presentation on tmt steel bar manufacturing
DESCRIPTION
PRESENTATION ON STEEL RE-ROLLING MILL AND TMT STEEL BAR MANUFACTURINGTRANSCRIPT
NAME : AMIT KARMAKARCOURSE : B.TECH (MECHANICAL)SECTION : M2006B42REG NO. :11007860COLLEGE : LOVELY PROFESSIONAL
UNIVERSITY
FINAL PROJECT PRESENTATION
InGAGAN FERROTECH
LIMITED,DURGAPUR(WB)
PROJECT ON TMT BAR MANUFACTURING
WHAT IS TMT BAR?
TMT MANUFACTURING PROCESS
TYPES OF RAW MATERIALS 1. BILLETS2. INGOTS
RAW MATERIALS
INGOTS : TRAPEZOIDAL SHAPE STRUCTURE MANUFACTURED BY CASTING FROM IRON ORE COLOR CODE IS ALLOTTED TO MINIMIZE THE ERROR THREE TYPES OF CROSS-SECTIONAL DIMENSION 3 4 X 4 4 inches ⅟ ⅟ 3 2 X 4 2 inches ⅟ ⅟ 4 X 5 inches 50-60 INCHES INGOT LENGTH IS USED IN TMT
PRODUCTION
RAW MATERIALS CONTINUE
BILLETS : ALMOST SIMILAR TO INGOTS BUT HAVE BETTER
SURFACE FINISH LESS CHANCE OF BLOW HOLES BEING PRESENT THE FINAL PRODUCT HAS BETTER FINISH WHEN
COMPARED TO INGOTS NO STANDARD COLOR CODING REQUIRED
RAW MATERIALS CONTINUE
COLOR CODING OF INGOTS : COLOR CODING IS DONE IN BASIS OF PRESENCE OF
PERCENTAGE OF CARBON IN INGOTS Below .18 –white paint .18 to .20 – blue paint .21 to .23 – green paint .24 to .26 – yellow paint .27 to .30 – orange paint Above .30 – red paint
RAW MATERIALS CONTINUE
PARAMETERS
Fe 415
Fe500
Fe550
Fe415D
Fe500D
CARBON(MAX) .30 .30 .30 .25 .25
SULPHUR(MAX) 0.060 0.055 0.055 0.045 0.040
PHOSPHORUS(MAX) 0.060 0.055 0.055 0.045 0.040
SULPHUR AND PHOSPHORUS(MAX)
0.110 0.105 0.100 0.085 0.075
CE(MAX) 0.42 0.42 0.42 0.42 0.42
GRADES OF TMT BARS
Manganese (Mn) – improves hardenability, ductility and wear resistance
Nickel (Ni) – increases strength, impact strength and toughness, impart corrosion resistance in combination with other elements.
Copper (Cu) – improves corrosion resistance Chromium (Cr) – improves hardenability, strength and
wear resistance, sharply increases corrosion resistance at high concentrations
Silicon (Si) – improves strength, elasticity, acid resistance etc.......
ALLOYING ELEMENTS
Tests involved on ingots and billets are Carbon percentage Sulphur percentage Phosphorus percentage
QUALITY TESTING OF BILLETS
Coal gas is used to produce heat energy in the Furnaces
Peak temperature goes up to 1200°C Billets are being heated for 4 hours There are total 8 burners in the furnace Burners are so adjusted that uniform
temperature is attained Three processes involved in Furnace i.e.
Feeding, Heating and ejection.
FURNACE
FEEDING : Feeding mechanism consists of worm gear
arrangementsHEATING : Preheating zone, intermediate heating zone
and final heating zoneFURNACE EXIT : Red hot billets are exited by Authorized
personnel in proper time and lead to Rolling mills
FURNACE CONTINUE
FURNACE CONTINUE
There are three mills present in the line
ROUGHING MILLS
INTERMEDIATE MILLS
FINISHING MILLS
ROLLING MILLS
ROUGHING MILL: First mill amongst three mills Gear ratio used is1:6 to provide sufficient
torque to rolls Three sets of roller present vertically In Roughing mill very small elongation and
gradually decreasing diameter is attained
ROLLING MILLS CONTINUE
After Roughing mill billets moves to next Rolling mill that is Intermediate Rolling Mill
But before entering the Intermediate Rolling mill billets needs to accelerate its velocity.
Pinch rolls are used to accelerate billets with the help of a motor of 50HP.
After Pinch rolls there is a set of CUTTER or SHEARER with a cone shaped guide ways to cut the ends of the rods for the better entering to the Intermediate rolls.
ROLLING MILLS CONTINUE
INTERMEDIATE ROLLS: The purpose of the Intermediate mill is to
attain considerable elongation and to prepare the rod to enter in the Finishing mill
Before entering to the Finishing Mill two Pinch rolls and a shearer are used.
FINISHING MILL: Precision Rolls are used to get nearly
accurate dimensions Also facilitates the brand imprint
ROLLING MILLS CONTINUE
INTERMEDIATE TO FINISHING
This quenching process is called Thermex Technology.
TMT bars are made to pass through specially designed pipes carrying nozzles and pressure gauges
Water is sprayed through the nozzle to change the temperature of the rods abruptly
Velocity of the water and pressure of the water results the hardening of the rods
After the TMT treatment the rods are made to fall on the Cooling bed.
TMT QUENCHING
Before falling on the Cooling bed, the speeds of the bars are reduced by using a speed breaker
After complete cooling on the cooling bed, the TMT rods are sent for the Inspection and Dispatch
TMT QUENCHING CONTINUE
Thank You