NAME : AMIT KARMAKARCOURSE : B.TECH (MECHANICAL)SECTION : M2006B42REG NO. :11007860COLLEGE : LOVELY PROFESSIONAL

UNIVERSITY

FINAL PROJECT PRESENTATION

InGAGAN FERROTECH

LIMITED,DURGAPUR(WB)

PROJECT ON TMT BAR MANUFACTURING

WHAT IS TMT BAR?

TMT MANUFACTURING PROCESS

TYPES OF RAW MATERIALS 1. BILLETS2. INGOTS

RAW MATERIALS

INGOTS : TRAPEZOIDAL SHAPE STRUCTURE MANUFACTURED BY CASTING FROM IRON ORE COLOR CODE IS ALLOTTED TO MINIMIZE THE ERROR THREE TYPES OF CROSS-SECTIONAL DIMENSION 3 4 X 4 4 inches ⅟ ⅟ 3 2 X 4 2 inches ⅟ ⅟ 4 X 5 inches 50-60 INCHES INGOT LENGTH IS USED IN TMT

PRODUCTION

RAW MATERIALS CONTINUE

BILLETS : ALMOST SIMILAR TO INGOTS BUT HAVE BETTER

SURFACE FINISH LESS CHANCE OF BLOW HOLES BEING PRESENT THE FINAL PRODUCT HAS BETTER FINISH WHEN

COMPARED TO INGOTS NO STANDARD COLOR CODING REQUIRED

RAW MATERIALS CONTINUE

COLOR CODING OF INGOTS : COLOR CODING IS DONE IN BASIS OF PRESENCE OF

PERCENTAGE OF CARBON IN INGOTS Below .18 –white paint .18 to .20 – blue paint .21 to .23 – green paint .24 to .26 – yellow paint .27 to .30 – orange paint Above .30 – red paint

RAW MATERIALS CONTINUE

PARAMETERS

Fe 415

Fe500

Fe550

Fe415D

Fe500D

CARBON(MAX) .30 .30 .30 .25 .25

SULPHUR(MAX) 0.060 0.055 0.055 0.045 0.040

PHOSPHORUS(MAX) 0.060 0.055 0.055 0.045 0.040

SULPHUR AND PHOSPHORUS(MAX)

0.110 0.105 0.100 0.085 0.075

CE(MAX) 0.42 0.42 0.42 0.42 0.42

GRADES OF TMT BARS

Manganese (Mn) – improves hardenability, ductility and wear resistance

Nickel (Ni) – increases strength, impact strength and toughness, impart corrosion resistance in combination with other elements.

Copper (Cu) – improves corrosion resistance Chromium (Cr) – improves hardenability, strength and

wear resistance, sharply increases corrosion resistance at high concentrations

Silicon (Si) – improves strength, elasticity, acid resistance etc.......

ALLOYING ELEMENTS

Tests involved on ingots and billets are Carbon percentage Sulphur percentage Phosphorus percentage

QUALITY TESTING OF BILLETS

Coal gas is used to produce heat energy in the Furnaces

Peak temperature goes up to 1200°C Billets are being heated for 4 hours There are total 8 burners in the furnace Burners are so adjusted that uniform

temperature is attained Three processes involved in Furnace i.e.

Feeding, Heating and ejection.

FURNACE

FEEDING : Feeding mechanism consists of worm gear

arrangementsHEATING : Preheating zone, intermediate heating zone

and final heating zoneFURNACE EXIT : Red hot billets are exited by Authorized

personnel in proper time and lead to Rolling mills

FURNACE CONTINUE

FURNACE CONTINUE

There are three mills present in the line

ROUGHING MILLS

INTERMEDIATE MILLS

FINISHING MILLS

ROLLING MILLS

ROUGHING MILL: First mill amongst three mills Gear ratio used is1:6 to provide sufficient

torque to rolls Three sets of roller present vertically In Roughing mill very small elongation and

gradually decreasing diameter is attained

ROLLING MILLS CONTINUE

After Roughing mill billets moves to next Rolling mill that is Intermediate Rolling Mill

But before entering the Intermediate Rolling mill billets needs to accelerate its velocity.

Pinch rolls are used to accelerate billets with the help of a motor of 50HP.

After Pinch rolls there is a set of CUTTER or SHEARER with a cone shaped guide ways to cut the ends of the rods for the better entering to the Intermediate rolls.

ROLLING MILLS CONTINUE

INTERMEDIATE ROLLS: The purpose of the Intermediate mill is to

attain considerable elongation and to prepare the rod to enter in the Finishing mill

Before entering to the Finishing Mill two Pinch rolls and a shearer are used.

FINISHING MILL: Precision Rolls are used to get nearly

accurate dimensions Also facilitates the brand imprint

ROLLING MILLS CONTINUE

INTERMEDIATE TO FINISHING

This quenching process is called Thermex Technology.

TMT bars are made to pass through specially designed pipes carrying nozzles and pressure gauges

Water is sprayed through the nozzle to change the temperature of the rods abruptly

Velocity of the water and pressure of the water results the hardening of the rods

After the TMT treatment the rods are made to fall on the Cooling bed.

TMT QUENCHING

Before falling on the Cooling bed, the speeds of the bars are reduced by using a speed breaker

After complete cooling on the cooling bed, the TMT rods are sent for the Inspection and Dispatch

TMT QUENCHING CONTINUE

Thank You