RAJASTHAN INSTITUTE OF ENGINEERING &

TECHNOLOGY JAIPUR, RAJASTHAN

DEPARTMENT OF MECHANICAL ENGINEERING

A PRESENTATION ON

INDUSTRIAL TRAININGAT

Shri Sharma Steeltech (India) Pvt. Ltd.

Jaipur

SUBMITTED BY :-Dharmendra Dudi12EREME018 Dept. of Mech. Engg.

SUBMITTED TO:- Mr. Raghav Singh Asst. ProfessorDept. of Mech. Engg.

CONTENT Company profile

Manufacturing process

Thermo – Mechanical Treatment

Cutting & Shipping

The industry was established in 2008 with the prime motive of manufacturing TMT steel bars with the diameter 8mm, 10mm, 12mm, 25mm. The plant produce approximately 35000 of steel rods on daily bases with the annual turnover of 300 cr (approx.). This industry is the sister branch of “Sharma rolling mill private Ltd”. The industry is setup in the 2 arc of land area where the machine setup is in 0.5 arc. Most of the area is set free for material handling purpose. The industry has well developed machine setup. Most of the machines in the industry are CNC.

Company’s ProfileAddress :- Khasra No.245, Village Bawari Murtikala Zone, Sarna Dungar, Industrial area, Jhotwara, Jaipur, Rajasthan(India)

HEATING ZONE

RAW MATERIA

L

FURNANCE

(1100°-1200°)

CRUSHER(POWDER)

COAL

To Pre-rolling zone

PRE- ROLLING ZONE

ROLLER(VERTICAL)

To rolling zone

ROLLER(HORIZONTAL

)

CUTTER(START\

END)

From heating zone

ROLLING ZONE

ROLLER(25mm)

ROLLER(10mm)

ROLLER(12mm)

TMT(Thermo-

mechanical treatment)

ROLLER(8mm)

To cutting and shipment

Testing

CUTTING AND SHIPPING

Double scissor – 60mm

Scissor – 12mm

On dispatch platform (manually)

Load in trucks (by crane)

Shipping

RAW MATERIAL In general two types of raw material are used, namely

Trapezoidal structureManufactured by casting.Length - 52-60 inches.breadth and height

1. 3 4 X 4 4 inches⅟ ⅟2. 3 2 X 4 2 inches⅟ ⅟3. 4 X 5 inches

Low quality TMT bars are produced.

Ingot Billet Cuboidal shape. Manufactured by casting.Length – 20 feetbreadth and height 4 X 5 inchesBetter quality TMT bars are produced.Less chance of blow holes.

Furnace The furnace is now divided as in three sub

process:- 1. Feeding 2. Heating 3. Ejection

Feeding Feeding is done with the help of conveyer rollers.

At a time only 12 pieces of ingots are feeded.

Worm gear pushing the ingots into the furnace.

The ingots are placed on the conveyer rollers manually; tongs are used in the positioning onto the conveyor system.

Heating Consume crushed coal as a fuel.

Coal having CV above 5000 is used.

Temp. Range 1100°-1200°

Burners vary from 4-8 in numbers.

It make ingot feasible for rolling.

constantly heated for 4 hours

The furnace interior is made of refractory bricks to withstand the high temperatures. There are also certain doors at the side for inspection during maintenance.

Ejection

Ejection gate

The gate opens when an ingot is ready to be rolled and the rollers in the path provided, carry the heated ingot onto the roughing mill.

Path leads to rollers

Coupling

Rollers pair

Guide way to guide the ingot to different rolling pairs

In this section the hot ingots has to pass through the three different rolling pairs

Roughing Mill

Important points in roughing mill:-The ingot comes out of the furnace it is slowly led

to the roughing mill.In this section most of the elongation is done as the

cross sectional area decreases with gradually increase in length.

In the first rolling pair ingot passes for 7 times and single pass for rest of the two.

A motor of power 1200HP is used which runs the bearing coupling and gear box effectively in the same order.

To accelerate the speed of ingot pinch rolls are used.

Cutter Important Points

It was located between roughing and intermediate rolling.It cuts front and back end of the red hot rod.It allows proper entering of rod in next mill.Generally blades moves in to and fro motion.Cut red hot rod by shearing action.Automated part run by gear arrangement.The sheared waste pieces are put aside as scrap.

Sheared pieces

Cutting Blade

Intermediate Mill

Guide Way to guide red hot rod from one roller to other within intermediate mill

Control panel : it control the entire intermediate mill setup.Pinch Rolls

Shaft Arrangement

Important points in intermediate mill :After passing through cutter the rod enters in the

intermediate mill.In this only a small reduction in dimension takes

place as most of the reduction completed in roughing mill.

Its main function is to prepare the specimen for the finishing mill.

It is operated by DC motor of 850HP.

Important points

Finishing MillThe rollers are made with precision and in such a way that the exact dimension can be obtained. It also facilitates for the brand imprint to be put onto the rod.Separate motors are used for each roller. Before entering in this section two pinch rolls are placed to improve the speed .The final dimensions of the TMT steel bar are achieved by finishing rollers.

Thermo – Mechanical Treatment

Here hardening takes place.Reduce the temperature abruptly which results in the hardening of the outer surface of the rod.Extend of hardness depends on the pressure of water.Pressure ranges from 10 Kg/m – 14.5 Kg/m.The rods are made to fall on the cooling bed after the TMT treatment.

Water supplying pipes at 10 Kg/m

Pressure Gauge

Nozzle

Treated Bar

TMT Quenching Box

CUTTING AND SHIPPINGBlind Scissor:- It cuts the bar in 60m. It is also known as the double scissor because is cut the bar with the help of two blades as shown.After passing through the blind scissor the bars

were brought to the dispatch plate form where the bars again cut in the length of 12m. The bars are future cut or may not depending upon the demand of customer . Then bundles of bars are prepared which is future load in the trucks etc. for shipping.

Material Handling

Thank you

Any Queries ..?