“INDUSTRIAL TRAINING REPORT” OF SIX WEEK INDUSTRIAL TRAINING UNDERTAKEN AT

“AARTI STEEL LIMITED”

UNDER THE INFLUENCE OF Er. AJESH KUMAR TRAINING INCHARGE

SHIRI GURU GRANTH SAHIB WORLD UNIVERSAITIY FATEHGARH SAHIB

SUBMITTED TODr. HARPUNEET SINGH

SUBMITTED BYHarinder singh13095105M.Tech( 5 yrs )Mechanical

PREFACE

I feel great pleasure in bringing out this report on industrial training .this report is primarily designed t equip the person with ideal guidance and knowledge for getting 100% satisfaction from this report.

This report is outcome of my fruitful experience however and claim is made regarding the original research but presentation and treatment of subject is in my own style. I hope this report will help you t get through your mind with report will with flying colors and my elders will find this report as good assignment material .inspire of best efforts. Certain discrepancies might have crept in this report as such constructive suggestions are highly appreciated.

ACKNOWLEDGEMENT

“An engineer with theoretical knowledge is not a complete engineer, practical knowledge is very important furan engineer to develop and apply engineering skills” I express my sincere thanks to my training and placement officer who has given me privilege to undergo six weeks industrial training at “Aarti steels limited”, Ludhiana (Pb). I am thankful to Mr. Mahesh Mittal for giving me this opportunity to get required of my course.I am thankful to Mr. Balbir Singh (Management Reperantative) and my chief instructor and project in charge for their creative guidance and valuable suggestions while undergoing the training. The help and cooperation extended by the staff of “Aarti steel” is fully acknowledged. Words are not enough to thanks for their help and guidance

CONTENTS

Introduction to the company Organization chart Steel and material properties Major manufacturing equipment Process flow chart Election arc furnace Ladle refining furnace Vacuum degassing and continuous costing Rolling and its various operations Rolling processes and rolling mills Rolling defects Inspection and testing Company product profile Quality assurance Miscellaneous Manufacturing range Marketing function Strengths attributions formidable status.

INTRODUCTION TO THE COMPANY

Aarti steels ltd. Represents a fully integrated steel manufacturing company with manufacturing facilities of carbon ,Non alloy and alloy steel rounds and squares, flats sponge iron.Power and ferro alloys the company also manufactures spring wires and tyre bead wire. The total products Portfolio of the company is assigned to the automobile industry. Manufacturing carbon steels,alloy steels,non alloy & special steels.

AARTI STEEL LIMITED

We represent a fully integrated steel manufacturing company with state of art plant located in Punjabi and Orissa with a total installed capacity of 2 lakh tones per annum and 90 mw of power. We have being ranked best among mini steel plants of our size and status, due to our strong steps on quality assurance.

STEEL AND MATERIAL PROPERTIES

Steel is an alloy by combining iron and other elements, the most common of these being carbon.when carbon is used,its content in the steel is between 0.2% and 2.1% by weight,depending on the grade.other alloying elements sometimes used are manganese,chromium,vanadium and tangusten carbon and other elements act as a hardening agent Prevating dislocations in the iron atom crystal lattice from sliding past one another.varying the amount of alloying elements and the form of their presence in the steel (solute elements precipitated phase) controls qualitiesSuch as the hardness,ductility,and tensile strength of the Resulting steel.steel with increased carbon content can be made harder and stronger than iron,but such steel is also less ductile than iron.

Alloys with a higher than 2.1% carbon cntent are known as cast iron

MATERIAL PROPERTIES

PROCESS FLOW CHART

RAW MATERIAL ELECTRIC ARC FURNACE

VACUUM LADLE REFINING FURNACE

CONTINUOUS CASTING BLOOM CONDITIONING

CONDITIONING & FINISHING ROLLING MILL

INSPECTION AND TESTING DESPATCH

ELECTRIC ARC FURNACE

An Electric Arc Furnace (EAF)

EAF is a furnace that heats charged material by means of an electric arc. Arc furnaces range in size from small units of approximately one ton capacity (used in foundries for producing cast iron product) up to about 400 ton units used for secondary steel making. Arc furnace used in research laboratories and by dentist may have capacity of only a few dozen grams. Industrial electric arc furnace temperatures can be up to 1,800 (3272) while laboratory unit can exceed 3,000.(5432) Arc furnaces differ from introduction furnaces in that the charged material is directly exposed an electric arc and the current in the furnace terminals passes through the charged material.

LADLE REFINING

After tapping from electric arc furnace , the ladle furnace is put on LF refining position.LF refining is conducted through arc heating and argon blowing. During the process, the steel deoxidization,desulfurization,the adjustment of steel temperature and chemical composition are completed.in primary slag, there is no vaccum function in LF,but room of vacuum device may be obligated in LF zone for future development.

ROLLING (METAL WORKING)

In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness and to make the thickness uniform. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is termed as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is termed as cold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process, and cold rolling processes the most tonnage out of all cold working processes

A Rolling Schematic

HOT ROLLING PROCESS

Hot rolling is a metalworking process that occurs above the recrystallization temperature of the material. After the grains deform during processing, they recrystallize, which maintains an equiaxed microstructure and prevents the metal from work hardening.

COLD ROLLING PROCESS

Cold rolling occurs with the metal below its recrystallization temperature (usually at room temperature), which increases the strength via strain hardening up to 20%. It also improves the surface finish and holds tighter tolerances.

CONTINUOUS CASTING

Continuous casting (Tundish and Mold).

1:Ladle 2: Tundish

3:Mold 4:Plasma torch.

5.Stopper. 6:Straight zone.

ROLLING MILLS

A rolling mill, also known as a reduction mill or mill, has a common construction independent of the specific type of rolling being performed:

TYPES OF ROLLING MILLS

1.Two-high mill 2.Two high reversing mill3. Three –high mill 4.four-high mill5.Cluster mill

Surface defects

There are five type of surface defects- LapThis type of defect occurs when a corner or fin is folded over and rolled

SliversProminent surface ruptures.Some other defects which are given below-

BurningCracking of material due to long furnace stay or over heating of material

CracksThey are caused by improper rolling temperature, too much reduction of roll or poor conditioning of billet

Fins and over fillingNarrow beads are found in the rolling direction of material. They occur by wrong adjustment of rolls and excessive stock from previous pass.

INSPECTION AND TESTING

1. Optical microscope2. Stereo microscope3. Moulding machine4. Ultrasonic5. Automatic polisher6. Rockwell handles tester7. Brinell hardness tester