required shape, stress
relieved/annealed and send to CMS for further operations like drilling and heat
treatment .The raw material for bull head hammer is being procured from M/s
VSNL, BHADRAWATI, and the material specification is 50CrMO4. Average life of
bull-head hammer is 60 hrs, but for the last three months its average life has
drastically come down to 30hrs. I am going to study on failure of bull-head
hammers and the reasons for decrease of life. In my project, I am also trying to
suggest what modifications may be possible regarding raw material, processes
so that life of the Bull head hammer may be enhanced as well as breaking/fracture
can be minimized which will ultimately effect saving of raw material , production
cost and equipment availability.
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Engineering shops & Foundry is set up to meet the requirements of Ferrous &
non-ferrous spares of different departments. Engineering shops & Foundry is
divided into Central Machine Shop, Steel Structural Shop, Forge shop, Foundry
and Utility equipment repair shop.
Products: Raw material for shafts, couplings, gears, pinions, flanges bull head
hammers for sinter plant hammer crusher, drill rods for blast furnace, v-hooks for
SMS, straightening of pallet middle frames of sinter plant.
The shop is designed for production of shafts, coupling:- flanges etc.
and also of forged shapes such as crusher hammer heads, special bolts, nuts,
etc.The repair and testing of chains are also carried out. The annual production
from the shop is about 2,400 tons based On 300 working days per year and two
shifts per day. These inputs consisting of ingots, billets, blooms and flats of
various sizes.
In heavy forging section, open die forgings of long shafts, gear blanks,
couplings etc. is made with the help of 2-ton bridge type pneumatic hammers.
Each hammer will be provided with twin chamber heating furnaces. Floor type
manipulator and Jib Crane are provided for handling heavy jobs. In general
forging section, 1 ton, 500 Kg, and 200 Kg hammers with separate heating
furnaces are provided. A 2 ton drop stamp hammer with a heating furnace
trimming press etc. is provided for stamping. For cutting them to size, a cold saw,
a billet shear and gas cutting facilities are provided. For stress relieving, a bogie
type-annealing furnace is provided.
STRUSTURAL SHOP
Inputs:- Sheets of various sizes, plates, angles, channels, beams for fabrication
of jobs.
Production & services: All types of fabrication jobs, repair of slag pots of
SMS, Mfg. And repair of tundishes for SMS, Mfg. Of scrap boxes for SMS, for
sinter plant, hot metal ladle for SMS, 500 metres launder for SMS, mfg. Of KAMAG
body for FMD, repairing of buckets for LMMM, WRM.The annual production of
fabricated structures are about 4,500 tones and the input consisting of sheets,
plates, channels, angles, beams etc. are, about 5,100 T .
For marking, cutting to size, forming and bending, guillotine shear,
circular saw plate bender, gas cutting unit etc. are provided. For welding
transformer, automatic and semi-automatic machines and submerged arc welding
machines are provided. Painting is carried out partly with help pf spray guns and
partly by hand. Wire brush, spray guns etc. are provided. A maintenance section
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equipped with lathe, shaper, drill etc. are provided for running repair of shop
equipment.
FOUNDRY
Inputs: Pings, MS scrap, ferro alloys, graphite electrodes, sodium silicate, silica
sand CO2 gas, moulding additives etc.
Products: Steel, cast iron & non ferrous castings, Emergency containers,
tundish covers, bull gear for SMS, hot metal runners, ladle paw for blast furnace,
coke roll liners, sprockets, pallets for sinter plant, raw supports, bowl for RMHP,
guide troughs for WRM, face of scrap bucket for MMSM, slag pot segments for
SSS repair, ingots for forge shop, non ferrous castings like bushes (below 20 kg)
etc.
Iron castings up to a weight of 5 tons will be produced. A main frequency
coreless induced furnace with two 2-ton capacity crucibles and a 5T capacity
main frequency coreless induction furnace for melting iron are provided. There is
a centralized sand preparation unit. A drier and a bin is be provided for green
sand. Belt conveyors transport green sand, prepared mix and burnt sand.
Moulds and cores are drier in 3 ovens lip pour ladles with capacity between 50 kg
and 10 tons is provided for handling hot metal. Two swing frame grinders and two
pedestal grinders are provided for finishing of iron castings.
Steel castings up to maximum piece weight of 10 T and Steel Ingots up
to 1.3 tons for forging are produced. An 8 Ton direct arc furnace and a two-ton
medium frequency electric induction furnace is installed for melting of steel scrap
and pig iron. Each of the two sand mixers is having 1.5-ton batch. A bogie hearth
furnace for annealing/ normalizing of plain carbon steel castings and fixed hearth
furnace for heat treatment of manganese steel castings with quenching facility is
provided. The woodwork shop manufactures patterns for foundries. The principal
equipment for pattern making will be band saws, disc grinding, wood working
lather, adequate facilities are provided for saw grinding, painting, timber and
pattern storage etc.
SSS
C C
U U
C FDY C S
S
T T
P M O
O
FS M
M S S E
E
R
R CMS - UERS
CENTRAL MACHINE SHOP
FS - FORGE SHOP
FDY - FOUNDRY
HAMMER CRUSHER
HAMMERS
COUPLING
BEARING
BEARING
Out of the spares supplying by ES&F, Bull head hammer is one of the important
spares, which is used in Hammer crusher of Sinter Plant for crushing of Dolomite and
NECK
AREA
120 mm
100 mm 100 mm
Limestone. These hammers are made in Forge shop and Central machine shop.
In Forge shop, raw material is forged to the required shape, stress
relieved/annealed and send to CMS for further operations like drilling and heat
treatment .The raw material for bull head hammer is being procured from M/s
VSNL, BHADRAWATI, and the material specification is 50CrMO4. Average life of
Bull-head hammer is 60 hrs,
Technical specifications OF BULL HEAD HAMMERS as per drawing:
2. The soaking of metal at that temp until the structure becomes uniform
throughout the mass.
3. The cooling of the metal at some predetermined rate to cause the
formation of desired structure within metal / alloy for desired purpose.
ANNEALING - The purpose of annealing is to soften the steel so that it may be
more easily machined and to relieve the internal stresses which may have been
caused by working the metals or by unequal contraction in casting .The process
of annealing involves heating the metals slowly to the required temp , then
holding at that temp for long enough to enable the internal changes to take place
and finally cooling slowly . Annealing reduces the hardness , increases ductility
and usually reduces its strength.
HARDENING- Hardening is a heat treatment process .It is made to devlop high
hardness to resist wear as well as to improve strength, elasticity, ductility and
toughness to the material.Hardening process consists of heating the steel to a
temperature above critical point, holding at this temp for considerable period and
finally quenching in water, oil or molten salt bath.
TEMPERING - When a steel specimen has been fully hardened, it is very hard and
brittle and has high residual stresses . The steel is unstable and tends to contract
on aging . The internal stress can be relieved by an additional heating process.
This heating process is called tempering. After specimen has been fully
hardened by quenching from above critical temp, it is reheated to some temp
below the critical temp for a certain period of time and then allowed to cool in still
air . the temp to which it is reheated depends upon the composition and the
degree of hardness or toughness desired. Tempering reduces the elastic limit and
ultimate strength lightly but they are still higher than they were before drawing.
Hardening with subsequent tempering serves the following purposes for bullhead
hammer. It develops high hardness to resist wear and to enable it to cut another
metals. It also improves strength, elasticity, and ductility.
Tempering is a term historically associated with the heat treatment of
martensite in steels. It describes how the microstructure and mechanical
properties change as the metastable sample is held isothermally at a temperature
where austenite cannot form. The changes during the tempering of martensite can
be categorised in to stages. During the first stage, excess carbon in solid solution
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COMPOSITION OF 50CRM04:
MANGANESE- It is added to all low and the manganese content is high over one
percent, then it is classified as a manganese alloy. it lowers the critical range of
temperature.
SPHERODOISED ANNEALING – The machinability of high carbon tool steel is at
its best condition when the structure is composed of grained or globular pearlite.
An alloy steels, including those of the carbide class, as well as ball bearing steels
should have a structure of globular pearlite in the deliverable state. The process
of producing a structure of globular pearlite is known as spheredoising or
spherodoised annealing.
8. BHH is sent to Central Machine shop after inspection. They are sent in
batch as Batch size is 400 jobs per batch.
(1) Heating the hammers up to 600 +0+25 at a constant rate of 150.c /hr.
(2) soaking at 600.c for 30 minute.
(3) Raising the temp from 600.c to 875.c at 100.c/hr.
(4) Soaking at 875+0+25 for 2 hrs.
(5) Quenching in recirculating water up to 100 mm.
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©TEMPERING-
500
100
time
TEMPERING CYCLE FOR BHH
1
PROCESS FLOW DIAGRAM FOR BHH
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1.TRANSPORTATION
2.SHEARING OF BILLETS
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3. HEATING FOR FORGING UPTO 1250.C
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4. FORGING
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6.INSPECTION FOR DIMENTIONAL CHECKING
7.TRANSPORTATION TO CMS
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8.DRILLING OF 50 MM HOLE
9.HARDENING 9
10. TEMPERING 1
0
11. SAMPLING
1
1
12.INSPECTION FOR HARDNESS CHECKING
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13. TRANSPORTION TO CUSTOMER
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Problems are being faced by Sinter Plant wrt BHH.
LOW LIFE
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FRACTURE
LOW PRODUCTION
CUSTOMER SATISFACTION
PICTURE 1
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PICTURE2
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PICTURE-3
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PICTURE-4
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SECOND BULL HEAD HAMMER :- This hammer has given less life. The following
are the figures of Bull Head hammer whose life was <20 hrs .
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The above figure shows the absence of tempered martensite structure due to
improper heat treatment. When this BHH is checked for hardness, it’s hardness is
low, which shows softness of material resulting in low life.
Third BULL HEAD HAMMER - After implementing some suggestions like usage of
Fixture rod without bend for quenching, proper heat treatment and quenching, In
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the first week of march, one set of bull head hammers(45 nos.) has given life of
55 to 60 hrs .Two pieces in the size of 100x100x15 mm were cut from the head
portion of that bull head hammer and sent to QATD for detail analysis regarding
Micro structure at four points has been studied and it matches with our
requirement ,i.e existence of tempered martensite with hardness 380- 550 range
for BHH. The following are micro structure figures . Its hardness is in the range
450-525 BHN .
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Hardness at different points has been done .From the figure it is very clear that
center of BHH head at three different thickness may also be compared .It is 573
BHN at surface, 451 at the next 15mm thickness and after 30mm it is 388 mm. This
trend shows heat treatment effectiveness slows down for inside positions.But it is
stamping
(b) Heat treatment as per proposed cycle is difficult to achieve due to poor
(c) Heat transfer rate is difficult to achieve in furnaces since there is no facility of
to control the heat treatment , pyrometer may be used for checking temp of
measured temp , different burners of heat treatment furnace may be kept on or off
so that uniform temp of each bull head hammer may be achieved as per
(d) Tempering furnace also has no facility to control the heat transfer rate. Air-
uniformly.
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hammers.
for checking of toughness of bull head hammer. Izod impact test / charpy test
max 100 mm in head area, but due to boiled water bubble formation length may
(g)proper care during heat treatment can be done, pyrometer may be used for
this measured temp different burners of heat treatment furnace may be kept on
or off so that uniform temp of each bull head hammer may be achieved as per
max 100 mm in head area, but due to boiled water bubble formation length may
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(i) Due to not proper recirculation of water, in quench area steam layer forms,
which resists further cooling and contact of water. so it is desired that proper
(j)Range of hardness as per drawing is 380 to 500 BHN.This large range may
lead to variation of properties of each and every bull head hammer. This range
should be minimized in order to get uniform properties of each and every bull
head hammer.
BABLIOGRAPHY