axtel screw feeder report

AXTEL INDUSTRIES LIMIED, VOCATIONAL TRAINING REPORT.

A

Vocational Training Report

At

AXTEL INDUSTRIES LIMITED

Village Nurpura, P.O. Baska

Tal. Halol – 389350

Dist. Panchmahal

Gujarat, INDIA

Training Duration June 1 2015 to June 15 2015

Guided By: Mr. Sanketkumar Shah: Senior Manager-Fabrication

Mr. Krupesh thakor: Senior engineering-Production

Prepared By: Mahesh C Prajapati

Sudhir R Gohil

B.E. Mechanical Engineering Students,

Faculty of Technology and Engineering,

The M.S. University of Baroda.


Acknowledgement:

We have felt during our training period at AXTEL INDUSTRIES LIMITED HALOL

that a certain correlation between theoretical knowledge and practical

experience exist and balanced knowledge of both field leading to a safe and

better process and increase productivity.

We are cordially thankful to

Mr. Krishnam Raju KR: Vice President - Manufacturing

Mr. Rushang patel: Senior Manager-HR &

Mr. Bhadresh Parmar: Senior Officer-HR&

Mrs. Sumitra Makawana: Assistant Manager-HR,

For allowing us to perceive knowledge at AXTEL INDUSTRIES LIMITED.

We have got a helping hand and proper technical guidance during the training

period. We are thankful to all of them above for their cooperation, assistance

and love that we have got.

We are also thankful to Mr. D. S. Sharma (Head of Department, Mechanical)

and Mr. S.S. Soman (T & P officer) of our collage for motivation and giving an

opportunity to take training at AXTEL INDUSTRIES LIMITED HALOL.


Preface:

We have heard many times that “Experience is the best teacher”, but we have

actually realize that in our training period. Here we can differentiate the actual

performance and expected performance. It helps us to do excellent work with

ease and it also improves our technical skills and practical Knowledge. This

training has enhanced us manufacturing field of food processing equipment.

This training report consist of overview of company, general overview of

manufacturing of various Food processing equipment, welding procedures, and

detail study of different machine tools, cutting tools and machining operations.

We have been given the best attention by the plant engineers in all respect

including personnel safety. We were guided by Mr. Krupesh Thakor, Mr. Tapan

Bhatt and Mr. Ruchit Patel.

And we had also kind support from workers’ side with their huge experience

We are cordially thankful to them for spending their valuable time with us and

making our training successful and memorable.

Mahesh C Prajapati

Sudhir R Gohil


Index

1. Acknowledgement 2

2. Preface 3

3. AXTEL at A Glance 5

4. Screw Feeder MAIN PARTS 9

5. Application and their Manufacturing processes 10

6. Material Selection from M.S. or S.S. 19

7. SS304 Details and Properties 20

8. SS304 in IRON CARBON diagram 22

9. Welding Classification 24

10. Comparison between Welding Processes 25

11. Why TIG and MIG are used? 27

12. Summary 28


AXTEL at A Glance:

Company History:

AXTEL, a Baroda based company is incorporated in 1991. On 8th December,

1992, AXTEL entered into the capital market with a public issue of equity

shares. The company started its commercial production in the first quarter of

1993.

Overview:

Axtel is a customer oriented, technology driven company that is recognized for

turnkey systems, new product development and exemplary customer service.

Axtel’s expertise is in providing customized process solutions. As clients “one

source” supplier, it offer systems that provide solutions based on client’s

needs. Its wide product range and ability to develop new products, allows it to

make unbiased recommendations without forcing clients to choose from a

specific list only.

Amul Dairy, Cadbury, Nestle, Everest Masala, Real, ITC, Laxmi Enterprises, Laxmi Snacks & Hindustan Unilever Limited are well known clients of this company for their processing equipment and plant.


Equipment Manufactured:

Solids Handling: Sack Tip Stations

Bulk Loaders

Cyclones

Reverse Jet Filters

Dual Tunnel Diverter Valves

Belt Conveyors

Z-Bucket Elevators

Screw Feeders and Conveyors

Screw Feeders with Integral Valves

Octabin and Tote Tilters

Storage And Discharge:

Process Tanks

Storage Tanks And Silos

Intermediate Bulk Containers (IBC)

IBC Filling and Discharge Stations

Big Bag Handling Systems

Rotary Air Lock Valves

Bin Activators

Table Feeders

Butterfly Valves

Knife Gate Valves

Size Reductions:

Universal Mills (Stud Disc / Plate Beater)

Hammer Mills

Nibbler / Granulators

Cone Mills


Pre/ Lump Breakers

Knife Mills

Shredders

Roller Mills

Mixing and Blending: Horizontal U-Trough Mixers

Horizontal Round Trough Mixers

Vertical Single Shaft Mixers

Vertical Twin Shaft Mixers

Intensive Mixers / Conches

Paste Mixers

Double Cone Blenders

Sieving and Straining / Cleaning and Grading:

Rotary Sifters

Inline Rotary Sifters

Gyratory Sifters

Inline Gyratory Sifters

Vacuum Gravity Separators

Zigzag Classifiers

Detoners

Grader & Screeners

Specialized Process Equipments:

Steam Sterilizers

Dewatering Screw Presses

Horizontal Wiped Film Evaporators

Scraped Surface Heat Exchangers

Cooling Tunnels

Moulding Line Cooling Tunnels For Chocolates

IBC / Big Bag Filling Machines For Pasta

Drum Filling Machines


Shell And Tube Heat Exchangers

Continuous Fryers

Continuous Khoa Making Machines

Forming and Portioning Machines

Caramel Slab Former

Dough Kneaders for Hard Dough

Vacuum Dryers

Vacuum Drying Cabinets

Technical Collaborations: Wenger Inc., USA For Food / Feed Extrusion Systems

AnuTec GmbH, Switzerland For Powder Handling Systems

Vision Statement: To establish AXTEL as the leading supplier of process engineering

equipment to the food, pharmaceutical and chemical industries,

providing a profitable financial growth and return for shareholders

investments.

Mission Statement: To manufacture world class engineered equipment for food,

pharmaceutical and chemical industries meeting the highest standards

of quality, design and specification.


STUDY OF HORIZONTAL SCREW

FEEDER

Purpose of manufacturing: To

regulate the flow of powder horizontally or

at an angle.

MAIN PARTS

1. BODY

2. SCREW

3. NON DRIVE ASSEMBLY

4. DRIVE ASSEMBLY

5. AIR PURGING SYSTEM

6. HANGER ASSEMBLY


APPLICATION AND

MANUFACTURING OF ALL THE

PARTS

BODY

MATERIAL : SS304 for all

RM: Seamless pipe, Plate for flange, sheet for ducts.

APPLICATION: Provides housing for screw and material flow, Provides

connection with other parts.

MANUFACTURING PROCESS

1. Inspection of SEAMLESS PIPE

2. Cutting of pipe in BEND SHAW CUTTING MACHINE as per the length

required.

3. Cutting of pipe in LASER CUTTING MACHINE for the ducts.

4. TIG WELDING of the ducts.

5. STRAIGHTENING of the job. (First inserting shaft of I.D. in job and then

hammering)

6. TIG WELDING of the flanges.

7. BUFFING in the grinding shop.

8. Joining the ducts as per drawing (TIG welding for small parts and clamp

toggle parts)


1.1 DUCTS

APPLICATION: For input and output and sometime regulate flow.

• Duct for inlet.

• Duct for outlet.

• Duct for coupling assembly of screw

• Manhole duct.

1. First DEVELOPMENT of the surface as per requirement.

2. Cutting of that shape in LASER CUTTING MACHINE.

3. Turning of that shape by HAMMERING and PRESS WORK.

4. TIG WELDING at the joint.

1.2 FLANGES

• Quick opening flanges.

• Normal flanges.

APPLICATION: For coupling of drive and non drive assembly.



1. Cutting of the plate in LASER CUTTING MACHINE in the shape as

where it to be welded.

2. Chamfering of the plate in LATHE MACHINE

3. TIG WELDING of a part at flange for hinged at drive assembly only.

1.3 PAD

APPLICATION: For cleaning and cleaning at regular interval (MAINATANCE)


1. Cutting the plate in LASER CUTTING MACHINE

2. TIG WELDING of the plates. (SPOT WELDING)

3. During assembly TIG WELDING of those with hanging assembly.

2. FABRICATION OF SCREW

MATERIAL: SS304

RM REQUIRED: Seamless pipe, Shaft for end, sheet for flanges

APPLICATION: To control the flow of material. (HERE SUGAR POWDER)


MANUDFACTURING PROCESS

1. INSPECTION of seamless pipe.

p2. Cutting of seamless pipe in BEND SHAW CUTTING MACHINE

3. Chamfering at end in LATHE MACHINE

4. TIG WELDING of the end machined shaft with drive or non drive side.

5. STRAIGHTENING of the shaft on the lathe by HAMMERING by checking run

out by dial gauge gauge indicator.

6. GAUGING of the flight in the shaft.

7. TIG WELDING of the

8. Same for all other flight.

9. TIG WELDING of the opposite side flange.

10. STRAIGHTENING process

11. BUFFING process in grinding shop.

12. For further HIGH SURFACE FINISH it is sent to other industry

2.1 FINISHED PIPE ENDS

• Drive side

• Non drive side

• In middle for coupling of two screw.


APPLICATION: To have required strength for coupling and torque transfer.


1. Cutting of the shaft of required length in BEND SHAW CUTTING MACHINE in

machine shop.

2. Facing, centering, turning, taper turning and chamfering in LATHE MACHINE

3. Straight cut in the MILLING MACHINE

2.2 FLIGHT

• Small pitches flight

APPLICATION: To decide flow rate as per volume between two flight

• Large pitches flight

APPLICATION: To prevent the adhesion of material with flights.

• Reverse flight at non drive side

APPLICATION: To prevent flow of material in non drive side

MANUFACTURING PROCEDURE

1. Cutting of plate as per requirement in LASER CUTTING machine as per

drawing.

2. Bending of that shape in LOCAL BENDING MECHANISM according to pitches.


3. Gauging process.

3. NON DRIVE ASSEMBLY

PARTS

1. MAKE

• BRACKET

APPLICATION: Provides coupling and housing arrangement.

• BEARING COVER

APPLICATION: Prevent dust from entering.

• SEAL HOUSING

• SEAL CLOSER

• SEAL SHAFT

2. BUY

• SEAL

APPLICATION: To prevent leakage of material in bearing assembly.

• O RING

APPLICATION: To prevent of sugar from coupling flanges.

• SWING BOLT, EYE NUT, LOCK PIN

APPLICATION: For quick opening flange.

• SPACER

APPLICATION: To fill extra space originated due to machining error.

• BEARING


APPLICATION: To provide support to rotating shaft.

4. DRIVE ASSEMBLY

PARTS

1. MAKE

• BRACKET

APPLICATION: To provide coupling and housing arrangement.

• SEAL HOUSING

• SEAL CLOSER

• OIL SEAL

APPLICATION: To prevent flow of oil flow from bearing.

• MOUNTING PLATE

APPLICATION: For motor mounting.

2. BUY

• SEAL

• BEARING HOUSING ( MADE FROM CASTING )

• PULLY DRIVE

• MOTOR OF REQUIRED kW

• SWING BOLTS, EYE NUT AND LOCK PIN

• PULLEY BELTS.


• SPROCKET

MANUFACTURING OF BRACKETS

• 3 PARTS ARE WELDED AS SHOWN IN FIG

PART 1 (CONTAINING FLANGE PORTION)

1. Cutting it in as a required shape in LASER CUTTING MACHINE (HOLES ALSO)

2. TIG WELDING of the part for hinging assembly.

PART 2 (MIDDLE PORTION OF SHAPE OF PARTIAL CYLINDRICAL)

1. CUTTING of the plate in shape.

2. DRILLING the holes required in DRILLING MACHINE

3. Bending in radius HYDRAULIC PRESS

PART 3 (END PORTION OF CIRCULAR PLATE)

1. Cutting of plate in LASER CUTTING MACHINE

2. Drilling hole in DRILLING MACHINE

5. AIR PURGING SYSTEM


APPLICATION: It provides cooling and sealing and also stop entering of sugar

material in non drive assembly.

PARTS

1. Air flow controller.

2. Pressure regulator.

3. Pipe lines

4. Screw type arrangement.

All parts are bought out.

6. HANGER ASSEMBLY

APPLICATION: To provides coupling of two screws

PARTS

• SHAFT

• BEARING

• BEARING HOUSING

• SUPPORTING ROD

• HATCH COVER


Here we have studied that in most of the part of the

SCREW FEEDER mostly the material used is SS304

because of its specific properties.

COMPARISION OF M.S. AND S.S.

MILD STEEL STAINLESS STEEL

1. Major ingredients are C and Fe 1. Major ingredients are Cr, C and Fe

2 Very low corrosion resistant. 2. Very high corrosion resistant.

3. To prevent corrosion galvanizing. 3. Due to Cr corrosion resistant also improved

4. Low cost 4. High cost.

5. Contamination occurs. 5. Contamination does not occur.

6. C present 0.15-0.3% 6. C Present<0.08%

7. Hardness is higher 7. Hardness as per required

So here in food processing unit contamination and corrosion

should not be allowed because it will ruin the raw material of

food processing unit. So instead of M.S we prefer S.S. though

being costly.


DETAILS OF MATERIAL SS304

SS stands for Stainless Steel.

GRADE is 304.

It is series of 300 for STAINLESS STEEL

ALLOYING MATERIALS:

MATERIAL PERCENTAGES

(%)

ADDITION IN PROPERTIES

CARBON 0.08 Increases Hardness

CHROMIUM 18-20 Increases hardness and corrosion

resistance

NICKLE 8-11 Nonmagnetic property and helps in

the formation of the Austenite

structure.

MANGANESE <2 DEOXIDIZER during melting

To prevent the formation of

IRON SULFIDE

AUSTENITE Stabilizer

Reduces cost

SILICON <1 Corrosion resistance to sulfuric acid

PHOSPHORUS <0.045 Increment of tensile strength

SULPHER <0.03 To increase the Machinability

IRON BALANCE Main material


PROPERTIES:

• It has AUSTENITE type of grain structure.

• Atomic arrangement of type FACE CENTERED CUBIC (FCC)

• Excellent WELDABILITY and FORMABILITY

• It is NON MEGNETIC

• Highly CORROSION RESISTANT

• High TENSILE STRENGTH

• High HARDNESS

• Good MACHINABILITY

• It responds well to COLD WORKING which increases its HARDNESS

• It can be DRAWN into WIRES also

• Corrosion takes place in SALT MEDIA AND HELIDE ACIDS

• It has very ATTRACTIVE APPEARANCE


SS304 IN IRON-CARBON DIAGRAM


TTT CURVE

So now to get the AUSTENITE structure of SS304

we have to first heat treat the Fe alloy having

0.08% C upto about 2640 F temperature and

then to achieve the stable austenite structure

we have to cool the heated alloy as per the

TTT diagram so as to achieve SS304 of required

properties.


WELDING PROCESS


COMPARISION OF DIFFERENT WELDING

PROCESSES

PARAMETERS GTAW(TIG) GMAW(MIG) SAW

ELECTRODE Non consumable Consumable Consumable METAL DEPOSITION

RATE Low High High

ARC Visible Visible Submerged EYE PROTECTION Needed Needed Not Needed

TYPE OF CURRENT USED

DCSP DCRP DCRP

CURRENT CHARACTERISTC

Constant current Constant voltage -

STRENGTH High Less High USED FOR Small thickness Large thickness Heavy jobs

WELD POSITION All All Flat AWAILABILITY OF

WELDER Excellent Fair Poor

FLUX REQUIREMENT No No Yes INERT GAS REQUIRED Yes Yes No

POROSITY Very less Quite high Less


OTHER WELDING PROCEDERS

SMAW: It is not used where strength requirement is high and also spatter

defect is more in this case.

ELECTRON BEAM AND PLASMA WELDING: Only used when high PRECISION is

required because it is very costly method.

OXY ACETELYN GAS WELDING: Bulky system, low surface finish obtained and

less strength.

THERMIT WELDING: It is useful where electric supply is not there but it has

more possibilities of defects.

RESISTANCE WELDING: Useful only for LAP joints


WHY TIG AND MIG ARE USED?

TIG is used in industry because the weldment of TIG has high strength, low

spatter and low porosity. Also in this type of welding any AC or DC current can

be used as per requirements. All the welding positions are also possible with

this type of welding. It has got aesthetic looks also and it can be done easily.

But there is one disadvantage of TIG welding that it has very low metal

deposition rate so it can not be used for high thickness plates. And also welder

has to deal with the filler metal, work piece and torch.

So to come across these disadvantages we sometimes use MIG welding inspite

of TIG welding where strength and quality issues are not there.

.


SUMMERY

By performing this training at AXTEL INDUSTRIES LIMITED, We came

across the practical aspect of FABRICATION OF SCREW FEEDER.

In this training firstly we came across the SEQUENCE OF

MANUFACTURING PROCESS of the Screw Feeder and the RAW

MATERIAL required for that. The material used for that is SS304.

Then we came to know about the PROPERTIES OF MILD STEEL AND

STAINLESS STEEL and also concluded that why Stainless Steel is

preferred than Mild Steel though being costly.

Then we learned about the IRON CARBON DIAGRAM FOR Fe-C alloy

materials and found out that at which temperature S.S. is to be heat

treated to achieve AUSTENITE STRUCTURE of SS304.

Then we learnt that why TIG and MIG welding are preferred here. So we

studied the different type of welding like SMAW, SAW, TIG, MIG,

RESISTANCE WELDING AND THERMIT WELDING and learned the

positive aspects of TIG and MIG.

axtel screw feeder report

Documents