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DEPARTMENT OF MECHANICAL ENGINEERING

GITAM UNIVERSITY
VISAKHAPATNAM

INDUSTRIAL TRAINING REPORT


ON
ENGINEERING SHOPS AND
FOUNDRY
Report submitted in partial fulfilment of the requirement for the
award of Degree of bachelor technology in mechanical

engineering

FROM 02-05-2016 TO 27-05-2016


SUBMITTED BY
#######NAME#######

CERTIFICATE

DECLARATION

I hereby declare that internship report is authentic record of my work, performed


at VISHAKAPATNAM STEEL PLANT, VISHAKAPATNAM during the
period of 2nd may 2016 to 28th may 2016.Submitted in partial fulfilment of the
requirements of the award of degree of Bachelor of Technology in Mechanical
Engineering, GITAM INSTITUTE OF TECHNOLOGY, GITAM UNIVERSITY,
and the interpretations therein based on material collected by myself.

(Signature of the student)


#####NAME#####

DATE:

ACKNOWLEDGEMENT
Firstly, I would like to thank Mr V.SRINIVASULU for guiding me in the right
way to improve technical knowledge in my subject and helping me in getting
permission for doing my internship in STEEL PLANT. I would like to thank
my HOD, Mr. M R S Satyanarayana who accepted my request of internship in
STEEL PLANT.
I would like to thank my guide Mr. J. PRABHAKARA RAO who encouraged
me in all the aspects during my internship. His immense knowledge in subject
and his experience not only made me inspired but also gave me confidence to
achieve a valuable position in my life. Now I would like to thank all the service
departments of STEEL PLANT who helped in doing my internship comfortably
Now I would like to thank all my friends who made me feel comfortable and
befriended all the time.
######NAME#####
(ID NO)

TABLE OF CONTENTS
INTRODUCTION _________________________ 6
EQUIPMENT REPAIR SHOP _______________ 7
CENTRAL MACHINE SHOP(CMS) ____________ 14
STRUCTURAL STEEL SHOP (S.S.S) __________ 16
LIGHT & MEDIUM MERCHANT MILL (L.M.M.M) ___ 18

WIRE ROD MILL _________________________ 19


STEEL MELT SHOP _______________________ 20
CONCLUSION ___________________________ 21

INTRODUCTION
Visakhapatnam Steel Plant, popularly known as Vizag Steel is
an integrated steel producer in Visakhapatnam, India built using
German and Soviet technology. Its products have been rate the
best in the world market. The company has grown from a lossmaking industry to 3-billion-dollar Turnover Company
registering a growth of 203.6% in just four years. Vizag Steel
Plant was conferred Navratna status on 17 November
2010. Founded in 1971, the company focuses on producing
value-added steel, with 214,000 tons produced in August 2010,
out of 252,000 tones total of salable steel produced. It is the
largest single site plant in India and Asia Minor (or south and
East Asia combined).

EQUIPMENT REPAIR SHOP


Repair shop is like a diagnosis centre where the equipments
come for repairs or modifications. This shop mainly consists
of 4 sections:-

Fitting & Assembly

Machine

Fabrication

Reclination

1) Fitting & assembly - The 1st section takes us through the


dismantling kind of work where the components like
gearbox, hydraulic parts, conveyor drums etc. come for
repairs & they are separated down. After work is done they
are set back to original positions.
2) Machine - Machine section contains heavy lathe, milling,
grinding etc. They come in to play when there is any
precision modifications.
3) Fabrication - Penultimate section comprises of welding
wherein the desired product is made as per the design
4) Reclination - At last there lies the repairing section which
takes care of the decayed products.

PLANAR MACHINE
A planar is a type of metalworking machine tool that
uses linear relative motion between the work piece and a single
point cutting tool to cut the work piece. A planer is similar to a
shaper, but larger, and with work piece moving, whereas in a
shaper the cutting tool moves.

There are two types of planing machine. They are

LINEAR PLANING

HELICAL PLANING

APPLICATION OF PLANING :
The most common applications of planers and shapers
are linear-tool path ones, such as:
Generating accurate flat surfaces. (While not as precise
as grinding, a planer can remove a tremendous amount
of material in one pass with high accuracy.)
Cutting slots (such as keyways).
It is even possible to do work that might now be done
by wire EDM in some cases. Starting from a drilled or
cored hole, a planer with a boring-bar type tool can cut
internal features that don't lend themselves to milling or
boring (such as irregularly shaped holes with tight
corners).

BALANCING MACHINE
When a part of machine is rotating it is important to balance the
mass evenly so that no vibrations occur.

In balancing machine there will be two centers on which the


rotating part is mounted.
It is joined on one end to the rotating shaft as shown in the
fig and the other end is mounted on the two rollers.
There will be two electrical sensors placed on the two ends
which shows the mass imbalance on the digital meter as
shown in the fig.
Imbalance in mass and the position where it is present is
also shown so that the mass is removed or added to make it
balanced.
The most important thing is that the person who is operating
the balancing machine must be very skilled.
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MILLING MACHINE
Milling is a versatile machine tool that uses a rotating milling
cutter, while the work piece reciprocates in contact with the cutting
tool. After lathe machine milling machine is most widely used in
manufacturing operation .The most important difference between
milling machine and lathe is lathe uses a single point cutting tool
whereas milling machine uses a multipoint cutter.

WORKING:
Milling machine has multi point cutters in which of the cutting
edges removes material for only part of the rotation of the cutter.
Because of this each of the cutting edge has time to cool before it
removes material again , so cooling will be effective in case of
milling machine.
TYPES OF MILLING MACHINES:
Knee and Column type
Production (bed) type
Plano millers
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GRINDING MACHINE
Grinding is a process in which the grinding wheels made of
abrasive particles are used to remove the material from the work
piece. In this the machining materials which are too hard for
other machining processes such as tool and die steels and
hardened steel materials. The machine which is used to perform
the grinding operation is known as GRINDING machine.

WORKING:
The most important part in the grinding machine is the grinding wheel
(tool) which will be mounted on a rotating shaft and the material to be
machined is traversed across the wheel. The hardness of the material
used as abrasive particle for grinding wheel must be more than that of
the material to be machined.
TYPES OF GRINDING MACHINES:
Grinding machines are classified based on the shape of the workpiece
to be machined. The grinding wheels used may be one or more.
Cylindrical grinding machine

Surface grinding machine


Centerless grinding machine

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SHAPER MACHINE
Shaper is one of the reciprocating machine tool. Shaper is a
relatively slow machine tool with very low metal removal
capability. So it is being replaced by more versatile milling
machines in many industries. It uses a single point cutting tool
which is mounted on the clapper box, which in turn is mounted on
the ram.

WORKING:
The ram while undergoing the cutting stroke pushes the cutting tool
through the work piece to remove the material. When ram returns no
cutting stroke take place. In between return and cutting strokes the table
moves in a direction perpendicular to the cutting direction termed feed
direction. The reciprocating motion in the shaper is because bull gear and
pin which run by a motor. To reduce the idle time a process known as
quick return motion mechanism is implemented in shaper.
TYPES OF SHAPERS:
Universal shaper
Draw cut shaper
Vertical shaper
Hydraulic shaper
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CENTRAL MACHINE SHOP


The heart of VSP lies in this shop. As we can
guess by the name itself its the main place where machining is
done. The production can consist of cutting, shaping, drilling,
finishing, and other processes. The machine tools typically
include lathes, milling machines, machining centers, multitasking
machines, drill presses, grinding machines, many controlled
with CNC.
There are 39 lathes in total in CMS of which 28 are
manufactured by Hindustan Machine Tools (H.M.T) & 11 are
from Heavy Engineering Corporation ltd (H.E.C). The horizontal
press of 160 tonnes capacity are used for disengaging the
connection between shaft & hole. Other simple techniques like
using torque wrench to reduce manpower, heating of hole to let it
expand & shaft sits on easily are frequently followed.
Now if we talk about the operations in the shop then there is :1) Boring being carried out for making crane wheels.
2) Turning operation on lathe for making gears blanks.
3) Milling is done on gear blanks to make spur gear or helical gear. Here there is
a need of doing indexing that may be direct indexing or differential indexing.
4) Grinding for sharpening the cutting tools.

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STRUCTURAL STEEL SHOP (S.S.S)


This is one of the oldest shops in VSP. The main role of this shop
is welding & cutting. They do cutting with the help of a CNC
machine which has the required design feeded in it. There is also
a provision of doing manual cutting by using LPG-Oxygen
mixture. LPG is carried in blue & Oxygen in black pipeline. In
welding they use consumable electrodes (E6010) which has a
flux coating on it for better & faster cutting.
The work is done according to the requirement if
there is a need to make a structure for any department then they
plan for minimum energy utilization. Then the work design is
made as per the dimensions. The work is carried out under the
supervision of the manager. The different parts so produced are
welded together according to the specifications. The made
structure is transported to the destination to differentiate between
different grades of steel, colour codes are set. Colour codes of
different types of steel are :
1) Red - EN 24
2) Yellow - EN 18
3) Green - EN 19
4) Blue - C 45

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LIGHT & MEDIUM MERCHANT MILL (L.M.M.M)


The mill consists of big furnaces in which
billets are fed in. There are 2 furnaces working simultaneously to
meet the requirements. Billets go inside the furnace through an
automated process & stays inside it for few hours. Furnaces
which are computer controlled are made under observation. Once
the temperature crosses 1500 Celsius they are brought out &
carried over to rolling process. Now a billet which is of square
cross-section need to be transformed to circular shape to
manufacture wire rods. Passing through rollers setup the shape
slowly changes to circular one. As the process goes on the
diameter slowly reduces. At last the wire rods so obtained are
laid down for cooling over a large rack like structure where it
cools down. The maintenance of rollers takes place frequently.
Later on rods are transported to clients. The finished products
include wire rods & long products like reinforcement bars,
rounds, squares, flats, angles, channels, billets etc.

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WIRE ROD MILL (W.R.M)


The difference between LMMM & WRM is, coiled wire rods are
made in latter as the final product. The billets manufactured at
SMS are transported to WRM. They are loaded near the furnace
wall. They are heated & passed onto the rollers similarly as
LMMM. In the immediate next stage the head & toe part of the
billets are cut down. The reason behind it is to get appropriate
dimensions at the end. At once 4 billets are fed inside. Inside the
process there are guide valves which are used for marking a term
VIZAG TMT. This indicates the company logo. After
completion of this the coils are allowed to cool down by passing
it through showers. The stating part of the coil is cut down
because of its irregular shape. After cooling its time to mark for
grade, batch, date etc. For example blue paint is marked for
Fe500D grade, 621091, May 16. There are different colours for
different grades of steel. Thereafter they are sealed & put in
storage yard.

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STEEL MELT SHOP (S.M.S)


This shop prepares steel & makes products like blooms, billets,
bars etc. The process of making steel starts from heating up a
iron ore in a large laddle. The next step is to add some scrap to it
to make it separable from other elements. The scrap is mixed
from all the departments & carried till the laddle & dropped in it.
This takes some time to prepare the steel out of this. After
completion of the steel its transported to other section where
products are made out of it. The first process is an overhead job
as the metal comes in a laddle. Metal is poured in the tundish
which has a nozzle at its end. Beneath the nozzle there lies mould
of any required shape. To maintain the temperature in tundish
some additives are thrown directly inside it. After cooling the
products are kept aside. The major difference between blooms &
billets is cross-sectional area. The cross-sectional area of bloom
is greater than 36 in2 whereas cross-section area of billet is less
than 36 in2

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CONCLUSION
At the end of the internship training, I could gain a lot of practical
experience which cannot be found through the books. Now I could
clearly relate my mechanical engineering subjects to the real life
practical experience. The departments where I did my internship
gave me a strong basics about foundry, wood workshop, machine
design, heat transfer which I have learnt in my past 3 years and now
I could clearly relate to the theory and practical due to industrial
exposure.Finally this industrial internship helped me for

better understanding what I am going to face in my future as


mechanical engineer and also a better understanding about
my subjects and its relation to the outside world

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