METAL & STEEL

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METAL & STEEL :

METAL & STEEL Vocational training at --- METAL & STEEL (Power flows from the barrel of the gun…… we make it)

RAMAKRISHNA MISSION SHILPAMANDIRA:

RAMAKRISHNA MISSION SHILPAMANDIRA Training Period - 05.10.2015 to 17.10.2015 LIST OF THE STUDENTS( DME) Parijat Saha 7. Partha Tung Avishek Debnath 8. Pritam Ghosh Subhasish Naskar 9. Arnab Kansabonik Prithwiraj Das Sayan Mukherjee Suman Das

INTRODUCTION:

INTRODUCTION Metal & steel factory, Ishapore is the main product of basic Ferrous & non-ferrous raw material for military hardware. High strength. Superior toughness. High degree of accuracy . Light weight. Proper chemical bonding. Heat resistant.

Company profile:

Company profile Indian Ordnance Factories under * MINISTRY OF DEFENCE * GOVERNMENT OF INDIA In 1872, a gunpowder factory was established at Ishapore known as “Foundry and Shell Factory”( now known as Gun and shell factory). Subsequently In 1892, steel manufacturing is started. In 1920, it became an independent unit in the family of Ordnance Factories and had come to be known as "Metal & Steel Factory, Ishapore (MSF)"

Main products:

Main products T-72 Tank Barrel. Mapple Barrel. T-90 Tank Barrel. LFG Barrel (light field gun). IFG Barrel. Bofors Casing. Arjun Tank Barrel.(Mk- 1 & 2). Pinaka Rocket Tube. TA pin.(link) Adaptor of 130mm Mortar.

T-90 tank layout(125 mm) Arjun Tank ( Mk 2):

T-90 tank layout(125 mm) Arjun Tank ( Mk 2) Bofors Barrel (130 mm) LFG Gun

Pinaka rocket Adaptor of 130mm Mortar.:

Pinaka rocket Adaptor of 130mm Mortar . IFG Gun 130 mm( dia ) * 2500 mm Mortar

List of Sections :

List of Sections TR Section (Tool Room) 05.10.15 to 06.10.15 ( 2 days) 2. CCS Section (Cartridge Case Section) 07.10.15 to 08.10.15 ( 2 days) 3. NGF Section (New Gun Forging) 09.10.15 to 10.10.15 ( 2 days) 4. GMS Section (Gun Machining Shop) 12.10.15 ( 1 day) 5. GHT Section (Gun Heat Treatment) 13.10.15 to 14.10.15 ( 2 days) 6. RFS Section (Radial Forging Shop) 15.10.15 to 107.10.15 ( 3 days)

TOOL ROOM :

TOOL ROOM Tool room of Metal & Steel is a very important section where many tools are prepared which are use in this factory. Die. Punch. Gauges (different sizes). There are various types of machines are used for required machining process. Lathe ( engine, turret & capstan ,CNC). Grinding m/c ( cylindrical, rotary, surface, plough). Band saw m/c. Slotting m/c. Ball press. Wire cut EDM ( electro discharge machining). Milling m/c. Radial d rill m/c.

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Band saw m/c Wire cut EDM Plough grinding m/c

CARTRIDGE CASE SECTION:

CARTRIDGE CASE SECTION Main product : 20 mm, 23 mm, 30 mm Cartridge Case. Machinery : Power Press ( cupping, first draw, 2 nd draw ) Fly press or Ball press( stamping). CNC Lathe. Multi spindle Lathe.

PROCESS FLOW CHART:

PROCESS FLOW CHART 1. STEEL BLANK PREPARE. 2. CUPPING. 3. 1 st DRAW. 4. 2 nd DRAW. 5. CUTTING. 6. HEAD PRESSING. 7. NECKING & PERFORATING. 8. TURNING OF RIM & LENGTH 9. INSPECTION, HEAT TREATMENT, INSPECTION & DESPATCH. Steel blank Size 72.5mm dia * 16 (+/-) 0.4 mm thickness

HARDENING:

HARDENING MOUTH ANNEALING

Dimension of Cartridge Case(30 mm):

Dimension of Cartridge Case(30 mm) Total Length 164 – 165 mm. Depth of primer 15 – 15.43 mm. Boss thickness 17.7 – 19 mm. Head 39.66 – 40 mm. Avg. wall thickness of mouth 1.0 – 1.2 mm. Under Head 39.66 – 40 mm. Groove 34.16 – 34.5 mm. Recess 16.24 – 16.48 mm. Depth of recess 2.55 – 2.72 mm. Inside mouth 29.2 – 29.34 mm. Core 11.73 – 12.04 mm. Base thickness 13.5 – 15 mm. Width of groove 3.5 – 3.8 mm.

USEFULLNESS OF 30 mm CARTRIDGE :

USEFULLNESS OF 30 mm CARTRIDGE

PROCESS FLOW CHART OF MAKING BARRELS:

PROCESS FLOW CHART OF MAKING BARRELS RECEIVING OF INGOTS NEW GUN FORGING SHOP RADIAL FORGING SHOP DISPATCH INSPECTION DEPARTMENT HEAT TREATMENT GUN MACHINING SHOP

Slide18:

NEW GUN FORGE In New Gun Forging the materials or ingots came from ESR or LFVD section. To obtain it’s desired shape & size some steps like annealing , forging & finally power press are done. Press forging works by slowly Applying a continuous force.

Slide19:

MACHINERY USE IN THIS SHOP 1. ANNEALING FURNACE : Annealing is a heat treatment process that alters physical and some times chemical properties of metal It involves heating the metal above recrystallization temperature and then cooling All furnaces are electric type Max temp. Is around 800-900 degree Celsius Operating for 8 hours a day capacity 35 MT 8 zones in furnace each having 300 amps SPECIFICATION:-

Slide20:

2.OIL FEED FORGING FURNACE Used for preheating the anneal billets and ingots up to a certain tem. These are all oil fired furnace & heat transmitted by radiation . furnace temp. 1150-1200 Celsius. capacity 35 MT. operating cycle has 3 divisions . heat up time soaking time forging time 29 hours for heating metal charge Normal oil pressure 5 bar Bogie contains for layers 1. Hysil surface 2. gold SFI 3. HFI 4. 45 % Al2O3

Slide21:

3. MANIPULATOR It holds & temporally stores hot forge ingots. works with power press 4.HYDRAULIC POWER PRESS In this metal is stretched beyond yield point to form the desire shape capacity 2650 ton made by ZDAS

Slide23:

GUN MACHINE SHOP (GMS) A machine shop is a room ,building or company where machining is done In GMS machines & machine tools are described below: 1. CNC DEEP HOLE BORING MACHINE ☻ Max bore dia 350 mm for length 12000 mm ☻ Max. Solid drill dia 250 mm ☻ Max wt. Of job 8 ton with 2 steady rest

Slide24:

2. CNC TURNING LATHE:- MAX. DIA OF JOB 550 mm CNC SYSTEM SINUMARIK 840 D 3. BAND SAW MACHINE:- It is a power tool which uses a blade consisting of continuous band of metal with teeth along one edge. saw TPI 2/3,3/4,5/8,8/12 parting & cutting of pinaka tube, barrel

Slide25:

2.UNIVERSAL MILLING MACHINE:- Man drive power 11 KW CNC system Siemens OPERATIONS DONE HERE :- DRILLING BORING TURNING FACE MILLING STEP TURNING CENTRE DRILL

Slide26:

HEAT TREATMENT SHOP WHAT IS HEAT TREATMENT ? Heat treatment is defined as an operation of combination of operations. Involving heating & cooling of a metal & alloy in its solid state with the object of changing the characteristics of the material . OBJECTS : improve machinability. refine grain size mechanical properties & hardness, shock resistance . STAGES OF HEAT TREATMENT stage 1- Heating the metal slowly to ensure a uniform temp. stage 2- Soaking the metal at a given temp. for a given time & cooling the metal to room temp. stage 3- cooling the metal to room temp.

Slide27:

FOUR TYPES OF HEAT TREATMENT: ANNEALING 2.NORMALIZING 3. HARDENING 4. TEMPERING QUENCHING MEDIA: WATER OIL AIR MACHINERIES IN THIS SHOP FURNACE QUENCHING TANK STRAIGTENING PRESS BRINNEL HARDNESS TESTING M/C EOT CRANE BATCH TYPE FURNACE

CONCLUSION:

CONCLUSION From this vacational training we really feel it, for this way METAL& STEEL FACTORY,ISHAPUR has many contributions. Here good industrial environment and professional attitude helps us to know how to perform a job in an industry safely .

ACKNOWLEDGEMENT:

ACKNOWLEDGEMENT T.P.O. shell of our college. Mr. MS. Raw(A.G.M, MSF). Mr. U.S Srivastava(H.O.S/N.G.F.). Dr. Uddipon Mukherjee(W.M, H.R.D). All J.W.M of six sections.

THANK YOU:

THANK YOU

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