Industrial Training Report (Bhushan Steels Pvt. Ltd.)

Name

: VIVEK RAJ YADAVUniv. Roll No.

: 0809140089Academic Session: 2008-2012

JSS ACADEMY OF TECHNICAL EDUCATION, NOIDA

JSS MAHAVIDYAPEETHA

DEPARTMENT OF MECHANICAL ENGINEERINGCONTENT

1.0 Acknowledgement.3

2.0 Abstract ............... 4 3.0 Histry of the company......54.0 Company profile...7

5.0 Vision of the company..86.0 Policies of company.9

7.0 List of departments visited in training..10

7.1 HR slitting.11

7.2 Pickling.12

7.3 Rolling mills.......14

7.4 Electrochemical cleaning..17 7.5 Annealing...20 7.6 Normalization....22

7.7 Skin pass mill.24

7.8 Cold roll stilling/Cut to length.....25

7.9Qualitycontrol.....28 7.10 Research and development..29 7.11 Galvanising plant.....32 7.12Rollgrindingmachine......37 7.13 Narrow plant........418.0 Conclusion...429.0 References.......43

ACKNOWLEDGEMENT

I would wish to express my gratitude to my H.O.D Dr. C.V.Chandrashekhara for providing me the opportunity to explore studies beyond academics. I am also thankful to BHUSHAN STEELS Ltd for allowing me to undergo the SUMMER TRAINING PROGRAMME in their organization. At last but not the least I extend my thanks to all the staff members for providing valuable information regarding the plant and processes that formed the core of the training.

ABSTRACT

In 30 days of my industrial training I have learned about various processes such as cold rolling slitting etc. I had a good exposure to these processes which added more to my knowledge. I worked on galvanising plants in which galvanization process takes place,on steel.basically zinc or aluminium coating is done on the steel,for increasing life of steel and making it suitable for use, but at Bhushan steel they also coat steel with galume a mixture of 55% zinc + 43% aluminium + 2% silicon. Its coating is very effective and useful.silicon is basically used just to improve adhesion of the other two material on the steel. Other products of the industry are colour coated coil, hard tempered coil, billets, sponge iron, tubes, etc.

HISTRY OF THE COMPANY

Year events 1983 - The company was incorporated on 7thJanuary, under the name of Jawahar Metal Industries Private Limited for the manufacture of cold rolled steel strips and steel ingots at Sahibabad Industrial Area, District Ghaziabad.

1987 - On 14th January, Brij Bhushan Singal and his sons Sanjay Singal and Neeraj Singal and associate companies took over the management of the company by acquiring the entire share capital of the company.

1989 - The company undertook the setting up of a new plant for the manufacture of wide width Cold Rolled Steel Strips with integrated plant facilities.

1992 - The name of the company was changed to the present name of Bhushan Steel & Strips Limited and fresh Certificate of Incorporation was issued on 9th June.

1993 - The company made its maiden Public Issue of 22 lac equity shares of Rs.10 each at a premium of Rs.55 share aggregating Rs. 1430 lacs in September/October.

1994 - The galvanising plant was commissioned in January. Presently the company has facilities for the manufacture of 1,20,000 tonnes per' annum of wide width cold rolled steel strips and 1,00,000 tonnes per annum of galvanised sheets.

1995 - The Cold Rolling Expansion the Company is installing state of the art 1600mm width 6HI combination Universal Crown Mill (UCM) of Hitachi, Japan with sophisticated features for shape control and surface finish to cater to the requirements of the automobile and white goods sector.

1996 - The Part B of 68,94,800 14% unsecured fully convertible Debentures aggregating Rs 8375 Lacs have been converted into Equity Shares w.e.f. 1st April.

1998 - With the commissioning of the new plant recently set up at company's existing site at Sahibabad (UP), the company is now exploring further growth possibilities of setting up a modern Cold Rolling cum Galvanizing Unit at West Coast of the Country.

1999 - During the year, the company has set up a dedicated service centre for large OEM customers at Sahibabad so as to ensure supplies to them on 'just in time' concept.

2000 - The Delhi-based Bhushan Steel and Strips' to set up a Rs 750 crore cold rolled steel plant is likely to hit a road block.

2002-Strikes an important position in the market for cold rolled steel for automobiles, feeding over 70% of demand for car bodies.

2003-Enters into a strategic alliance with Sumitomo Metal Industries of Japan under which, the latter has further extended process know-how for the manufacture of automotive steel sheets for a period of six years

2004-Bhushan Steel awards Rs 36 cr order for BHEL

2006-Bhushan Steel & Strips Ltd has informed that Sh. Sanjay Singal, has ceased to be a Director of the Company w.e.f. October 18, 2006.

2007-Company name has been changed from Bhushan Steel & Strips Ltd to Bhushan Steel Ltd

2008-Bhushan Steel Ltd has informed that w.e.f. September 23, 2008, Sh. B B Tandon has been appointed as an Additional Director on the Board of the Company as a Independent Non-Executive Director.

2009-Bhushan Steel buys Aussie exploration firm

2010- Bhushan Steel Ltd has informed that Life Insurance Corporation of India has appointed Smt. Sunita Sharma, their representative as a Nominee Director on the Board of the Company.

COMPANY PROFILE

TYPE : PRIVATE

FOUNDED IN : 1987

HEADQAURTERS : INDIA

KEY PERSONS : Brij Bhushan Singhal (Chairperson)

Neeraj Singhal (Managing Director)

INDUSTRY : STEEL

WEBSITE : www.bhushangroup.comVISION OF THE COMPANY

The vision of evolving into a totally Integrated Steel Producer by committing to achieve the highest standards of Quality through

The key to Vision is to use rigorous conceptual framework and to understand how that framework connects to the underlying DNA of enduring great companies.

A well-conceived vision consists of two major componentsCORE IDEOLOGYand anENVISIONED FUTURE. A good vision builds on the interplay between these two complementary Yin-and-Yang forces; it defines What we stand for and Why we exist that does not change theCore Ideologyand sets forth What we aspire to become, to achieve.

It is true to say that most of our vision statements express an element of ambition.BSLs vision of total integration is a lot closer to realization today. Through seamless backward integration, BSL is consolidating its position on the entire steel value chain from iron ore to specialized is surging ahead.

POLICIES OF THE COMPANY

BHUSHAN STEEL LTD, SAHIBABAD

Integrated Quality, Environment, Occupational Health & Safety Management System Policy

Bhushan Steel Ltd. commits to produce cold rolled and galvanized steel sheets of world class quality in a safe, healthy and clean environment by involving employees with continual improvements in system implementation, technological advancement, operational integration, prevention of pollution & hazards maintaining

Legal compliance and satisfying needs & expectations of Customers.

For environment management system we have ISO 14001:2004 certification

For quality system we have ISO/TS 16949:2002 certification

For safety management system we have OHSAS 18001:2007 certification for quality system we have ISO/TS 16949:2002 certification.

For Safety Management System we have OHSAS 18001:2007 CertificationLIST OF DEPARTMENT VISITED IN TRAINING

1. HR SLITTING 2.HRS/PICKLING 3. ROLLING MILLS

4. ECL

5. ANNEALING

6. SKIN PASS MILL

7. CRS/CTL

8. QUALITY

9. R&D

10. UTILITY11. GP12. RGM

13. NARROW PLANTHR SLITTINGRoll slitting, also known aslog slitting, is ashearingoperation that cuts a large roll of material into narrower rolls. The log slitting terminology refers back to the olden days of saw mills when they would cut logs into smaller sections. They would also use these saw mills to cut iron rods into smaller sections; seeslitting mill. The multiple narrower strips of material are known asmults(short for multiple)By today's definition, slitting is a process in which a coil of material is cut down into a number of smaller coils of narrower measure. Potential workpieces are selectively thin (0.001 to 0.215 in.) and can be machined in sheet or roll form. Slitting is considered a practical alternative to other methods due to its high productivity and the versatility of materials it can manage.Soft materialsSeveral methods are available for soft materials like plastic films and paper.Razor blades, straight, or circular blades are being used. Some blades cut through the material while others crush the material against a hard roll. Those are similar to knives and cut the material into narrow strips, which are called coils when being rewound. The cutting blades can be set to a desired width. Some machines have many blades to increase the options of cutting widths, others have just a single blade and can be set to a desired location. The slit material is being rewound on paper or plastic cores on the exit side of the machine.

Examples of materials that can be cut this way are: adhesive tape, foam, rubber, paper products, foil, plastics (such as tarps and cling wrap), glass cloth, fabrics,release linerand film.Hard materials For harder materials, such assheet metal, blades cannot be used. Instead a modified form of shearing is used. Two cylindrical rolls with matching ribs and grooves are used to cut a large roll into multiple narrower rolls. This continuous production process is very economical yet precise; usually more precise than most other cutting processes. However, the occurrence of rough or irregular edges known as burrs are commonplace on slit edges. PICKLINGPickling (metal)

Picklingis ametalsurface treatment used to remove impurities, such as stains, inorganic contaminants,rustorscalefromferrousmetals,copper, andaluminumalloy. A solution calledpickle liquor, which containsstrong acids, is used to remove the surface impurities. It is commonly used to descale or cleansteelin varioussteelmakingprocesses.

ProcessManyhot workingprocesses and other processes that occur at high temperatures leave a discoloring oxide layer or scale on the surface. In order to remove the scale the workpiece is dipped into a vat of pickle liquor.

The primaryacidused ishydrochloric acid, althoughsulfuric acidwas previously more common. Hydrochloric acid is more expensive than sulfuric acid, but it pickles much faster while minimizing base metal loss. The speed is a requirement for integration in automaticsteel millsthat run production at high speed; speeds as high as 800ft/min (~243 metres/min) have been reported.

Carbon steels, with an alloy content less than or equal to 6%, are often pickled in hydrochloric or sulfuric acid. Steels with an alloy content greater than 6% must be pickled in two steps and other acids are used, such asphosphoric,nitricandhydrofluoric acid. Rust- and acid-resistant chromium-nickel steels are pickled in a bath of hydrochloric and nitric acid. Mostcopperalloys are pickled in dilute sulfuric acid, butbrassis pickled in concentrated sulfuric and nitric acid mixed with sodium chlorideandsoot.[1]Injewelry making, pickling is used to remove the oxidation layer from copper surfaces, which occurs after heating. A diluted sulfuric acid pickling bath is used.

Sheet steel that undergoes acid pickling will oxidize (rust) when exposed to atmospheric conditions of moderately high humidity. For this reason, a thin film of oil or similar waterproof coating is applied to create a barrier to moisture in the air. This oil film must later be removed for many fabrication, plating or painting processes.

DisadvantagesAcid cleaning has limitations in that it is difficult to handle because of its corrosiveness, and it is not applicable to all steels.Hydrogen embrittlementbecomes a problem for some alloys and high-carbon steels. The hydrogen from the acid reacts with the surface and makes it brittle and causes cracks. Because of its high reactance to treatable steels, acid concentrations and solution temperatures must be kept under control to assure desired pickling rates.Waste productsPickling sludgeis the waste product from pickling, and includes acidic rinse waters, metallic salts and waste acid.]Spent pickle liquor is considered ahazardous wastebyEPA.Pickle sludge from steel processes is usually neutralized with limeand disposed of in aland fill. After neutralization the EPA no longer deems the waste a hazardous waste. The lime neutralization process raises thepHof the spent acid and makesheavy metalsin the sludge less likely to leach into the environment.Since the 1960s, hydrochloric pickling sludge is often treated in ahydrochloric acid regenerationsystem, which recovers some of the hydrochloric acid andferric oxide. The rest must still be neutralized and disposed of in land fills.The by-products of nitric acid pickling are marketable to other industries, such asfertilizerprocessors

ROLLING MILLS

CCR is lo

Inmetalworking,rollingis ametal formingprocess in which metal stock is passed through a pair of rolls. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above itsrecrystallizationtemperature, then the process is termed ashot rolling. If the temperature of the metal is below its recrystallization temperature, the process is termed ascold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process and cold rolling processes the most tonnage out of allcold workingprocesses.

There are many types of rolling processes, includingflat rolling,foil rolling,ring rolling,roll bending,roll forming,profile rolling, andcontrolled rolling.

Hot rolling is ametalworkingprocess that occurs above the recrystallization temperature of the material. After the grains deform during processing, they recrystallize, which maintains anequiaxedmicrostructureand prevents the metal from work hardening. The starting material is usually large pieces of metal, likesemi-finished casting products, such as slabs, blooms, and billets. If these products came from acontinuous castingoperation the products are usually fed directly into the rolling mills at the proper temperature. In smaller operations the material starts at room temperature and must be heated. This is done in a gas- or oil-firedsoaking pitfor larger workpieces and for smaller workpiecesinduction heatingis used. As the material is worked the temperature must be monitored to make sure it remains above the recrystallization temperature. To maintain asafety factorafinishing temperatureis defined above the recrystallization temperature; this is usually 50 to 100 C (122to 212F) above the recrystallization temperature. If the temperature does drop below this temperature the material must be re-heated before more hot rolling. Hot rolled metals generally have little directionality in their mechanical properties and deformation inducedresidual stresses. However, in certain instancesnon-metallic inclusionswill impart some directionality and workpieces less than 20mm (0.79in) thick often have some directional properties. Also, non-uniformed cooling will induce a lot of residual stresses, which usually occurs in shapes that have a non-uniform cross-section, such asI-beamsandH-beams. While the finished product is of good quality, the surface is covered inmill scale, which is anoxidethat forms at high-temperatures. It is usually removed viapicklingor thesmooth clean surfaceprocess, which reveals a smooth surface. Dimensional tolerances are usually 2 to 5% of the overall dimension.

Hot rolling is used mainly to producesheet metalor simple cross sections, such asrail tracks.

Cold rolling

Cold workingCold rolling occurs with the metal below its recrystallization temperature (usually at room temperature), which increases thestrengthviastrain hardeningup to 20%. It also improves thesurface finishand holds tightertolerances. Commonly cold-rolled products include sheets, strips, bars, and rods; these products are usually smaller than the same products that are hot rolled. Because of the smaller size of the workpieces and their greater strength, as compared to hot rolled stock, four-high or cluster mills are used. Cold rolling cannot reduce the thickness of a workpiece as much as hot rolling in a single pass.

Cold-rolled sheets and strips come in various conditions:full-hard,half-hard,quarter-hard, andskin-rolled. Full-hard rolling reduces the thickness by 50%, while the others involve less of a reduction. Quarter-hard is defined by its ability to bebentback onto itself along thegrain boundarywithout breaking. Half-hard can be bent 90, while full-hard can only be bent 45, with thebend radiusapproximately equal to the material thickness. Skin-rolling, also known as askin-pass, involves the least amount of reduction: 0.5-1%. It is used to produce a smooth surface, a uniform thickness, and reduce theyield-point phenomenon(by preventingLuder bandsfrom forming in later processing).It is also used to breakup the spangles in galvanized steel.[citation needed]Skin-rolled stock is usually used in subsequent cold-working processes where good ductility is required.

Other shapes can be cold-rolled if the cross-section is relatively uniform and the transverse dimension is relatively small; approximately less than 50mm (2.0in). This may be a cost-effective alternative toextrudingor machining the profile if the volume is in the several tons or more. Cold rolling shapes requires a series of shaping operations, usually along the lines of: sizing, breakdown, roughing, semi-roughing, semi-finishing, and finishing.

ProcessesFlat rollingFlat rolling is the most basic form of rolling with the starting and ending material having a rectangular cross-section. The material is fed in between tworollers, calledworking rolls, that rotate in opposite directions. The gap between the two rolls is less than the thickness of the starting material, which causes it todeform. The decrease in material thickness causes the material to elongate. Thefrictionat the interface between the material and the rolls causes the material to be pushed through. The amount of deformation possible in a single pass is limited by the friction between the rolls; if the change in thickness is too great the rolls just slip over the material and do not draw it in.The final product is either sheet or plate, with the former being less than 6mm (0.24in) thick and the latter greater than; however, heavy plates tend to be formed using apress, which is termedforming, rather than rolling.

Oftentimes the rolls are heated to assist in the workability of the metal. Lubrication is often used to keep the workpiece from sticking to the rolls. To fine tune the process the speed of the rolls and the temperature of the rollers are adjusted. Foil rollingFoil rollingis a specialized type of flat rolling, specifically used to producefoil, which is sheet metal with a thickness less than 200m (0.0079in)The rolling is done in acluster millbecause the small thickness requires a small diameter rolls.[3]To reduce the need for small rollspack rollingis used, which rolls multiple sheets together to increase the effective starting thickness. As the foil sheets come through the rollers, they are trimmed and slitted with circular or razor-likeknives. Trimming refers to the edges of the foil, while slitting involves cutting it into several sheets Aluminum foilis the most commonly produced product via pack rolling. This is evident from the two different surface finishes; the shiny side is on the roll side and the dull side is against the other sheet of foil.ELECTROCHEMICAL CLEANING

Electrochemical Cleaning (ECC)SMis a very effective process using the same physics, equipment, and chemicals we use in our proprietary "spot" electropolishing technique. Discovered when a customer had a product residue issue that looked like classic "rouge" yet when industry accepted de-rouging chemical applications were tried they proved completely ineffective. In an experiment we used the spot electropolish procedure whereby electrolyte was applied to the stained surface and the DC current was activated and the "hand tool" was applied to and moved over the surface the stain was removed immediately. Because of this discovery we were able to completely clean 5,10,15K GALLON & larger vessels in hours instead of days.

Once discovered this method has found several very cost effective applications where ECC can be used in place of more expensive and less effective chemical or manual processes while delivering a micro surface improvement to the area being cleaned where optional processes at best do nothing to improve and at worst can etch the micro surface.

ApplicationsDe-rouging:ECC has been found to be very effective for removing rouge for both electropolished and non-electropolished surfaces. An added benefit observed on items de-rouged using ECC is the rouge is very slow to return. Though conventional de-rouging and passivation methods would yield a clean product contact surface the rouge would begin to reform in a matter of hours. Equipment de-rouged using ECC has shown the rouge resisted returning for months and in some cases years.

Grey Residue: On equipment with a sanded or mechanically polished stainless steel surface only it is common to find a grey residue present when the surface is wiped with an alcohol soaked cloth. In many instances the entire surface of a vessel, as an example, will be hand wiped for hours using "clean wipes" until all of the grey residue has appeared to have been removed. The vessel may then be passivated or cleaned in place and allowed to dry only to have the grey residue return at visibly the same concentration as observed before the cleaning operation.

It is believed this grey residue is made up of stainless steel powder created by the sanding process and electrostatically adhered to the mechanically polished surface (PIC). No amount of wiping or chemical cleaning has proven to completely remove this residue. Understandably Quality Control personnel find this condition unacceptable concerned if the grey residue can be wiped off, it stands to reason it can come loose during product processing and become an undesirable additive.

ECC can completely remove this grey residue in one application by electrolytic action as metal is removed ion by ion with the very outermost surface and any residue being removed. In dozens of applications this condition has successfully been treated in one application eliminating grey residue from the equation.

Weld Scale and Discoloration:Prior to successful use as a de-rouging or surface contaminant removal process, ECC was developed specifically for removing weld discoloration directly on a weld or in the heat affected zones adjacent to the weld.

The process utilizes a mild acid electrolyte solution and DC current that when applied to a weld or heat affected zone (HAZ) very rapidly removes discoloration. On large construction projects utilizing austenitic, super-austenitic or nickel alloys, weld discoloration has historically been removed by mechanical polishing, blasting or a harsh chemical application, all of which alter the appearance when compared to untreated surrounding surfaces. The process has also been shown to improve corrosion resistance in these areas comparable to that of the surrounding base metal.

ANNEALING

Annealing, inmetallurgyandmaterials science, is aheat treatmentwherein a material is altered, causing changes in its properties such asstrengthandhardness. It is a process that produces conditions by heating to above the recrystallization temperature, maintaining a suitable temperature, and then cooling. Annealing is used to induceductility, soften material, relieve internal stresses, refine the structure by making it homogeneous, and improvecold workingproperties.

In the cases ofcopper,steel,silver, andbrass, this process is performed by substantially heating the material (generally until glowing) for a while and allowing it to cool. Unlikeferrous metalswhich must be cooled slowly to annealcopper, silver and brass can be cooled slowly in air or quickly byquenchingin water. In this fashion the metal is softened and prepared for further work such as shaping, stamping, or forming.

ThermodynamicsAnnealing occurs by thediffusionof atoms within a solid material, so that the material progresses towards its equilibrium state. Heat is needed to increase the rate of diffusion by providing the energy needed to break bonds. The movement of atoms has the effect of redistributing and destroying thedislocationsin metals and (to a lesser extent) in ceramics. This alteration in dislocations allows metals to deform more easily, so increases their ductility. The amount of process-initiatingGibbs free energyin a deformed metal is also reduced by the annealing process. In practice and industry, this reduction of Gibbs free energy is termed "stress relief".. The relief of internal stresses is a thermodynamically spontaneous process; however, at room temperatures, it is a very slow process. The high temperatures at which the annealing process occurs serve to accelerate this process. The reaction facilitating the return of the cold-worked metal to its stress-free state has many reaction pathways, mostly involving the elimination of lattice vacancy gradients within the body of the metal. The creation of lattice vacancies is governed by theArrhenius equation, and the migration/diffusion of lattice vacancies are governed byFicks lawsof diffusion. Mechanical properties, such as hardness and ductility, change as dislocations are eliminated and the metal's crystal lattice is altered. On heating at specific temperature and cooling it is possible to bring the atom at the right lattice site and new grain growth can improve the mechanical properties.

StagesThere are three stages in the annealing process, with the first being therecoveryphase, which results in softening of the metal through removal ofcrystaldefects (the primary type of which is the linear defect called a dislocation) and the internal stresses which they cause. Recovery phase covers all annealing phenomena that occur before the appearance of new strain-free grains.The second phase isrecrystallization, where new strain-free grains nucleate and grow to replace those deformed by internal stresses.If annealing is allowed to continue once recrystallization has been completed,grain growthwill occur, in which the microstructure starts to coarsen and may cause the metal to have less than satisfactory mechanical properties. Controlled atmospheresThe high temperature of annealing may result in oxidation of the metals surface, resulting in scale. If scale is to be avoided, annealing is carried out in a special atmosphere, such as withendothermic gas(a mixture of carbon monoxide,hydrogen gas, andnitrogen gas).

Themagneticproperties ofmu-metal(Espey cores) are introduced by annealing the alloy in ahydrogenatmosphere.

Setup and equipmentTypically, large ovens are used for the annealing process. The inside of the oven is large enough to place the workpiece in a position to receive maximum exposure to the circulating heated air. For high volume process annealing, gas fired conveyor furnaces are often used. For large workpieces or high quantity parts Car-bottom furnaces will be used in order to move the parts in and out with ease. Once the annealing process has been successfully completed, the workpieces are sometimes left in the oven in order for the parts to have a controlled cooling process. While some workpieces are left in the oven to cool in a controlled fashion, other materials and alloys are removed from the oven. After being removed from the oven, the workpieces are often quickly cooled off in a process known as quench hardening. Some typical methods of quench hardening materials involve the use of media such as air, water, oil, or salt.Diffusion annealing of semiconductorsIn thesemiconductorindustry,siliconwafers are annealed, so thatdopantatoms, usuallyboron,phosphorusorarsenic, can diffuse into substitutional positions in the crystal lattice, resulting in drastic changes in theelectricalproperties of the semiconducting material.

NormalizationNormalizationis an annealing process in which a metal is cooled in air after heating in order to relieve stress.

It can also be referred to as: Heating aferrousalloy to a suitable temperature above the transformation temperature range and cooling in air to a temperature substantially below the transformation range.

This process is typically confined to hardenable steel. It is used to refine grains which have been deformed through cold work, and can improve ductility and toughness of the steel. It involves heating the steel to just above its upper critical point. It is soaked for a short period then allowed to cool in air. Small grains are formed which give a much harder and tougher metal with normal tensile strength and not the maximum ductility achieved by annealing. It eliminatescolumnargrains and dendritic segregation that sometimes occurs during casting. Normalizing improvesmachinabilityof a component and provides dimensional stability if subjected to further heat treatment processes.Process annealingProcess annealing, also called "intermediate annealing", "subcritical annealing", or "in-process annealing", is a heat treatment cycle that restores some of the ductility to a work piece allowing it be worked further without breaking. Ductility is important in shaping and creating a more refined piece of work through processes such asrolling,drawing,forging,spinning,extrudingandheading. The piece is heated to a temperature typically below theaustenizingtemperature, and held there long enough to relieve stresses in the metal. The piece is finally cooled slowly to room temperature. It is then ready again for additional cold working. This can also be used to ensure there is reduced risk of distortion of the work piece during machining, welding, or further heat treatment cycles.

The temperature range for process annealing ranges from 260 C(500 F) to 760 C(1400 F), depending on the alloy in question.

Full anneal

A full anneal typically results in the second most ductile state a metal can assume for metal alloy. It creates an entirely new homogeneous and uniform structure with good dynamic properties. To perform a full anneal, a metal is heated to its annealing point (about 50C above the austenic temperature as graph shows) and held for sufficient time to allow the material to fully austenitize, to form austenite or austenite-cementite grain structure. The material is then allowed to cool slowly so that theequilibriummicrostructure is obtained. In some cases this means the material is allowed to air cool. In other cases the material is allowed to furnace cool. The details of the process depend on the type of metal and the precise alloy involved. In any case the result is a more ductile material that has greaterstretch ratioand reduction of area properties but a loweryield strengthand a lowertensile strength. This process is also called LP annealing forlamellar pearlitein the steel industry as opposed to aprocess annealwhich does not specify a microstructure and only has the goal of softening the material. Often material that is to be machined, will be annealed, then be followed by further heat treatment to obtain the final desired properties.

Short cycle anneal

Short cycle annealingis used for turning normal ferrite into malleable ferrite. It consists of heating, cooling, and then heating again from 4 to 8 hours.

Resistive heatingResistive heatingcan be used to efficiently annealcopper wire; the heating system employs a controlled electricalshort circuit. It can be advantageous because it does not require atemperature-regulatedfurnacelike other methods of annealing.

The process consists of two conductivepulleys(step pulleys) which the wire passes across after it is drawn. The two pulleys have anelectrical potentialacross them, which causes the wire to form a short circuit. TheJoule effectcauses the temperature of the wire to rise to approximately 400 C. This temperature is affected by the rotational speed of the pulleys, the ambient temperature, and the voltage applied. Where t is the temperature of the wire, K is a constant, V is thevoltageapplied, r is the number of rotations of the pulleys per minute, and tais theambient temperature:

The constant K depends on the diameter of the pulleys and the resistivity of the copper.

Purely in terms of the temperature of the copper wire, an increase in the speed with which the wire passes through the pulley system has the same effect as an increase in resistance. Therefore, the speed with which the wire can be drawn through varies quadratically as the voltage applied.

SKIN PASS MILL

After annealing, coils may require a final rolling called a temper pass, skin pass or planish pass. This involves a controlled light reduction to establish the final thickness, impart the desired surface finish, flatten the strip to improve shape and create the required hardness or temper of the material. COLD ROLL SLITTING / CUT TO LENGTH

Some customers require a steel to be of a particular thickness other than the general increment sizes rolled in the hot mill or thinner than the minimum thickness rolled in the mills. These steels are processed in the cold roll reduction mill. These mills are capable of rolling steel to the precise thickness that the customer orders and are a major part of the steel strip production process. The reduction mill in the plant I worked had four rolls in the mill that were stacked upon each other. This arrangement is known as a two high mill. There are two working rolls between which the strip is passed and two large back-up rolls, one on top of the working rolls and one on the bottom. The back-up rolls apply the tremendous pressures required to cold roll (reduce) the strip between the working rolls. The working rolls are usually about two to three feet in diameter while the back-up rolls are about seven to eight feet in diameter. The rolls are made of high alloy steel so they can withstand the tremendous pressure they are under while rolling without deforming. Because of this the rolls are ground in a large lathe using a very large grinding wheel on a movable carriage. Depending on the surface finish required of the strip the working rolls will either have a highly polished (mirror like) finish or a dull finish on them. All working rolls are ground on the lathe in the mill to a highly polished surface periodically. The rolls that have a dull finish on them are shot blasted after grinding to produce the desired surface.

After grinding to a polished surface the rolls that need a dull finish are placed on a large carriage which has a set of rubber rolls on it. The carriage then travels on a small rail track into a large enclosure and the door is closed down. On top of this enclosure is a large hopper filled with fine steel balls called shot. This shot is very small in diameter (about half the size of a BB or smaller) and is very hard. It is fed down a chute and using either compressed air or a impeller type system it is accelerated to high speed (in excess of a hundred miles per hour) and blasted against the surface of the roll. The rubber rolls on the carriage rotate causing the steel roll to rotate so all its surface is exposed to the shot blast. The shot comes in a variety of sizes and hardness grades and different types are used depending on the type of surface finish required on the rolls. After a predetermined cycle time the roll is removed from the Wheelabrator, as it is called and is ready to be used in the mill.

A saddle type conveyor runs along the side of the reduction mill. Steel coils are place on this conveyor by overhead cranes using the same C hook as at the entry and exit ends of the pickle lines. This saddle conveyor moves the coils along to the reduction mill where they are lowered onto a frame at the entry side of the mill. A transfer saddle operated by the mill operator moves out to the frame and picks up the coil and moves it back into the feed mandrel on the entry side. The operator cuts the strap, freeing up the loose end of the coil. He opens a space between the work rolls and feeds the end of the exit side. On the exit side is another expandable mandrel the same as the catcher mandrels of the hot mills and pickle line. The entry operator feed the strip until the exit operator can catch the end in the open segment of his mandrel, expanding it and trapping the end of the strip. The entry operator then closes the gap in the working rolls down on the strip. Pressure (thousands of tons) is applied by the back-up rolls by means of hydraulically operated screws, to the working rolls and the reduction rolling process begins. If the thickness of the steel needs to be greatly reduced, the strip will be passed back and forth between the rolls a number of times with the rolls adjusted for each pass. Due to the great amount of pressure exerted in the reduction process the steel strip becomes very hot. In order to prevent the steel from becoming too hot and sticking to the work rolls, the rolls are flooded with a coolant consisting of 95% water and the other 5% water soluble oil. The end of the strip that is in the exit mandrel is not released in the multiple pass process nor is it completely unwound from the entry mandrel. In the final pass through the reduction mill, the portion that was not reduced from the entry end is trimmed off in a set shears just before they enter the work rolls to the exit side. A transfer saddle on the exit side then moves the coil back onto the conveyor that runs beside the mill.

QUALITY CONTROL

Quality controlis a process by which entities review the quality of all factors involved in production. This approach places an emphasis on three aspect

1. Elements such as controls, job management, defined and well managed processes, performance and integrity criteria, and identification of records

2. Competence, such as knowledge, skills, experience, and qualifications

3. Soft elements, such as personnelintegrity,confidence,organizational culture,motivation,team spirit, and quality relationships.

The quality of the outputs is at risk if any of these three aspects is deficient in any way.

Quality control emphasizes testing of products to uncover defects, and reporting to management who make the decision to allow or deny the release, whereasquality assuranceattempts to improve and stabilize production, and associated processes, to avoid, or at least minimize, issues that led to the defects in the first pun For contract work, particularly work awarded by government agencies, quality control issues are among the top reasons for not renewing a contract.

"Total quality control", also calledtotal quality management, is an approach that extends beyond ordinary statistical quality control techniques and quality improvement methods. It implies a complete overview and re-evaluation of the specification of a product, rather than just considering a more limited set of changeable features within an existing product. If the original specification does not reflect the correct quality requirements, quality cannot be inspected or manufactured into the product. For instance, the design of a pressure vessel should include not only the material anddimensions, but also operating, environmental,safety,reliabilityandmaintainabilityrequirements, and documentation of findings about these requirements.

RESEARCH AND DEVELOPMENT

The phraseresearch and development(alsoR and Dor, more often,R&D), according to theOrganization for Economic Co-operation and Development, refers to "creative work undertaken on a systematic basis in order to increase the stock of knowledge, including knowledge of man, culture and society, and the use of this stock of knowledge to devise new applications".

Research and development is often scientific or towards developing particulartechnologiesand is frequently carried out as corporate or governmental activity.

OverviewNew product design and development is more often than not a crucial factor in the survival of a company. In an industry that is changing fast, firms must continually revise their design and range of products. This is necessary due to continuous technology change and development as well as other competitors and the changing preference of customers. Without an R&D program, the firm must rely onstrategic alliances,acquisitions, and networks to tap into the innovations of others.

A system driven bymarketingis one that puts the customer needs first, and only produces goods that are known to sell. Market research is carried out, which establishes what is needed. If the development is technology driven then it is a matter of selling what it is possible to make. The product range is developed so that production processes are as efficient as possible and the products are technically superior, hence possessing a natural advantage in the market place.

R&D has a special economic significance apart from its conventional association with scientific and technological development. R&D investment generally reflects a government's or organization's willingness to forgo current operations or profit to improve future performance or returns, and its abilities to conduct research and development.

The top eight spenders in terms of percentage of GDP wereIsrael(4.53%),Sweden(3.73%),Finland(3.45%)Japan(3.39%),South Korea(3.23%),Switzerland(2.9%),Iceland(2.78%) andUnited States(2.62%).[2]TheCommitment to Development Indexranks these countries, rewarding them for research and development that support the creation and dissemination of innovations of value to developing countries.

In general, R&D activities are conducted by specialized units or centers belonging tocompanies,universitiesandstateagencies. In the context ofcommerce, "research and development" normally refers to future-oriented, longer-term activities inscienceortechnology, using similar techniques toscientificresearch without predetermined outcomes and with broad forecasts of commercial yield.

Statisticson organizations devoted to "R&D" may express the state of anindustry, the degree ofcompetitionor the lure ofprogress. Some common measures include:budgets, numbers ofpatentsor on rates of peer-reviewedpublications. Bank ratios are one of the best measures, because they are continuously maintained, public and reflect risk.

In the U.S., a typical ratio of research and development for an industrial company is about 3.5% of revenues. A high technology company such as a computer manufacturer might spend 7%. AlthoughAllergan(abiotechcompany) tops the spending table with 43.4% investment, anything over 15% is remarkable and usually gains a reputation for being a high technology company. Companies in this category includepharmaceutical companiessuch asMerck & Co.(14.1%) orNovartis(15.1%), and engineering companies likeEricsson(24.9%).[3]Such companies are often seen as poor credit risks because their spending ratios are so unusual.

Generally such firms prosper only in markets whose customers have extreme needs, such as medicine, scientific instruments, safety-critical mechanisms (aircraft) or high technology military armaments. The extreme needs justify the high risk of failure and consequently high gross margins from 60% to 90% of revenues. That is,gross profitswill be as much as 90% of the sales cost, with manufacturing costing only 10% of the product price, because so many individual projects yield no exploitable product. Most industrial companies get only 40% revenues.

On a technical level, high tech organizations explore ways to re-purpose and repackage advanced technologies as a way ofamortizingthe high overhead. They often reuse advanced manufacturing processes, expensive safety certifications, specialized embedded software, computer-aided design software, electronic designs and mechanical subsystems.

Research has shown that firms with a persistent R&D strategy outperform those with an irregular or no R&D investment programme

GALVANISING PLANT

Metal protectionIn current use, the term refers to the coating ofsteelorironwithzinc. This is done to preventgalvanic corrosion(specifically rusting) of theferrousitem. The value of galvanising stems from the relative corrosion resistance of zinc, which, under most service conditions, is considerably less than those of iron and steel. The effect of this is that the zinc is consumed first as a sacrificialanode, so that it cathodically protects exposed steel. This means that in case of scratches through the zinc coating, the exposed steel will be cathodically protected by the surrounding zinc coating, unlike an item which is painted with no prior galvanising, where a scratched surface would rust. Furthermore, galvanising for protection of iron and steel is favoured because of its low cost, the ease of application, and the extended maintenance-free service that it provides.

The term galvanizing, while correctly referring to the application of the zinc coating by the use of a galvanic cell (also known as electroplating), sometimes is also used to refer to hot dip zinc coating (commonly incorrectly referred to as hot dip galvanizing). The practical difference is that hot dip zinc coating produces a much thicker, durable coating, whereas genuine galvanizing (electroplating) produces a very thin coating. Another difference, which makes it possible to determine visually which process has been used if an item is described as 'galvanized', is that electroplating produces a nice, shiny surface, whereas hot dip zinc coating produces a matte, grey surface. The thin coating produced by electroplating is much more quickly consumed, after which corrosion turns to the steel or iron itself. This makes electroplating unsuitable for outdoor applications, except in very dry climates. For example, nails for indoor use are electroplated (shiny), while nails for outdoor use are hot dip zinc coated (matte grey). However, electroplating and subsequent painting is a durable combination because the paint slows down the consumption of the zinc. Car bodies of some premium makes are corrosion protected using this combination.

Nonetheless, electroplating is used on its own for many outdoor applications because it is cheaper than hot dip zinc coating and looks good when new. Another reason not to use hot dip zinc coating is that for bolts and nuts size M10 or smaller, the thick hot-dipped coating uses up too much of the threads, which reduces strength (because the dimension of the steel prior to coating must be reduced for the fasteners to fit together). This means that forcars,bicyclesand many other 'light' mechanical products, the alternative to electroplatingboltsandnutsis not hot dip zinc coating but making the bolts and nuts fromstainless steel(known by the corrosion grades A4 and A2).

Electroplated steel is visually indistinguishable from stainless steel when new. To determine whether a part is electroplated or stainless steel, apply amagnet. The most common stainless steelalloys(including those used for bolts and nuts) are not magnetic or only very slightly attracted to a magnet.

HistoryOriginally, "galvanization" was the administration of electric shocks (in the19th centuryalso termedFaradism, afterMichael Faraday). It stemmed from Galvani's induction of twitches in severedfrogs' legs, by his accidental generation ofelectricity. Thisarchaicsense is the origin of the meaning ofgalvanicwhen meaning "affected/affecting, as if by a shock of electricity; startled".Its claims to health benefits have largely been disproved, except for some limited uses inpsychiatryin the form ofelectroconvulsive therapy(ECT). Later the word was used for processes ofelectrodeposition. This remains a useful and broadly applied technology, but the term "galvanization" has largely come to be associated withzinccoatings, to the exclusion of other metals.

Galvanic paint, a precursor tohot-dip galvanization, was patented byStanislas Sorel, ofParis,Francein December, 1837. The earliest known example of galvanizing of iron was found on the 30th September 1999 by theRoyal ArmouriesMuseumon a17th centuryIndianarmour in their collection. Zinc coatingsZinc coatings prevent corrosion of the protected metal by forming a physical barrier, and by acting as asacrificial anodeif this barrier is damaged. When exposed to the atmosphere, zinc reacts with oxygen to formzinc oxide, which further reacts with water molecules in the air to form zinc hydroxide. Finally zinc hydroxide reacts with carbon dioxide in the atmosphere to yield a thin, impermeable, tenacious and quite insoluble dull gray layer ofzinc carbonatewhich adheres extremely well to the underlying zinc, so protecting it from further corrosion, in a way similar to theprotectionafforded toaluminiumandstainless steelsby their oxide layers.

Hot-dip galvanizingdeposits a thick robust layer that may be more than is necessary for the protection of the underlying metal in some applications. This is the case inautomobilebodies, where additional rust proofing paint will be applied. Here, a thinner form of galvanizing is applied byelectroplating, called "electrogalvanization". The hot-dip process slightly reduces the strength of the base metal, which is a consideration for the manufacture ofwire ropeand other highly-stressed products. The protection provided by this process is insufficient for products that will be constantly exposed to corrosive materials such as salt water. For these applications, more expensivestainless steelis preferred. Somenailsmade today are electro-galvanized.

As noted previously, both mechanisms are often at work in practical applications. For example, the traditional measure of a coating's effectiveness is resistance to asalt spray. Thin coatings cannot remain intact indefinitely when subject to surface abrasion, and the galvanic protection offered by zinc can be sharply contrasted to more noble metals. As an example, a scratched or incomplete coating ofchromiumactually exacerbates corrosion of the underlying steel, since it is less electrochemically active than the substrate.

Galvanized surface with visible spangle

The size ofcrystallitesin galvanized coatings is an aesthetic feature, known asspangle. By varying the number of particles added for heterogeneousnucleationand the rate of cooling in a hot-dip process, the spangle can be adjusted from an apparently uniform surface (crystallites too small to see with the naked eye) to grains several centimetres wide. Visible crystallites are rare in other engineering materials. Protective coatings for steel constitute the largest use of zinc and rely upon the galvanic or sacrificial property of zinc relative to steel.

Thermal diffusion galvanizing,a form ofSherardizing, provides a zinc coating on iron or copper based materials partially similar to hot dip galvanizing. The final surface is different than hot-dip Galvanizing; all of its zinc is alloyed.[4]Zinc is applied in a powder form with "accelerator chemicals" (generally sand,[5]but other chemicals are patented). The parts and the zinc powder are tumbled in a sealed drum while it is heated to slightly below zinc's melting temperature. The drum must be heated evenly, or complications will arise. Due to the chemicals added to the zinc powder, the zinc/iron makes an alloy at a lower temperature than hot dip galvanizing. This process requires generally fewer preparatory cleanings than other methods. The dull-grey crystal structure formed by the process bonds stronger with paint, powder coating, and rubber overmolding processes than other methods. It is a preferred method for coating small, complex-shaped metals and smoothing in rough surfaces on items formed with powder metal.

Eventual corrosion

Rusted corrugated steel roof

Although galvanizing will inhibit attack of the underlying steel, rusting will be inevitable, especially due to natural acidity of rain. For example,corrugated ironsheet roofing will start to degrade within a few years despite the protective action of the zinc coating. Marine and salty environments also lower the lifetime of galvanized iron because the highelectrical conductivityofsea waterincreases the rate of corrosion. Galvanizedcar framesexemplify this; they corrode much quicker in cold environments due toroad salt. Galvanized steel can last for many years if other means are maintained, such aspaintcoatings and additionalsacrificial anodes.ROLL GRINDING MACHINE

Giant rollers still need intricate precision

A roll grinder has little in common with a precision tool at first glance. This is due on one hand to its dimensions - the rollers for machining can be up to 400 tons, dead weight and up to 10 m in length - and on the other hand due to the surroundings of the rolling mill where thousands of tons of steel are being manoeuvred and processed. However, a second look reveals the high-precision character of such a machine: in addition to several measuring axes, a grinding machine has at least four machining axes, which are implemented by means of Servo Drives:

W-axis: Spindle head turns the roller which is clamped centrally in a steady rest

X-axis: Grinding wheel feeds vertical to the roller

Z-axis: Grinding wheel traverses parallel to the roller

C-axis: Grinding wheel microfeeds via a tilting axis

The roller to be ground is clamped in the spindle head and is driven by it. A high-precision incremental measuring instrument with two tactile measuring sensors traces the turning roller and determines the current form and diameter as well as detects any possible damage on the surface of the roller. The machine operator sets the parameters for cylindricity, final diameter, surface quality and structure or abrasion, depending on the required result. The control system calculates the grinding process from these parameters. Continuous measuring is carried out simultaneously in order to record the results of the grinding process and determine or correct the required values for the next travel.

Certain manufacturing processes in the steel and paper industries require a precisely defined roller form. These can be conical or spherical or - looked at from the longitudinal axis - display a sinusoidal or bottleneck form (CVC). These variations of form are not visible to the naked eye, as they are on the order of millimetres. The automotive industry, for example, has specific requirements for the surface structure of the sheet metal in order to have shine and reflective properties in the sprayed bodywork, which could not be achieved by spraying alone. The necessary grinding precision goes down to 1/1000 mm in concentricity and the same in geometrical accuracy. In order to do justice to this complex task, HCC KPM Electronics has produced a control system which can be applied with only minor adaptations to all kinds of machines - all on the PLC and Motion Control solution, TwinCAT PTP and NC I/CNC software.

Synergy from customer expertise and an intelligent control concept

In order to utilize the benefits of a central control concept in terms of commissioning, maintenance and performance, the electrical design engineers at Herkules aimed to run as many functions as possible in software and decided in favour of TwinCAT. The open software structure and the dynamic functions for controlling axis movement that TwinCAT provides enabled Herkules to integrate the expertise acquired over many years of developing their own control system into the software PLC and create the "HCC/KPM 10" roll grinder control system.

Almost all the functionalities provided by TwinCAT are used:

3 PLC tasks in one run-time system with 1 or 10 ms interval time

1 NC task with up to 10 axes with 2 ms interval time

almost all programming languages (IL, FBD, ST, SFC) in the PLC projects

application of PTP axis functions and complex multi-table coupling for the grinding processes with correction parameters from the grinding current, grinding wheel wear and measured deviations from the required form to the actual form of the roller

communication with integrated visualization based on Visual Basic and operating guidance through the ADS DLL communication interfaces

TwinCAT NC I for interpolating functions e.g. to mill concentric grooves in the surface of the roller

Lightbus is used as the fieldbus to incorporate the peripheral Beckhoff Bus Terminals within the machine. For communication with the Servo Drives, the Ethernet- based EtherCAT bus system is predominantly used. A major benefit of EtherCAT on one hand is its real-time capability and high data throughput - with bus cycle times of less than 1 ms - and, on the other, simple handling using TwinCAT. Only one free network port is necessary in the control PC. The Servo Drives are connected via standard network cables.

NARROW PLANT

In narrow plant the width of the coils being passed is small ranging from 110-530 mm. Rolling is performed by 4 rollers without any intermediate rollers. Here also annealing and ctl facilties are available. Instead of electrochemical cleaning here rewinding operation is used.

CONCLUSION

IT GIVES ME IMMENSE PLEASURE TO SAY THAT I HAVE SUCESSFULLY UNDERGONE 30 DAYS OF INDUSTRIAL TRANING IN BHUSHAN STEEL LTD. IT WAS A LIFETIME EXPERIENCE . I LEARNED A LOT OF NEW THINGS ,AND LOT OF NEW WAYS OF SOLVING A PROBLEM. I WANT TO CONCLUDE MY REPORT ON A POSITIVE NOTE AND I HOPE THAT THE EXPERIENCE WHICH I GOT WILL ALSO B FRUITFUL IN MY CAREER AHEAD.BIBLIOGRAPHY

1.www.bhushan-group.com

2. Wikipedia.com

3.Ghosh and Malik-Production EnginneringJSS MAHAVIDYAPEETHA

JSS ACADEMY OF TECHNICAL EDUCATION

DEPARTMENT OF MECHANICAL ENGINEERING

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