Industrial Training Report on

VULCAN INDUSTRIAL ENGINEERING CO LTDSurvey No. 1091,

Sunav - Kasor Road, Piplav, Anand, Gujarat - India 388460

Phone: +91 2697 235811, 235812

G. H. PATEL COLLEGE OF ENGINEERING AND TECHNOLOGYBakrol gate, Vallabh Vidyanagar

REPORT BY:

1. Aakash Gandhi 2. Siddharth Parekh 3. Harsh Goplani4. Utsav Jain

Vulcan Industrial Engg. Co. Ltd.

Vulcan Industrial Engg. Co. Ltd. has its main plant at Sunav. We visited the Vulcan Industrial Engineering Sunav plant for our industrial training.

The products that are supplied by this plant are-

Gearbox (Simple and Annular) Spur Gears Helical Gear Double-Helical Gear Herringbone Gear Spiral Bevel Gear Annular Gear Gearbox Housing Driveshaft Satellite Housing Sun pinion Forced Lubrication System

Drill Pipes Raise Bore Hammers Bits Deck Bushing Roller Stabilizer Shock Hub

Borehole Drilling Vehicle Spares

Guide Rail Sleeve Web plate Output Flange Bushing Brake Hub Dipper Handle Head End

The plant has various departments such as Raw Materials, Foundry, Production, Assembly, Drill Pipes and Research & Development. There is a training center located at some distance from other departments.

The SAP is the skeleton of the company. SAP stands for Systems, Applications, Products in data processing. It is a method by which a company receives a purchase order from the customer and relates to its engineering and manufacturing team. Based upon the order, the manufacturing engineering team gives a feedback which is supplied to the customer in the form of quotation. Once the order is confirmed by the customer, a sales order is generated by the industry to the design and engineering team. Then the design team formulates a process and the design of the product. Then the products are shortlisted. List is made for products that would be purchased and the products that would be manufactured. The parts that are needed to be purchased are forwarded to the purchasing team which develops a purchase order based on it. The design of the products which need to be manufactured is forwarded to the manufacturing team. Then the manufacturing teams handles the manufacturing, assembly and final inspection of the product. Then the product is delivered to the customer within the deadline.

Raw Materials DepartmentAfter the purchase order of raw materials, these materials are first brought to RM shed. Raw material department is the place where all the raw materials are inspected and only then it is allowed for processing. We met the department head, and he gave us the overview of the RM Department. RM Shed is important because if the defect present in the material is carried throughout it is detected only in the assembly department. The raw materials are given the color coding on the basis of strength, material used and life.

A sample of all the kinds of material is collected and then all the required tests are carried out. Sample is cut from the gross raw material through gas cutting.

Following tests are carried out on the raw materials-

Impact Test Tensile Test Brinell Hardness Test Ultrasonic Test

Following materials are used in the manufacturing of products-

Materials that are tempered in the heat treatment process-

EN- 8 EN- 9 EN- 19 EN- 24 EN- 36 EN- 353 C- 45

Materials that are carburized in the heat treatment process-

20MnCr5

17CrNiMo6

Foundry Department

In this department, the scrap is melted and casted into the rough design of the product.

The process involves Moulding -> Smelting -> Pouring -> Solidification -> Retrieve

Mixer is used to mix water, resin, silica sand (old or new) and hardener in appropriate proportions. New silica sand is called facing sand and the used silica sand is called the baking sand. The sand around the pattern contains new silica sand, resin and hardener. Whereas the rest of the mould contains used silica sand, resin and hardener. The silica sand is used 2-3 times. Induction furnaces are used in the foundry.

The foundry has three types of furnaces depending on the casting material poured-

Manganese-Bronze Aluminum-Steel Copper

Pouring temperature for materials-

Manganese-Bronze: 1373-1473 K (Melting temperature 1273 K) Aluminum-Steel: 1823-1873 (Melting temperature 1723 K) Copper: 1433-1533 K (Melting temperature 1333 K)

Patterns are made of wood and aluminum. Many thermo-col models of pattern are made. These designs of patterns are sent to the pattern manufacturer. Chills are used to prevent overheating of the mould when molten metal is poured inside the cavity. Patterns are made according to the customer requirement. Cope and Drag patterns are also used. Manual vibration is carried out to remove patterns from the mould to avoid breakage of mould cavity.

Types of Casting-

Centrifugal Casting Horizontal Centrifugal Machine Vertical Centrifugal Machine

Sand Casting

Probability of occurrence of defects in sand casting is higher compared to centrifugal castings.

Castings made using centrifugal casting-

Bush (made from Manganese-Bronze)

Castings made using sand casting-

Housing Satellite housing

Process of Centrifugal Casting-

Ingots are the excess molten material left during the casting process which can be reused. Here, this ingot is made of Manganese-Bronze. This ingot is fed in the furnace and heated up to the temperature as mentioned above. A small amount of zinc powder is added. A small sample of molten metal was taken during the process and the amount of zinc was calculated in the molten metal. If there is a deficiency in the amount of zinc, some amount of zinc is added and then the sample is again taken from the molten metal to calculate the amount of zinc. This process is repeated until the required amount of zinc is obtained. It is kept in the furnace for 60 to 90 minutes. During boiling bubble formation is observed. Temperature measuring device is used for measuring the temperature of the molten metal.

During this period, ladle is heated up to 450-500 °C and the dye is also heated up to 250 °C in order to avoid solidification at the time of pouring. De-excluder is also added in the furnace to remove dissolved gasses from the molten metal. The ladle is insulated with the glass wool. A weighing device was attached to the ladle for measuring the amount of molten metal which is poured in the ladle. The weight of the molten metal to make the bush is around 60 kg. The furnace can tilt about a pivot for pouring the molten metal in the ladle which is mounted on the hook of the overhead crane. Then this molten metal is poured in the pathway which guides the molten metal in to the dye. Kerosene paint is applied on the pathway to avoid the solidification of the molten metal. The molten metal takes the shape of the dye. When the molten metal takes the shape of dye, the dye is cooled using water to solidify the molten metal. The casting is kept in the dye for about an hour and then it is hammered out of the dye. The final casting of the bush is obtained.

Process of Sand Casting-

After the mixing of Silica Sand (Old or New), Resins, Hardeners and water, the mixture is poured around the pattern. Chills are provided for avoiding overheating of the sand mould during the casting process. The pattern includes runners and gates. Riser cavity is also made inside the mould. It is rammed manually to reinforce the mould. Air vents are provided for making it possible for air to exit the mould and molten metal to enter the mould. The pattern is removed with the help of screws. The screws are tightened in the holes provided screws in the pattern and then removed gently. Little vibration is needed to remove the pattern without damaging the mould cavity.

The sand mould is left to dry for a day or so. The pressurized jet of air is applied on the surface of the mould for removing the dirt and left over sand particles. Then the thin layer of kerosene paint is applied on the mould surface and then the inflammation is carried out for hardening reinforcing of the mould. Then the cope and drag is aligned and screwed.

The melting process in the sand casting is similar to that of the centrifugal casting. The furnace is designed for melting Aluminum-Steel alloy. The molten metal of Aluminum-Steel is poured in furnace.

The molten metal is poured in the mould using the ladle which is preheated in the ladle preheater. The molten metal takes the shape of the mould and is left to dry for few days. Then the mould is hammered and the casting is retrieved. A machine converts the blocks of sand in powder form.

The risers are removed and the grinding is carried out of the casting to match the details of the output required. the boring and chamfering of the core is also done by a lathe machine. In short, a rough machining is carried out in the foundry. Exhaust chimneys are provided in the foundry for the smoke and hot air to escape.

Research & Development Department

In this department, samples collected from the RM department are tested for their strength and quality. Quality Control of the final product is also carried out here.

Following tests are carried out in this department-

Impact Test Tensile Test Ultrasonic Test

Forced Lubrication System(FLS)

Forced Lubrication System is used for cooling and filtering of the lubricating oil inside the gear box.

Forced lubrication system are usually used for gearboxes in which the rpm of the gear is very high. The high rpm of the gear causes the rise of temperature. This causes the rise of temperature of the lubricating oil. For cooling the gear and the lubricating oil FLS is provided outside the gearbox.

With the help of pump, lubricating oil inside the gearbox travels into the filter. From filter, it travels to the heat exchanger and then back to the gearbox. The lubricating oil gets cleaned inside the filter after the removal of impurities. The cooling water comes in and out of the heat exchanger via pipes. The heat transfer takes place between the cooling water and the lubricating oil and thus cooling the lubricating oil. The pressure of the fluid is also measured using the pressure gauge to regulate the pressure of the lubricating oil.

Drill Pipes

The cylindrical pipes are received from Maharashtra. These pipes are welded in the department to connect a bore on one end and the other end is welded to form a head.

Both types of welding viz., friction welding and arc welding are carried out. These can be interconnected to form a long drill pipes. A cutting tool is installed at the front end of this drill pipe, the other end is connected to the mining machine.

During the mining process, TNT material is send in these hollow pipes, and explosion is carried out in the earth. Sometimes a hard rocks surface is reach below the earth surface. This situation becomes difficult for the cutting tool to operate. To deal with the situation the whole drill pipe assembly is drawn out and hammers are inserted and pushed by force, this hammers breaks the surface of the rocks and hence mining is continued.

Quality ControlThe dimension correction of the spiral bevel gear was carried out on the lathe.

The dimensions of the gear were made identical to the standard gear. The gear was colored to check the dimensional defects. The first gear takes around one day for bringing it into the dimensional tolerance. The other gears are manufactured with the preset values of indexing inside the lathe according to the first gear. So, other gears are manufactured in lesser time.

The deep penetration test of the products is carried out in R&D Department. The products with external cracks are rejected and sent back to the foundry. The Fluorescent Magnetic Powder along with kerosene is polished on the surface of the job. The surface cracks and defects are observed in the Ultraviolet light. The entire test is carried out inside a dark room.

Production and Assembly departmentProduction department mainly deals with the Machining of gear, all kinds of pinion and motor shaft, bush, upper and lower housing, annulus, satellite gear housing, shaft, gear box.

Production department has 4 bays divided for specific kind of work like basic operation, heat treatment, final assembly, welding.. Material after being tested in RM department is send to Production where it is machined in steps as per the Route sheet. Hence this shed houses different machine tools for machining the components .

Component or the product in Vulcan:

1. Shovel parts.2. Drill parts3. Industrial gears and gear box4. Drilling accessories

Different Machines installed in Production Department.

1. Centre type lathe -manual operated2. Computer pneumatic control-CNC3. Horizontal machining centre-HMC4. Vertical machining centre-VMC5. Milling and slotting machining -manual and automatic.6. Hobbing machine.7. Deburring machine.8. Profile grinding machine9. Equipment for heat treatment.

Bay-1

Bay 1 mainly deals with the operation such as hobbing which is carried on HOBLER MACHINE, milling, face and bore grinding, turning etc. Moreover there was deburring section along with the final inspection area. In deburring section both deburring and chamfering operation were carried out so as to avoid sharp edges and corners in the products. It had the special room which has two Gear Grinding CNC Machine. One of the grinding machine has moving table which can be adjusted in two horizontal direction and also rotary motion. While in other one only tool can be adjusted. Both the grinding machine uses sensor oil and coolant liquid. The point of interest in that section was they were using oil as a coolant so as to avoid the high temperature effect due to high RPM of grinder. The reason behind AC in that room is to maintain the room temperature to avoid the temperature effect on job to do precise machining.

Bay-2

Bay 2 has gear box assembly section where gear were assembled in the gear housing as per the diagram based on the design calculation made as per the customer requirement. Gear box were made by gear train arrangement with the help of bearing (taper or roller). Error like backlash are recognized and reduced to acceptable level. After complete assembly the gear box is connected with motor and load and other parameter are measured in order to standardize the product.

Bay 3

Bay 3 is the heat treatment section where the processes such as normalizing, annealing, nitride carburizing, etc. are done. There was also a tool room in that section which had sufficient instruments to check hardness and toughness after the process of heat treatment. Heat treatment consist of five furnace along with two oil and two water tank for quenching purpose. Also shot blasting operation is carried out in this section in order to remove the rust that has formed after quenching.

Bay 4

Bay 4 was the area where welding was carried out. That section deals with gear plank on which the bush, ring kind of components necessary for the production of gear are welded and after that the gear is processed for machining in Bay 1. The interesting component present there was large dipper handle lying on the floor. Heat treatment was also carried out for stress relieving in the gear plank. Apart from this paint section is there where the gear box housing is coloured.