INDUSTRIAL TRAINING IN HINDALCO INDUSTRY LIMITED, RENUKOOTAn In-Plant Training Report Submitted by BHUPENDRA SINGH In partial fulfillment for the award of the degree of B.TECH In MECHANICAL ENGINEERING VIT UNIVERSITY (Estd. u/s 3 of UGC Act 1956) Vellore - 632 014, Tamil Nadu, India SCHOOL OF MECHANICAL AND BUILDING SCIENCE NOVEMBER 2011 1 Introduction Hindalco: An industry leader in aluminium and copper Hindalco Industries is India's largest Aluminium manufacturing Company and is a subsidiary of the Aditya Birla Group. It is run by one of the world's youngest billionaires, Mr. K.M. Birla. 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. Short overview of company Type Private Industry Founded Headquarters Key people Revenue Products Total assets Employees Parent Website Metals 1962 Mumbai, India Kumar Mangalam Birla (Chairman) ▲ US$14.87 billion (2008) Aluminium and Copper US$18.31 billion (2008) 13,675 Aditya Birla Group Hindalco.com 2 HEAD OFFICE & WORKS: P.O. Renukoot - 231271, Distt. Sonebhadra (U.P.), INDIA. Phone: +91 5446 52077-9, Fax: +91 5446 52107, 52427. E-mail:
[email protected] EXPORT OFFICE: 9/1, R. N. Mukherjee Road, Calcutta - 700 001, INDIA. Phone: +91 33 2480949, 2200464. Fax: +91 33 2200214. E-mail:
[email protected] Vision: To be a premium metals major, global in size and reach, excelling in everything we do, and creating value for its stakeholders Mission: To relentlessly pursue the creation of superior shareholder value, by exceeding customer expectation profitably, unleashing employee potential, while being a responsible corporate citizen, adhering to our values. 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 Hindalco's Alumina Plant employs the conventional Bayer’s process was commissioned with an initial capacity of 40,000 MTPA which has now increased to 660,000 MTPA. The Company has been inducting new technology from time to time and the most recent initiative in this regard is the adoption of Alusuisse Precipitation Technology for energy efficiency and capacity enhancement. The major raw materials for the Alumina Plant are Bauxite, Steam and Caustic Soda. Bauxite is procured from the Company's Mines in Jharkhand and Chhatisgarh, as well as through market purchases and requirement of steam is met thru Cogeneration plant at Renukoot. Aluminium Smelter The Company's Smelter commenced operations in 1962 with 1 Potline having a capacity of 20,000 MTPA. The smelter now has 11 Potlines with 2038 Pots installed with annual capacity of production of 3,42,000 MT. The Smelter employs the Hall Heroult Electrolysis Process for the extraction of Aluminium from Alumina. Basic raw materials for the smelter are Alumina, Power, Anodes and Aluminium Fluoride. Alumina is produced by the Company's Alumina Refinery at Renukoot, Power is made available from the Company's Captive Power Plant at Renusagar and Cogeneration plant at Renukoot and Anodes are produced at the Carbon Plant located in the Renukoot . Aluminium Fluoride is sourced from the Company’s JV, amongst other sources. 4 Fabrication Plant The Fabrication Plant at Renukoot comprises of 4 Main Sections: Remelt Shop Cast House Rolling Mills Extrusion & Conform 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. 5 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 Aluminium Ingots Uses Remelted and used in the form of Castings, Consumer Durables, Powders & Chemicals, Redraw Rods etc. Supplied to Secondary Extruders for the production of Extruded Profiles Drawn to smaller Diameter for applications - largely in Conductors & Cables. Transport, Electrical & Architectural Applications Electronics, Consumer Durables, Aluminium Billets Aluminium Wirerods Aluminium Sheet Products Aluminium Extrusions Major consumption in Architectural applications. Others include Transport, Computer Hardware, Textile Machinery, Strategic Applications Packing of Food and Pharmaceuticals Cars Aluminium Foils Aluminium Alloy Wheels 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 and vision: Vision: “To achieve total customer satisfaction.” Mission: “to deliver value for customer through protective, timely, flexibly & and Cost effective service.” equipment, which can machine up to: 1. 1250 mm dia on vertical boring machine. 2. 1000 mm dia x and 3000 mm long on lathe. 3. 30” dia and 30’ long job on lathe. 4. Grinding of Loma saw blade and many more type job depending on requirement. Central mechanical workshop is divided into five sections: 1. Machine shop & fabrication ( plant repair section) 2. Spare part section ( plant spare section) 3. Black smithy & press area 4. Air tool & machine maintenance 5. Tool room 7 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. Spare part section (plant spare section): P.R’s are received to make spare for the plant. The job in this section is made new. Black smithy & press area: Different tool of reduction plant & dc casting are repaired. Bending, shearing, sling and press operation are also performed in this section. Air tool & machine maintenance: 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. 8 LAYOUT OF WORKSHOP 9 LAYOUT OF WORKSHOP 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 10 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 Main pats of tail stock: 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. 11 Carriage: • Contains certain parts such as Apron, Saddle, cross slide, compound rest and tool post • Tool post accommodates the tool Main parts of carriage: carriage holds the tool bit and moves it longitudinally (turning) or perpendicularly (facing) under the control of the operator. The operator moves the carriage manually via the handwheel (5a) or automatically by engaging the feed shaft with the carriage feed mechanism (5c). This provides some relief for the operator as the movement of the carriage becomes power assisted. The handwheels (2a, 3b, 5a) on the carriage and its related slides are usually calibrated, both for ease of use and to assist in making reproducible cuts. The carriage typically comprises a top casting, known as the saddle (4), and a side casting, known as the apron (5). 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 crossslide. On most lathes, only one direction can be engaged at a time as an interlock mechanism will shut out the second gear train. 12 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. Feed rod and lead screws: 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. 13 Specification of NH 26 14 Lubrication system of the NH 26 We use servo 68 as a coolest combining with water in ratio of (oil:water :: 1:15) 15 LUBRICATION POINT IN NH 26: Cutting Fluid & Lubricant: 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. 16 Tool Materials and Tools used in Lathe Machine High Carbon Steel 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. High Speed Steel (H.S.S.) 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 17 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. FUNCTION OF THE ANGLES: Radial Rake Angle (Milling) - Side Rake Angle (Single Point Tool). This angle has a major effect on power efficiency and tool life. 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. 18 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. Inclination Angle (Same in Milling and Turning). This has a significant effect on the direction of the chip. Positive inclination directs the chip outward and negative inclination directs the chip toward the center of the cutter. The inclination angle is perpendicular to the direction of tool travel. Any change in axial rake angle, radial rake angle or chamfer angle can change the inclination and therefore the direction of the chip flow: 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. Nose Radius (Milling and Single Point) This strengthens the culting edge, improves finish and influences tool life. Too large a radius increases radial forces and induces chalter. Too small a nose radius may result. in premature chipping or prevent proper distribution of the heat and break down the properties of the cutting tool material. Clearance Angles (Milling and Single Point). Primary clearance is directly below the cutting edge and is selected for the material being machined. It prevents the cutter or tool from rubbing on the workpiece. It also affects the strength of the tool. The secondary clearance is on the tooth form of the cutter or the shank of the single point tool. 19 Operations performed on Lathe Machine i. ii. iii. iv. v. vi. vii. viii. ix. Turning Thread cutting Chamfering Facing Knurling Grooving Drilling Reaming Boring & Counter boring Turning: Removal of excess material from the w/p to produce a cone-shaped or a cylindrical surface • • • • Straight turning: Rough turning & Finish turning Shoulder turning Taper turning Straight turning: Removing material along the axis of the w/p Produces cylindrical surface by removing excess metal Rough turning: Process of removal of excess material in a minimu time by applying High rate of feed (0.3 to 1.5 mm/rev) and heavy depth of cut (2 to 5 mm) 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) 20 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: Taper may be defined as a uniform increase or decrease in diameter of a piece of work measured along its length Producing a conical surface by gradual reduction in diameter from a cylindrical w/p Thread cutting: A thread is a uniform helical groove cut on or in a cylinder or cone. Thread cutting on a lathe is one of the most exacting lathe operations. It requires a thorough knowledge of the principles and procedures of thread cutting. It ties together a number of operations and dimensions in such a way that accuracy must be maintained to achieve a proper working thread. 21 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". 22 Knurling: Knurling is a manufacturing process, typically conducted on a lathe, whereby a visually-attractive diamond-shaped (criss-cross) pattern is cut or rolled into metal. This pattern allows hands or fingers to get a better grip on the knurled object than would be provided by the originally-smooth metal surface. Occasionally, the knurled pattern is a series of straight ridges or a helix of "straight" ridges rather than the more-usual crisscross pattern. 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. 23 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. 24 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. 25 Formula for calculation of cutting speed and reed rate: Cutting speed: Formula in British system: . . = × × 12 ./ Formula in metric system: . .= × × 1000 / Cutting time: ℎ × × ./ . = Feed rate: Is decided according to the job material and speed of spindle as per the chart by setting the lever. 26 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. 27 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. 28 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. 29 CONCLUSION It was a great privilege to undergo vocational training at Hindalco Industry Limited, Renukoot. Working in such an encouraging atmosphere with people dealing with latest technology working in tight schedule, dedicated to help was a privilege. While carrying out the industrial training I received tremendous support from all the staffs of the various departments. Working in different shops provided a real time experience of engineering and technology being used currently in manufacturing industry. The training helped me in great deal as I came to know and explore more information and gained invaluable knowledge about the subject. The training also helped me to gain knowledge about the industrial environment. This invaluable experience will help me further to adapt quickly in the environment of the company in future when I will have to join any company. 30