sterling tools (bolt manufacturing)

INDUSTRIAL TRAINING AT

STERLING TOOLS LIMITED(INDUSTRIAL ESTATE, DLF 5A, FARIDABAD)

BY:PRINCE NASWA

12MEU067ITM UNIVERSITY GURGAON

ABOUT STERLING TOOL’S• Sterling tools limited (STL), is a well-established,

dynamic and professionally managed company, is a leading manufacturer of fasteners in India.

• The company was incorporated as a private limited company in 1979 and was turned into a public limited company in 1994.

• STL is the third largest fastener manufacturing company in asia.

PRODUCTS: 1. Special Fasteners2. Standard Fasteners3. Chassis Fasteners4. Engine Fasteners

INTRODUCTION• An industrial fastener comprises a very wide range of

items like nuts and bolts, washers, studs, nails etc. Nuts and bolts consist a major link in the family of industrial fasteners and are used by every industry. Bolt is a piece of metal rod, whose one end is unsettled and other end is threaded. Nut is the item, which rolls on these threads.

RAW MATERIAL• Quality of bolts depends on the composition of various

elements in raw material. According to the composition required there are total 17 grades of raw material available. Grade is decided according to the costumer requirement.

Raw Material

Forging

Machining Heat Treatment

Surface finishing

Lab Test Dispatch

FORGING• Forging is a process in which material is shaped by the

application of localized compressive forces exerted manually or with power hammers, presses or special forging machines.

• In cold forging production rates are very high with exceptional die life. It improves mechanical properties and makes it rigid.

WIRE STRAIGHTENING:

• The wire is in the form of rolls. So it needs to be straightened before being forged.

• After straightening:

FEED TUBE STOPPER CUTTER DIE’S

c

HEAD FORMATION:It is a 4 station process:1. Cut off 2. Cone formation 3. Heading4. Final trimming

THREAD ROLLING• Thread rolling is a metal rolling process used extensively

in manufacturing industry to produce screws, bolts and other fasteners.

PROCESS:

MACHINING • Machining is a metal removal process in which excess

material is removed to obtain desired shape, size. Machining is done by using CNC machines which are highly efficient as they are more accurate, less time consuming. So, more productivity and are cost effective also.

• OPERATIONS PERFORMED:1. Parting off2. Threading 3. Grooving4. Turning5. Profiling 6. Undercutting 7. Face-grooving

LUBRICANT:

• Cutting oil used in lubricant is Mobil Cut- 100.• Lubricant composition is 3 to 5% of cutting oil.• DM water or RO water is used in lubricant.• Lubricant is changed after every 6 months.

Concentration of lubricant is checked daily using refractometer.

HEAT TREATMENT• Heat Treatment is the controlled heating and cooling

of metals to alter their physical and mechanical properties without changing the product shape.

Length of furnace is about 14.5m

PROCESS FLOW

LOADER OIL SKIMMER WATER SUPPLY

HARDENING CONVEYOR QUENCH IN OIL TEMPERING

FURNACE

DYEING TANK UNLOADING

• Gas flow meter is used to set LPG and Methanol concentration.

• Minimum 100KGs stock of methanol and LPGis must. This prevents the entrance of oxygen and maintains appropriate carbon content.

Gas flow meter Control panel

SURFACE FINISHING• ELECTROPLATING:Electroplating is the application of a metal coating to a metallic or other conducting surface by an electrochemical process.

PROCESS FLOW• PRE-TREATMENT:

• PLATING:

• POST PLATING:

• H

HOT AIR DRYER

POLLUTION CONTROL• Heat treatment industry has a share in the present

environmental degradation.• Two methods for control of pollution in an Industrial

unit : Use of equipment like gas scrubbers, ventilation fans,

washers etc. require considerable capital investment and also in value running expenses.

Use of high stack chimney and operating the unit at a time of favorable natural draught through chimney, helps to successfully disperse the dust and gases emitted from the unit at zero or negligible cost.

ENERGY CONSERVATION• It has become essential these days that the energy

conservation efforts are needed to be strengthened substantially.

• Various factors which affect fuel economy in industrial furnaces may be stated as :

1. Complete combustion with minimum excess air. 2. Proper heat distribution. 3. Operating at the desired temperature. 4. Reducing heat losses from openings. 5. Minimizing wall losses. 6. Waste heat recovery from flue gases.

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