HMC Internship Report

INTERNSHIP REPORT
INTERNSHIP REPORT AITAZAZ AHSAN 10-ME-04

HEAVY MECHANICAL COMPLEX,TAXILA
Aitazaz Ahsan 10-ME-04 9/7/13 HMC

HMC INTERNSHIP REPORT
AITAZAZ AHSAN 10-ME-04 WAQAS AHMED 10-ME-184 1

In the name of Allah, the most merciful,
The most beneficent


With much effort and time spent, we thank God for being able to complete the internship
in HMC.
We would like to convey our sincere gratitude to our internship advisor Mr.
Muhammad Shoaib, who believed in us and for his kind interest and guidance
without which this endeavor would not have been materialized. Special thanks to
him for his encouragement and support. Our gratitude goes to all workers for
providing us with helpful information and exchanging thoughts, family members
for their financial support and HMC for supporting us in doing our project.
Thank you.
Sincerely,
Aitazaz Ahsan (10-ME-04)
Waqas Ahmed (10-ME-184)


INTRODUCTION TO HMC
Heavy Mechanical Complex Ltd. (HMC)
Heavy Mechanical Complex Ltd. (HMC), Taxila is a major heavy engineering
subsidiary of the State Engineering Corporation (SEC) under the Ministry of Industries &
Production, Government of Pakistan.
In 1969, General YAHYA KHAN laid the basis of HMC. Then in 1971, HMC
started its production. In 1975, Prime minister of Pakistan ZULFIQAR ALI BHUTTO
inaugurated the HFF. For some years, these two industries worked separately. But after
some years, both were combined because for many works they had need of one
another
HMC defines itself as A technical institute in which all types of machines
including Sugar plants, Cement Plants, Road rollers, Over Head Cranes ranging from
0.5 to 50 tons Heat Exchanger boilers, Special Defense parts (i.e., NDC works), Special
Vibratory Rollers (which can bear statistically 10 to 12 tons vibratory load) and Pakistan
steel works. Some other processes that are also done by HMC are Designing and
manufacturing and assembling and installation with the certification of ISO 9001.
The Heavy Mechanical Complex (HMC), the biggest undertaking of its type in
Pakistan, was established in 1976 with Chinese assistance. The Heavy Forge Factory
(HFF) at this complex has proved crucial for Pakistan's defense production needs. HMC
has the capability for designing, engineering and manufacturing of industrial plants and
machinery. HMC has the largest fabrication and machining facilities in the country
equipped with Computer Aided Designing (CAD) and can undertake a variety of
fabrication / machining jobs on sub-contracting basis. HMC manufactures equipment for
hydro-electric power plants, thermal power plants, sulphuric acid plants, industrial
alcohol plants, oil & gas processing plants, and chemical & petro-chemical plants, etc.
Boilers, cranes, construction machinery, material handling equipment, steel structure,
railway equipment, etc. are some of the other products which are produced on regular
basis. The company's capabilities include engineering and manufacturing of Sugar Mills
ranging between 1,500 - 12,000 TCD (tons of cane crushing capacity per day), Portland
Cement Plants of 700- 5,500 TPD (tons per day) module and White Cement Plant of 50
- 1,000 TPD.
HMC have the resources to handle large projects with demanding delivery
schedules. Being the largest and most extensive fabrication and machining facility
equipped with state of the art technology. HMC provide manufacturing services to the
customers.
HMC have gained rich experience in designing and manufacturing of large projects
through collaboration with internationally reputed engineering organizations. All its
processing facilities are in-house including Designing, Fabrication, Machining, Iron and

Steel Castings, Forgings, Heat Treatment, Assembly, Sand Blasting, Painting and
Galvanizing etc.
Working staff
HMC includes the manpower round about 3000 estimated all officers, staff
members and workers.
Shops in Industry
There are several shops in HMC industry.
Almost all of the shops are mentioned below
Machine shop
Fabrication shop
Forging shop
Hydraulic shop
Steel foundry
Cast iron foundry
Heat treatment
Galvanize shop
Wood working shop (Pattern Shop)
Maintenance shop
Design department
Sales department /(PMD i.e. Project Management Department)
Accounts Finance and Administration
Power section

Capacity & Specifications
Machining capacity = 500*12 tons
Fabrication and Machining capacity= 1000*12
Total = 500*12 + 1000*12 = 18000 tons per annum
This production capacity can be increased time to time with the extension of man power
and other sources subjecting to sub contractors


Facilities
Design Center
Fabrication
Machining
Steel Foundry
Iron Foundry
Hydraulic Press
Die Forge
Quality Control
Design Center
Established in 1970
About 100 highly qualified and experienced design engineers are engaged in
designing.
Equipped with latest CAD tools (See Hardware & Software).
About 132 node local area network.
Complete design coherence
Integration through management information system.
Design plant & machinery including cement, sugar, thermal & hydro power
plants, chemical, oil & gas processing plants, boilers, pressure vessels, heat
exchangers, cranes, road construction machinery, steel structure, piping, ducting
and other similar heavy engineering equipment.
Quality Control
Inspection and testing is carried out as per the procedures established for ISO 9001 QA
System and ASME Code procedures. The inspection & testing activities are well backed
up with the following facilities:
Non Destructive Examination.

The facility consists of VT, UT, MT, PT, RT (Max 80mm thickness).
Material Testing Lab
The laboratory has the facility for checking chemical analysis of iron and steels, non
ferrous metals by spectrographic and wet chemical methods. Metallographic
Examination, Mechanical testing.
Instrument Calibration Laboratory
This laboratory has facilities for calibration of measuring and testing devices such as
pressure testing gauges, thermocouple, temperature recorders, measuring devices.

PRODUCTION PLANNING &CONTROL
PLANNING SECTION
Marketing Department

Contract with customer

Sale order No given
to product

Designer
Drawing made
Planning Section
List of
Components
made
Material
calculated
Demand for
Request form
Stock
available
Yes
No
MMG cell
Purchasing Dpt

GENERAL STORE:
HMC has one big general store which keeps all the parts which are used in
manufacturing products. Raw material parching is done by MMG (Material Management
Group)
DISPATCHING:
Dispatching is the selecting and sequencing the available jobs to be run at
individual workstations and assignment of those jobs to workers
A dispatch list is a listing of manufacturing orders in priority sequence. The dispatch list
is usually communicated to manufacturing detail information on priority, location,
quantity, and the capacity requirement of manufacturing order by operation. Dispatch
lists are normally generated daily and oriented by work center
Dispatching starts with input as route select and schedule chart. It concerns itself with
starting the process and operation of production. It triggers the starting of the production
activity on the shop floor through release of order and instructions, that are based on
pre-planned times and sequences contained in route sheets and schedule charts.
Dispatching determined the person who will do the job work order and authorizations
are issued to perform the work according to a planned sequence, using pre-scribed
tools and a time schedule. It is the duty of dispatching function to issue requisition for
material and tools on production order.
Dispatching of final product to Client
Dispatching cell is the main cell of PPC of HMC, when a product has been
manufactured and completed, than it is the responsibility of dispatch cell to dispatch the
final completed product to concern person or client.
When a product has been completed and assured by machine shop and fabrication
shop than they inform the dispatch cell, that product is ready for customer and move
order slip sent to dispatch cell.

Now dispatch cell after receiving the move order slip dispatch the final completed
product to concern person.
Packing is done by dispatch cell and wood type packing or other type of packing
depends on the product quality and type. Painting also done by dispatch cell according
to the customer demand.
After surface finishing and painting , dispatch cell give the sale and marketing issue
number to final product and attach the dispatched advice to product which include
information and precautionary measures about product uses and clearance by sale and
marketing department.. Than dispatch cell deliver the final product to relevant customer.
Delivery is two types, first customer himself take his product from HMC dispatch cell, in
this way delivery cost is not include in the manufacturing cost. In second type of delivery
HMC it delivers the product to customer site, in this delivery transportation included in
manufacturing cost.
Sale tax invoice is also made by Dispatch cell.
CTC Fabrication Shop
CTC stands for Central Technical Cell. Basically it is a drawing and planning section of
fabrication shop, in this section different drawings are analyzed and then sent to
different sections of fabrication shop depending upon the job and capacity of the shop.
The main jobs of CTC fabrication are:
Job feeding to shop
Planning
Material check
Observation from manufacturing till sale
In CTC we saw and studied drawings of pressure vessel, over head crane and
reduction furnace stage 5 drawings.


Fabrication Shop

Basically Fabrication Shop is divided into four sections: heavy bay section, medium
bay section, small bay section and marking and layout section
In Fabrication Shop machines and capacities are as follow
Heavy Bay
3000 ton press
1000 ton rolling machine
50 ton capacity cranes
Medium Bay
Shaft cutting Circular saw
Cutting Dia. 1350mm
Shaft welding machine
Height of beam 450mm

Small Bay
2.5 ton press
5 ton bending machine

Marking Layout and Cutting Section

Photo cell cutting machine
Electromagnetic or paper templates are used
CNC cutting machine
A German CNC cutting machine is used for cutting accurate and
complex parts
Plasma arc cutting machine for non ferrous metals
Semi automatic cutting machine
Oxygen and natural gas are used for cutting
Mechanical cutting machine(shearing machine)
Parallel cutting machine
Welding
Mainly welding is done in all bays of fabrication shop. The type of welding used in
fabrication shop is as follows
1. Arc Welding
A process utilizing the concentrated heat of electric arc to join metal by
fusion of the base metal plates with consumable electrode. DC or AC
current sources can be used to produce the arc.

2. Shielded Metal Arc Welding(SMW):
Arc is produced by touching the tip of coated electrode to the surface
of work piece and the moving it to appropriate distance to maintain the
arc. The heat generated melts the electrode tip and its coated over the
intermediate area of base metals. Slag is formed to protect the weld
against forming oxides, nitrides. Usually used in construction, ship
building, and pipeline work.
3. Submerged Arc Welding(SAW)
In this technique we shield the metal arc location using a granular flux.
It completely covers the welded region so that too protect against the

oxidation. The remaining flux can be recovered and used again in a
cycle.

4. Electro Slag Welding(ESW)
ESW deposits the weld metal into the weld cavity between two plates
to be joined and space is cooled by water cooled copper shoes to
protect molten slag fro running off. Usually used in special equipment
such as in nuclear industry.
5. Gas Metal Arc Welding(GMAW)
Also known as MIG Welding, Shields the weld zone with an inert gas
like argon, helium or gas mixtures. Deoxidizers present in the weld
makes multiple layers weld possible at the joint.


Advantages of MIG
No slag recovered
High welded metal deposition rate
High speed
Quality weld
Large gaps filled easily
6. Gas Tungsten Arc welding(TIG)
Here tungsten electrode is used as one pole of the arc to generate the
heat required and usually argon is used. It is usually suited to thin
materials producing the excellent quality weld.
NON DESTRUCTIVE LAB
Nondestructive test is used to identify the defects in welding joints in the NDT lab of
HMC .Following the main steps involved in non destructive lab.

NON-DESTRUCTVE TESTING

INTERPRETATION
INDICTION
FALSE NON-RELEVANT
RELEVANT
ACCEPT REJECT

Non destructive test is used for those materials which has sensitive properties, during
the test the characteristics or composition of material does not change.

NON DESTRUCTIVE EXAMINATION FACILITIES
x-ray radiography
Gamma ray radiography
Ultrasonic
Magnetic particle
Liquid penetrant
Eddy current
Spectroscopy
RADIOGRAPHY TECHNIQUES
Following Radiography techniques are in HMC non-destructive lab, but only three
type of radiography are used mostly X-ray ,ultrasonic ,and gamma ray radiography
because other radiography are expensive
X-ray Radiography
Gamma Ray Radiography
Neutron Radiography
Proton Radiography
Xero Radiography
Fluoroscopy

Micro Radiography
Flash Radiography
Auto Radiography
Electron transmit Radiography

WELDING
Defect found in the welding are
Cracks Blow holes
Crack Spatter
Lack of penetration Undercut
Pipes Tungsten inclusion
Porosity Restart of welding
Lack of fusion
Slag inclusions


PENETRANT PRINCIPLES:
1. A penetrant fluid applied to the surface of the piece which is to be tested and is
drawn into any defects.
2. Apply penetrant fluid; allow time for it to soak into cracks.
3. Remove surplus penetrant.
4. Apply a chalky developer provide which soaks up the dye penetrant from any
defects by source capillary action.
5. Surface show stain indict ion any defects.

CAMPARISON & SELECTION OF NDT PROCESSES FOR WELDING
GAS POROSITY
CATEGORY= Processing
Material: Ferrous and non ferrous welds.


NDT METHDS APPLICATION AND LIMITATIONS
Radiography testing Method.
1. Radiography is the most universally used NDT method for detection of gas
porosity in the weldments.
2. The radiography image of a Round Porosity will appear as oval shaped spots
with smooth edges, while elongated porosity will appear as oval shaped spots
with major axis. Sometimes several time longer then minor axis.
3. Foreign material such as loose scale, flux or splatter will effect validity of test
results.

Ultrasonic Testing Method
1. Ultrasonic testing equipments are highly sensitive, capable of detecting micro
separations.
2. Surface finishing and grain size will affect the validity of the test.

Eddy current Testing Method
1. Normally confined to thin wall welded pipes and tube.
2. Penetration restricts testing to a depth of more than one quarter inch.

Liquid Penetrant Testing Method
a. Normally confined to in processes control of ferrous and non ferrous
welds.
b. Liquid penetrant testing is like magnetic particle is restricted to surface
evaluation.
c. Extreme condition must be exercised to prevent any cleaning material and
liquid penetrant materials from becoming entrapped and contaminating the
rewelding operation.

Magnetic particle Testing Method

Normally used to detect gas porosity .Only surface porosity would be evident.
Near surface porosity would not be clearly defined, since indications are neither
strong nor pronounced
MACHINE SHOP
HMC has following machines
Gear shaper machine
Straight bevel machine
Gear hobbing machine
Vertical turret lathe machine
Horizontal lathe machine
Horizontal vertical slope type boring and milling machine.
Universal boring, milling, facing, threading, taping machine.
Plano milling machine.
Horizontal boring machine.
Redial drilling machine.
Column drilling machine.
Gear shaper tool machine
Slotting machine
BVT boring vertical turret machine
Face plat lathe machine.
Double housing planner
Vertical milling machine.


Gear Shaper
A gear shaper is a machine tool for cutting the teeth of internal or external gears. The
name shaper relates to the fact that the cutter engages the part on the forward stroke
and pulls away from the part on the return stroke, just like the clapper box on a planer
shaper. To cut external teeth, a different machine called a hobbing machine can be
used.
Spur Gears
They connect parallel shafts, have involute teeth that are parallel to the shaft and can
have internal or external teeth. They cause no external thrust between gears. They are
inexpensive to manufacture. They give lower but satisfactory performance. They are
used when shaft rotates in the same plane.
Helical Gears

Helical gears connect parallel shifts but the
involute teeth are cut at an angle to the axis of
rotation. Two mating helical gears must have
equal helix angle but opposite hand. They run smoother and more quietly. They have
higher load capacity, are more expensive to manufacture and create axial thrust. They
have longer and strong teeth. They can carry heavy load because of the greater surface
contact with the teeth. The efficiency is also reduced because of longer surface contact.
The gearing is quieter with less vibration.
Internal Gears:
Internal gears are hollow. The properties and teeth shape is similar as of external gears
except that the internal gear had different addendum and dedendum values modified to
prevent interference in internal meshes. They are designed to accommodate a wide
range of equipment. These are ideal and cost effective. The teeth are cut into the inside

diameter while the outside diameter is smooth. These gears are available only in brass.
Internal gear offers low sliding and high stress loading. They are used in planetary
gears to produce large reduction ratios.

When choosing a mating gear the difference between the number of teeth of girth gear
and the pinion should not be less than 15. Their non-binding tooth design ensures
smooth, quiet operation. They are used to transmit rotary motion between parallel
shafts, the shaft rotating in the same direction as the arrangement.
Worm Gears:
The Worm gear is the heart of most mills and kiln drive system. They can't be
used in spare parts inventory. They are also used in steel industry, sugar industry,
paper and pulp industry. The girth gear has been preferred over the gearless drives due
to their lower initial cost, simplicity to install, operate and maintain.
Hobbing:
Hobbing is a machining process for making gears, on a hobbing machine, which is a
special type of milling machine .The teeth or spines are progressively cut into the work
piece by a series of cuts made by a cutting tools called a hob. Compared to other gear
forming processes it is relatively inexpensive but still quite accurate, thus it is used for a
broad range of parts and quantities. It is the most widely used gear cutting process for
creating spur and helical gears

and more gears are cut by hobbing than any other
process since it is relatively quick and inexpensive.


Turning:

Milling:


HEAT TREATMENT AND TTC (TECHNICAL TRAINING CELL)
Training program subject:-
Study of process involved in the heat treatment of
different material according to the required hardness
Heat Treatment The Processes
Annealing
Normalizing
Hardening
Surface
Full
Case
Tempering
Stress releasing
Carburizing
Gas
Pack
Phosphating.

Heat treatment:-
Heat Treatment is the controlled heating and cooling of metals to alter
their physical and mechanical properties without changing the product shape.
Annealing: Used variously to soften, relieve internal stresses, and improve
machinability and to develop particular mechanical and physical properties. Annealing is
the process of slowly raising the temperature above the 3
rd
critical temperature. It is
held at this temperature for sufficient time as per requirement. It is then slowly cooled
down in a furnace. Usually used for high plane carbon steel.

Normalizing:
Normalizing is the process of raising the temperature above 3
rd
critical temperature
range. Usually up to 900 degree centigrade. It is held at this temperature and then
removed form the furnace and cooled at room temperature under natural convection.
The resulting material is soft; the degree of softness depends on the actual ambient
conditions of cooling. This process is considerably cheaper than full annealing since
there is not the added cost of controlled furnace cooling. Usually used for alloy steel.
Hardening:
Flame Hardening: A high intensity oxy-acetylene flame is applied to the selective
region. The temperature is raised high. The "right" temperature is determined by the
operator based on experience by watching the color of the steel. The overall heat
transfer is limited by the torch and thus the interior never reaches the high temperature.
The heated region is quenched to achieve the desired hardness. Tempering can be
done to eliminate brittleness.
Induction Hardening: In Induction hardening, the steel part is placed inside a electrical
coil which has alternating current through it. This energizes the steel part and heats it
up. Depending on the frequency and amperage, the rate of heating as well as the depth
of heating can be controlled. Hence, this is well suited for surface heat treatment. The
Induction and flame hardening processes protect areas exposed to excessive wear.
Items that we induction harden:
Spur Gears and Spur Pinions ,Helical Gears and Helical Pinions ,Sprockets ,Internal
Gears ,Bevel Gears ,Shafts and Pins ,Rails and Racks ,Wheels and Rollers Sheave
Wheels ,Links ,Axle Boxes ,Bushes.
Tempering: Tempering is a process done subsequent to quench hardening. Quench-
hardened parts are often too brittle. This brittleness is removed by tempering.
Tempering results in a desired combination of hardness, ductility, toughness, strength,
and structural stability. Tempering is done immediately after quench hardening. When

the steel cools to about 40 C (104 F) after quenching, it is ready to be tempered. The
steel can be heated to a temperature of 400 to 700 C (752 to 1292 F) that results in a
softer structure having more ductility and toughness.
Stress Relief: stress releasing is used to reduce residual stresses in large castings,
welded parts and cold-formed parts. Such parts tend to have stresses due to thermal
cycling or work hardening. Parts are heated to temperatures of up to 600 - 650 C (1112
- 1202 F), and held for an extended time (about 1 hour or more) and then slowly cooled
in still air.
Carburizing: Carbon diffusion (carburizing) produces a higher carbon steel composition
on the part surface. Carburizing, also known as carburization, is a heat treatment
process in which iron or steel is heated in the presence of another material (but below
the metal's melting point) which liberates carbon as it decomposes. The outer surface or
case will have higher carbon content than the original material. When the iron or steel is
cooled rapidly by quenching, the higher carbon content on the outer surface becomes
hard, while the core remains soft and tough. Carburization used a direct application of
coal packed onto the metal, packed in a box which is heated in a furnace. In gas
carburizing, drop wise kerosene oil is drip into the chamber containing metal to be
carburized.
Phosphating: Phosphate coatings are used on steel parts for corrosion resistance,
lubricity, or as a foundation for subsequent coatings or painting. Phosphate conversion
coatings can also be used on aluminum, zinc, cadmium, silver and tin.
Chemical used is 10:1 Gronodean and water.
Electric Furnaces:-
1. Car bottom furnace
Max. Temp = 950
o
C
Size =900 x 700 x 1800
Plotter and temperature indicator is attached with it.

2. Box type air furnace
It is small and large.
Max. Temp = 950
o
C
Size =600 x 500 x 1200
3. Pit type tempering furnace
Max. Temp = 950
o
C
Size =450 x 450 x 950
4. Salt bath furnace
Small, medium, large
Temp = 550-650
o
C
Size =300 x 400 x 500
Temp = 700-900
o
C
Size =300 x 400 x 800
Temp = 1050-1270
o
C
Size =200 x 300 x 800
5. Flame quenching plant
Vertical: 1200 x 600
Horizontal: 450 x 2400
6. High frequency induction machine
Description: It is in isolated room, it uses 10,000 volts. It have a copper ring that
induct heat to the components external part, it have a mechanism of movement of

job and quenching. Room is provided with oil and water drum for the purpose of
quenching.
7. Cleaner
Description: It is use to wash salt from metal surface after sand bathing.
8. Shot blasting
Description: It is used for the purpose of cleaning the surface of material subjected
to heat treatment.
9. Electric gas carburizing furnace
Description:
Temp = 950
o
C
Size = 300 x 600
10. Electric tempering furnace
Temp = 650
o
C
Size =950 x 1220
11. Salt bath
Size =2000 x 2000 x 1400
12. Water quenching tank
Size =1500 x 3000 x 3000


Introduction to Casting and Pattern Shop

Materials Processing has been defined as the science and technology by which
a material is converted in to a useful shape with a structure and properties that
are optimized for the proposed service environment.
Various operations and processes are involved in the manufacture of products
and components and these are classified in to four basic families as shown in
figure.

The material removal processes begin with an over size piece and remove
material to leave a desired shape. While these processes have often been
referred to as machining, that term is generally used to describe the mechanical
cutting of materials. It also means removal by all other means, including
chemical, thermal, and physical processes.
Casting processes exploit the fluidity of a liquid as it assumes the shape of a
prepared container and solidifies upon cooling.
Deformation processes exploit the ductility of certain materials, most notably
metals, and produce the desired shape by mechanical rearrangement, or
plasticity.
Consolidation processes are those processes that put pieces together, and
include welding, brazing, soldering, adhesive bonding, and mechanical fasteners.
Powder metallurgy is the manufacture of the desired shape from particulate
material and involves aspects of casting, forming, and consolidation.
Each of the various families has distinctive advantages and limitations, and the
various processes within the families have unique characteristics.
Cast products can have extremely complex shapes but also have structures
that are produced by solidification and are subject to associated defects, such as
shrinkage and porosity.
Material removal processes are capable of outstanding dimensional precision
but produces scrap as material is cut away to produce the desired shape.
Deformation processes can have high rates of production but generally require
powerful equipment and dedicated tools or dies.
In casting processes, a solid material is first melted, heated to proper
temperature, and sometimes treated to modify its chemical composition.
The molten material, generally metal, is then poured into a cavity or mold that
contains it in the desired shape during solidification.

Thus, in a single step, simple or complex shapes can be made from any
material that can be melted. The resulting product can have virtually any
configuration the designer desires.
In addition, the resistance to working stresses can be optimized, directional
properties can be controlled, and a pleasing appearance can be produced.
Cast parts range in size from a fraction of an inch and a fraction of an ounce
(such as the individual teeth on a zipper), to over 30 ft (10 m) and many tons
(such as the huge propellers and stem frames of ocean liners).
Moreover the casting processes have distinct advantages in the production of
complex shapes, parts having hollow sections or internal cavities, parts that
contain irregular curved surfaces (except those made from thin sheet metal), very
large parts, and parts made from metals that are difficult to machine.
Because of these features, casting is one of the most important of the
manufacturing processes.
CAST IRON & STEEL FOUNDARY
Basic Requirements of Casting Processes
Six basic requirements are associated with most casting processes.
1- A mold cavity, having the desired shape and size, must be produced with due
allowance for shrinkage of the solidifying material. Any geometrical feature
desired in the finished casting must exist in the cavity. Consequently, the mold
material must be able to reproduce the desired detail and also have a refractory
character so that it will not contaminate the molten material that it will contain.
2- A melting process must be capable of providing molten material not only at the
proper temperature, but also in the desired quantity, with acceptable quality, and
within a reasonable cost.
3- A pouring technique must be devised to introduce the molten metal into the
mold. Provision should be made for the escape of all air or gases present in the
cavity prior to pouring, as well as those generated by the introduction of the hot

metal. The molten material is then free to fill the cavity, producing a high-quality
casting that is fully dense and free of defects.
4- The solidification process should be properly designed and controlled.
Castings should be designed so that solidification and solidification shrinkage
can occur without producing internal porosity or voids. In addition, the molds
should not provide excessive restraint to the shrinkage that accompanies cooling.
If they do, the casting may crack when it is still hot and its strength is low.
5- It must be possible to remove the casting from the mold (i.e., mold removal).
With single-use molds that are broken apart and destroyed after each casting,
there is no serious difficulty. With multiple-use molds, however, the removal of a
complex- shaped casting may present a major design problem.
6- After the casting is removed from the mold, various cleaning, finishing, and
inspection operations may be required. Extraneous material is usually attached
where the metal entered the cavity, excess material may be present along mold
parting lines, and mold material often adheres to the casting surface. All of these
must be removed from the finished casting.
Casting Terminology
Before proceeding with the process fundamentals, it is helpful if we first
become familiar with a variety of casting terms. Figure 13-2 shows the cross
section of a two-part sand mold and incorporates many features of a typical
casting process.
The process starts with the construction of a pattern, an approximate
duplicate of the final casting. The molding material is then packed around
the pattern and the pattern is removed to produce a mold cavity.
The flask is the box that contains the molding aggregate.
In a two-part mold, the cope is the name given to the top half of the pattern,
flask, mold, or core.
The drag refers to the bottom half of any of these features.
A core is a sand shape that is inserted into the mold to produce the internal
features of a casting, such as holes or passages for water cooling.

A core print is that region added to the pattern, core, or mold that is used to
locate and support the core within the mold.
The mold material and the core then combine to form the mold cavity, the
shaped hole into which the molten metal is poured and solidified to produce
the desired casting.
A riser is an extra void created in the mold that will also fill with molten metal.
It provides a reservoir of material that can flow into the mold cavity to
compensate for any shrinkage that occurs during solidification.
The gating system is the network of channels used to deliver the molten
metal to the mold cavity.
The pouring cup (or pouring basin) is the portion of the gating system that
initially receives the molten metal from the pouring vessel and controls its
delivery to the rest of the mold.
From the pouring cup, the metal travels down a sprue (the vertical portion of
the gating system), then along horizontal channels, called runners, and
finally through controlled entrances, or gates, into the mold cavity.
Additional channels, known as vents, may be included to provide an escape
for the gases that are generated within the mold.
The parting line or parting surface is the interface that separates the cope
and drag halves of a mold, flask, or pattern and also the halves of a core in
some core-making processes.
Draft is the taper on a pattern or casting that permits it to be withdrawn from
the mold. The mold or die used to produce casting cores is known as a core
box.

Types of patterns
1. Wooden patterns
2. Metallic patterns
1. Wooden patterns are used when amount of castings are low and we need rough
finishing. They are not expensive.
2. Metallic patterns are used when amount of castings are very large and we need
fine surface finish. These are very expensive. Cost is compensated by the no. of
castings.


Forging Shop
Forging is term applied to a family of processes where deformation is induced by
localized compressive forces. The equipment can be manual or power hammers,
presses, or special forging machines. While deformation can be done in the hot, cold,
warm, or isothermal mode.
Forging is the oldest known metalworking process and it has been an effective method
of producing many useful shapes. High-powered hammers and mechanical presses
have replaced strong arm, hammer, and anvil, Modern metallurgical knowledge helps
the craftsman in controlling the heating and handling of the metal
The term forging usually implies hot forging done above the recrystallization
temperature Forging is a common term used in manufacture of semi-completed forms,
pressed from hot or cold metal blanks in open or closed dies, by the use of force on the
work piece. The amount of forging may be very less or quite large, and can be made of
brass, steel, or other metals. In hot forging process, the billet is heated to a
temperature, which is dependent upon the material being forged.
The forging material may be
Drawn out to increase its length and decrease its cross section,
Upset to decrease the length and increase the cross section,
Squeezed in closed impression dies to produce multidirectional flow.
Common forging processes include:
Open-die drop-hammer forging
Impression-die drop forging
Press forging
Upset forging

Forging Applications
Forged parts vary in size ranging from a few pounds up to 300 tons, and can be termed
into small, medium, and heavy forgings. Small parts include tools such as chisels, and
tools used in cutting and carving wood. Medium forgings include axles of cars, small
crankshafts, connecting rods, levers and hooks. Heavier forgings are shafts of power
plant generators, ships, turbines, columns of presses and rolls for rolling mills.
Methods of Hot Forging
Open Die Forging:
Heated metal parts are shaped between a top die attached to a ram, and a base die
connected to a hammer anvil or press bed. Metal parts are heated above their
recrystallization temperatures, and steadily shaped into the selected configuration
through the hammering or pressing of the work piece. The metal is never wholly
confined or restricted in the dies. The majority of open die forgings are formed on flat
dies. Although the open die forging method is often related with larger, simple shaped
parts such as bars, blanks, rings, hollows or spindles, it can be considered the final
option in custom intended metal components. Long life and high intensity parts,
optimized in terms of both structural integrity and mechanical properties, are produced
in different sizes, ranging from a few pounds to hundreds of tons in weight.
Closed Die or Impression Forging:
In this process the hot metal is trapped in recessed impressions, and is hydraulically or
mechanically pressed to a desired shape. Often two or more progressive impressions
are used, normally in conjunction with one or more preforming operations. A negative
image of the component to be made is sunk into a block or pair of blocks. The die set is
keyed or clamped into a press or hammer, which supplies the energy for the

deformation. This method is used to make cutlery, automotive parts, and parts for
aircraft engines.
Impression Die Forging Process Operations
In the simplest example of impression die forging, two dies are brought together and the
work piece undergoes plastic deformation until its enlarged sides touch the side walls of
the die. Then, a small amount of material begins to flow outside the die impression
forming flash that is gradually thinned. The flash cools rapidly and presents increased
resistance to deformation and helps build up pressure inside the bulk of the work piece
that aids material flow into unfilled impressions.
. The impression in the ram-operated "heading tool" is the equivalent of a hammer or
press top die. The "grip dies" contain the impressions corresponding to the hammer or
press bottom die. Grip dies consist of a stationary die and a moving die which, when
closed, act to grip the stock and hold it in position for forging. After each work stroke of
the machine, these dies permit the transfer of stock from one cavity to another in the
multiple-impression dies.
Hammer Forging
A forging method in which the part is distorted by recurrent blows using a forging
hammer, between impression and flat dies. This procedure is also called drop forging.


Forging Equipment
Forging Machine:
A forging machine includes an anvil mass and a ram block, to be released and struck
against it, between which forging is carried out. The machine comprises of a damping
mass, which experiences the blow and moves in a large amplitude of motion in
comparison with the amplitude of motion of the anvil mass, to damp the blows
conducted from the anvil mass to the stationary foundation of the machine.


Hydraulic Forging Press:
It consists of the press, the hydraulic intensifier, and the auxiliary water tank. A piece of
work is compressed between the dies. Numerous shapes of dies may be used. The
press head is forced down by hydraulic pressure on the ram in the cylinder, and is lifted
by steam pressure under the two pistons in the cylinders. The vertical motion of the
press head is directed by the four columns which hold the press firmly against distortion.
Water pressure is exerted through the pipe from the steam intensifier. Steam admitted
under the piston imparts the pressure to the water.
INSPECTION
Inspection is a process in which the material is just visually Checked by using many
apparatus like Verneir Caliper, Micro meter screw gauges, Tapes, Compasses etc.
When this is done, then a report is prepared containing all the references with respect to
that the material was passed out from the inspection stage and this is a necessary step
to assure the quality of the product. And is done where the status of the
manufacturing industry is to be maintained and the Quality of the manufactured
product is to kept up to the standards. The working process starts with agreement
between purchaser and manufacture, the manufacture provides Preformat Invoice
(PI) to the purchaser which explains the equipment specification and related price.
Then the purchaser issues the Purchase Order (PO) which confirming the
preformat invoice. Before start of manufacturing, the purchaser must provide
equipment inspection and test plan (ITP) to the manufacture. The ITP identifies all
inspection points for purchaser inspector. Then the manufacture needs to prepare the
project quality control plan based of this inspection and test plan. The manufacture
notifies purchaser inspector in advance to attend to her factory for witnessing the
inspections and tests. The communication and coordination channel between
manufacture, purchaser inspector and purchaser are agreed in the Pre-inspection
meeting (PIM).Based the international practice manufacture sends her notification

to the purchaser, and purchaser reviews the notification and after her approval sends
to the inspector. Then the inspector will be attended in the in manufacture shop
to witness the test or inspection. The purchaser inspector will send his/her inspection
visit report to the purchaser. Purchaser can assign his/her own inspector which is her
own direct employee or hire a third party inspection agency to carry out inspection.
Inspection and test plan has tabular format and its content extracted from construction
code. In each row of the table there is quality control and inspection requirement and
determine which party is responsible for control and inspection.
There are three parties in ITP, Manufacture, Third Party Inspector (TPI) and Client
or purchaser.
Normally the table accommodates 3 sections as following:
Before Manufacturing
During Manufacturing
Final Inspection

SUBMITTED TO : Mr.Shoaib (Instructing Manager)
Submitted By : Aitazaz Ahsan (10-ME-04)
Waqas Ahmed (10-ME-184)


Mechanical Engineering Department
University of Engineering and Technology
Taxila.

HMC Internship Report

Transféré par

Informations du document

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

HMC Internship Report

Transféré par

Droits d'auteur :

Formats disponibles

INTERNSHIP REPORT

INTERNSHIP REPORT AITAZAZ AHSAN 10-ME-04

Vous aimerez peut-être aussi