DANGO & DIENENTHAL (INDIA) Pvt. Ltd .

Duration of Training: 15/06/14 - 15/07/14

REPORT ON VACATIONAL TRAINING

MCKV Institute of Engineering

Department of Mechanical Engineering

ABOUT THE COLLEGE: MCKV INSTITUTE OF ENGINEERING was established in 1999 as the pioneering self-financing degree engineering college in the district of Howrah, West Bengal.

  Contact: MCKV Institute of Engineering.

243, G.T.Road(N),Liluah,Howrah-711 204.

Phone-(033) 2654 9315/17.

Fax-2654 9318.

Email:mckvie@vsnl.net

Website: www.mckvie.edu.in

The following students from the Department of Mechanical Engineering, MCKV Institute of Engineering, were a part of the Vacational Training at Dango & Dienenthal (India) Pvt. Ltd.

Asif Anwar Amit Kr. Pandit Amiyo Khanra Tanmoy Dey Srijan Roy Samaresh Samanta Sudipto Chakraborty Sujit Pal Umashankar Samanta Sudipta Jana

ABOUT THE COMPANY

Introduction: Dango & Dienenthal Pvt. Ltd is a Germany based company popular for its widely varying products in the fields of conventional & non conventional casting and forging industries. They provide personalized furnace equipments and PLC controlled robots for advanced manufacturing industries.

Services: The new manufacturing and service facilities near Kolkata were built in 2001 and extended in 2011. The plant Is located in the western part of the city. Next to Bombay road at Jangalpur Industrial Complex. It is adequately equipped to manufacture, assemble and also test large machines.

The company has successfully manufactured the required products for the following companies over the years.

Products1.Tap Hole Furnace Drill & Clay GunFurnace drill machine is used to drill pre determined area of a ladle furnace for drainage of hot molted metal.

The clay gun is followed by the drill to cover the drilled hole by special type of clay.

A tap hole drilling machine, a drill bit and a drilling method is used. A nitrogen gas supply line for pressurized nitrogen as a carrier gas and a cooling water supply line are provided to form water mist for cooling the drill bit, the drill rod, the main body of the drilling machine and the tap hole. Thus the drilling time period is remarkably shortened, the molten iron discharge time period is significantly increased, and the net consumption rate of the refractory material is considerably decreased. Therefore, by properly adjusting the amount of the molten iron existing within the lower portion of the blast furnace, the condition of the blast furnace can be stabilized, and the productivity can be improved. Advantageous conditions can be provided for the operation even under a high pressure and a high temperature environment.

2.Forging ManipulatorWhen maximum flexibility in transport and handling capabilities during the forging process is important a Mobile Forging Manipulator is used. The compact design and maneuverability of manipulators from DANGO & DIENENTHAL allow the transport of workpieces when space is limited.

Whether small or very large handling capacities are needed DANGO & DIENENTHAL offers both standard and customized solutions. The machines offer high reliability as well as great flexibility. The sturdy and compact design is adapted to the special operating conditions.

Economical aspects and hands-on experience are the decisive factors for selecting and arranging control levers, switches and buttons.

Characteristics:

1. Powerful tongs unit with large gripping range.

2. Multistage adjustment of closing force.3. Spring systems acting both vertically and horizontally to absorb shock loads.4. High maneuverability due to quick and flexible travelling behavior.5. Semi-automatic working cycles at request.6. Travel, steering, and tongs motions can be carried out at the same time excellent operator's

view in all directions.7. Air conditioned driver's cabin at request.8. Pumps driven by electric motor or diesel engine.9. Emergency functions.

3.Transport ManipulatorTransportation of cold or preheated ingots, discs or rings is performed by Transport Manipulators manufactured by DANGO & DIENENTHAL. Tool Manipulators guide and position tools at open-die forging presses. Both machine types either can be powered by diesel-hydraulic or electro-hydraulic drives.

Characteristics:

1. Sturdy design adapted to the conditions in hot metal forming plants.2. Energy-saving travelling while offering high carrying capacities.3. High maneuverability due to quick and flexible travelling behavior tongs changing system on

request.

4.Charging, Stoking & Distribution MachineQuite often the space on the furnace platform is limited and calls for compact and manoeuvrable vehicles. To meet this request, DANGO & DIENENTHAL machines are equipped with a special lever system which allows a short machine length when the tool arm is retracted. The machine travels with retracted tool. Only at the working position at the furnace the tool is extended to ensure an utmost reach into the furnace. The operator does not need to leave the control stand to change the stoking tool against the charging box. By means of the box, charging material can be brought to specific points in the furnace.

In case of tube charging, the material can be optimally distributed by the stoking tool. Deep stoking, crushing of slag bridges and opening of gas bubbles is easily possible either by means of the lever system when the machine is in resting position or by utilizing the mass energy when the machine is travelling.

Characteristics:1. Electro hydraulic drive with power supply via trailing cable or contact line ,alternatively Diesel

hydraulic drive.2. The special lever system ensures a short machine length with retracted tool arm.3. Changing of tools without manual assistance.4. Low overall height.5. High maneuverability due to quick-reacting and flexible steering and travel performances.6. Enclosed driver's cabin whichcan be equipped with air-conditioning on request hermetically

sealed hydraulic system.

Skimming Machine

Skimming machine is a special kind of foundry machine which is used to skim away the slag over the molten metal. This is basically a hydraulic operated machine which generates a large amount of force of skimming from a noticeable distance and operates the main broom i.e. the part which extends over and carries the skimming point.

SAM-7 and SAM-10 are the popular machines manufactured by the company, providing skimming solutions.

Heavy-Load RobotA material handling robot moves selects or packs products. These robots are also used to automate feeding or disengaging parts or tools from one location to another.

Characteristics:

1. sturdy design adapted to the conditions in hot metal forming plants.2. Energy-saving travelling while offering high carrying capacities.3. High maneuverability due to quick and flexible travelling behavior tongs changing system on

request.

During our training period at the DDS factory, we observed the detailed manufacturing operations of the popular skimming machine, SAM-7. The step by step assembly and production process of the machine are described in details as follows.

Order is received Analysis of required product Product Design & validation Raw material procurement Checking of Raw materials Distribution to various Machining shops as per requirement Parts are made using specialized machines with detailed drawing Assembly of parts dispatching.

IN DEPTH ANALYSIS OF MANUFACTURING OF “SAM-7”

INTRODUCTION: Skimming is the process of removal of slag floating on the molten metal surface. Skimming is done by tilting the ladle and using a reciprocating motion incorporated with the machine arm.

WHY IT IS IMPORTANT IN FOUNDRY FIELD :

Previously, the skimming was done manually. In this system of manual skimming, we need extra attention for the safety of the workmen and also its use is limited for a small processing unit only. Large amount of casting need a large quantity of molten metal - so the skimming to be done in huge area. So if manual operation is done here it will be more time taking and also a risk to the workmen. To avoid the risk we need to design a equipment which suits the needs.

SAM-7 is a miniature version of the skimming machine SAM-30, produced by the same company, with a few modifications.

Hydraulic power pack:Hydraulic Power Units are the main driving components of hydraulic systems. Consistently mainly of a motor, a reservoir and a hydraulic pump, these units can generate a tremendous amount of power to drive most any kind of hydraulic ram. Hydraulic Power Units are based on Pascal's law of physics, drawing their power from ratios of area and pressure.

Hydraulic Power Units can generally be used in any application that requires heavy and systematic lifting or other requirements for the repeated use of powerful and directional force.

In SAM-7 the power pack provides the driving motion for the Hydro motor.

Assembly of Power pack: In SAM-7 the Motor, pump, heat exchanger and filter are received and mounted as per design dimensions on the oil tank. The oil tank is separately prepared using the following steps.

The structure steel is marked and prepared for the cutting

Material is cut as per dimensions

SAM-7 Machine BodyHydraulic Power pack

Oil Tank Motor (30Hp) Pump (piston pump) Heat Exchanger (cross

flow, water cooled) Oil filter Manifold block DC valves Pressure gauge Hose & Pipes Pipe fittings

Skimming arm Base Main body Supporting roller for

arm movement Hydro motor Chain Sprocket

mechanism for arm advancement

Then the structure steel plates are welded to form the oil tank. Inspections are carried out to ensure that there is no leakage

The accessories are mounted separately and fitted to the tank. Pipes and hoses are connected to the accessories. Holes are drilled on the tank cover to fasten the mounted accessories rigidly to the tank.

Manufacturing of machine body:We were able to go through manufacturing of the main body and base of the skimming machine body.

The details of the processes are described below.

Structural steel work:In this process parts of the structural steel were cut out using gas cutter as per dimensions.

Welding: The cut out parts are welded together by MMAW. The welds were further checked by DP testing. Then the parts were sent for normalizing.

Machining: The parts are machined to get desired dimensional tolerance for various fitting.

The operations and tools used for these purposes are explained below.

Operation: Boring

Machine tool used: Horizontal boring machine (Scharmann)

Boring machine has a long bed which is used to mount the job with respect to the

Dye penetration test on welded part

Boring operation on machine body

spindle. Proper alignment of the job is done by adjusting the bed with respect to the machine spindle by some conventional mechanism.

This machine can be automated through a huge extent to get the suitability of the operation. At DDS, PLC controlled boring machine is available with the conventional features.

The normalized body was mounted on the machine bed. Then the boring operation was done using a single point boring tool.

Small sized cylindrical parts are machined by lathe machine, drilling machine, PLC controlled vertical milling machine etc. Figure 5 liquid nitrogen cylinder

Electrical circuits for supply of electricity also made by the engineers of the company. The DOL starter, control panel are made by them for the SAM-7.

Additional Operations involved in processing of different part bodies:

Along with the main body , different necessary small and medium sized part bodies are also produced side by side using the following operations and machine tools

Parts requiring smooth surface finish were machined by the face milling machine.Using this machine almost perfect dimensional accuracy is obtained.

Medium sized jobs which require certain turning and facing operations were machined in the conventional engine lathe.

The holes were drilled using radial drill. Relatively complex shaped parts with intricate details are sent to CNC operated lathe

and milling machines. The pipes and hoses were tightly fitted into the machine, including the power pack,

with the help of a hose crimping machine, pipes were bent using a pipe bending machine.

Figure 6 vertical milling machine (PLC controlled)

During mounting and transportation of the assembly parts, two EOT cranes were extensively used.

EOT Crane

Hose crimping machine

Final Assembly of skimming machine:

After the machining and preparations of separate body parts are finished, the final assembly is done. The workmen, under proper guidance, carry out this job.

When the assembly is over, the final inspections are made. The machine then undergoes paint-job. Finally, the completed machine is dispatched to the concerned customer.

Figure: Assembly of the boom

AcknowledgementsWe sincerely acknowledge the support and guidance of the following personalities and Institutions . Without their help, this training would have not been a success.

Mr. Asish Kumar Ghosh (Manager),and all the engineers & workmen of Dango & Dienenthal (India) Pvt. Ltd. for guiding us during this period of training and providing us with the knowledge of different industrial processes.

Prof. (Dr.) Ranjib Biswas (H.O.D.,Mechanical Engineering Dept), Prof. (Dr.) Parasar Bandyopadhyay (Principal).

We, the students of Mechanical Engineering Department,MCKV Institute of Engineering , sincerely thank all the members and employees of Dango & Dienenthal (India) Pvt. Ltd for the support, and guidance provided to us during this period of vacational training.